PLASMA CUTTING

POWER SUPPLY
PAK Master® 38XL
Used With PCH-42 RPT SureLok™ Torch

A-01721

Instruction Manual

June 21, 2002 Manual No. 0-2872

 WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-
ating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

PAK Master® 38XL
Instruction Manual Number 0-2872

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711

www.thermadyne.com

Copyright 2001 by
Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written per-

mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or
any other cause.

Printed in the United States of America

Publication Date: June 21, 2002

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

 TABLE OF CONTENTS

SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and Warnings ..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes ........................................................... 1-3
1.06 Documents De Reference ............................................................................ 1-5
1.07 Declaration of Conformity ............................................................................. 1-7
1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:
INTRODUCTION & DESCRIPTION .................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ..................................................................................... 2-1
2.03 Specifications & Design Features ................................................................. 2-1
2.04 Options And Accessories ............................................................................. 2-2

SECTION 3:
INSTALLATION PROCEDURES ....................................................................................... 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Location ................................................................................................ 3-1
3.03 Unpacking Procedure ................................................................................... 3-1
3.04 Electrical Connection ................................................................................... 3-1
3.06 Torch Connection ......................................................................................... 3-3

SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction .................................................................................................. 4-1
4.02 Operating Controls ....................................................................................... 4-1
4.03 Getting Started ............................................................................................. 4-2
4.04 Recommended Cutting Speeds .................................................................... 4-3

SECTION 5:
SERVICE ......................................................................................................................... 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Maintenance ................................................................................... 5-1
5.03 Common Operating Faults ........................................................................... 5-1
5.04 Troubleshooting Guides ................................................................................ 5-2
5.05 Basic Troubleshooting Guide ........................................................................ 5-2
5.06 Advanced Troubleshooting Guide ................................................................. 5-3
5.07 Troubleshooting Flow Charts ........................................................................ 5-4
5.08 Test Procedures ......................................................................................... 5-11
5.09 Power Supply Component Replacement Procedures ................................. 5-14
 TABLE OF CONTENTS (continued)

SECTION 6:
PARTS LISTS .................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 Power Supply Replacement Parts ................................................................ 6-2
6.04 Complete Assembly Replacement ............................................................... 6-4
6.05 Options and Accessories ............................................................................. 6-4

APPENDIX 1: SEQUENCE OF OPERATION BLOCK DIAGRAM ............................................. A-1

APPENDIX 2: ROUTINE MAINTENANCE SCHEDULE ............................................................ A-2

APPENDIX 3: RECOMMENDED CUTTING SPEEDS .............................................................. A-3

APPENDIX 4: NON-CE SYSTEM SCHEMATIC ........................................................................ A-4

APPENDIX 5: CE SYSTEM SCHEMATIC ................................................................................. A-6

 SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes-
sional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structions before using the equipment. Call 1-603-
298-5711 or your local distributor if you have any
questions.
Date: November 15, 2001
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
formation regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth de-
fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
1-1 GENERAL INFORMATION
 • Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publica-
tions.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable ma-
terial in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc pro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
• To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the deci-
bels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
GENERAL INFORMATION
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding hel-
met or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the work-
piece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu-
ments, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-
PATION AND EDUCATIONAL EYE AND FACE PRO-
TECTION, obtainable from American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the Ameri-
can National Standards Institute, 1430 Broadway, New
York, NY 10018
1-2 Date: November 15, 2001
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain-
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-
tainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-
ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Associa-
tion, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARA-
TION FOR WELDING AND CUTTING OF CONTAIN-
ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: November 15, 2001
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au person-
nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
1-3 GENERAL INFORMATION
• Eloignez toute fumée et gaz de votre zone de respira-
tion. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combus-
tibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com-
bustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
1-4 Date: November 15, 2001
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
Date: November 15, 2001
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRA-
VAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na-
tional Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American Na-
tional Standards Institute, 1430 Broadway, New York,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Pro-
tection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-
tional Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
1-5 GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL, disponible auprès de la National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan-
dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 Date: November 15, 2001

1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro-
pean Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

Date: November 15, 2001 1-7 GENERAL INFORMATION

1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).

Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

GENERAL INFORMATION 1-8 Date: November 15, 2001

 SECTION 2: 2.03 Specifications & Design
Features
INTRODUCTION &
A. Pak Master 38XL Power Supply
DESCRIPTION
The following applies to the Pak Master 38XL Power Sup-
ply only:
2.01 Scope of Manual 1. Controls
This manual contains descriptions, operating instructions • AC POWER on/off Switch
and maintenance procedures for the Pak Master 38XL
Plasma Cutting System. Service of this equipment is re- • CURRENT Output Control
stricted to properly trained personnel; unqualified per- • PRESSURE Regulator Control with Pressure Gauge
sonnel are strictly cautioned against attempting repairs 2. Control Panel Indicators
or adjustments not covered in this manual, at the risk of
voiding the Warranty.
AC GAS DC OVER TEMP
Read this manual thoroughly. A complete understand-
ing of the characteristics and capabilities of this equip- 3. Input Power
ment will assure the dependable operation for which it
was designed. • 120/220 VAC (±10%), 50/60 Hz, Single-Phase
Domestic unit supplied with 10 ft (3 m) Input
2.02 General Description Power Cable and Molded Plug
The Power Supply provides a system which can cut most • 220 VAC (±10%), 50/60 Hz, Single-Phase
metals from gauge thickness up to 3/8 inch (9.5 mm).
CE unit supplied with 10 ft (3 m) CE Input
The Power Supply provides 29 amps maximum output Power Cable without Plug
cutting current (limited to 20 Amp on 120VAC service).
All electrical, pilot, and gas control circuitry is included. • 100/200 VAC (±10%), 50/60 Hz, Single-Phase
Japan unit supplied with 10 ft (3 m) Input
Power Cable without Plug
4. Output Power
Continuously variable from 12 to 29 Amps maximum.
Limited to 20 Amps maximum with 100 VAC and
120 VAC units using 20 Amp service.
5. Open Circuit Voltage (OCV)
375 vdc
6. Duty Cycle (see NOTE)

A-01721 NOTE
The duty cycle will be reduced if the primary in-
put voltage (AC) is low or the DC voltage is higher
than shown in the chart.

Power Supply Duty Cycle

Ambient 104° F 104° F 104° F

Temperature (40° C) (40° C) (40° C)

Duty Cycle 40% 60% 100%

Current 29 Amps n/a Amps n/a Amps
DC Voltage 92 vdc n/a vdc n/a vdc

Manual 0-2872 2-1 INTRODUCTION & DESCRIPTION

7. Work Lead 13. Power Supply Dimensions
10 ft. (3.0 m) with clamp
8. Cut Capacity TOP
PANEL
Maximum cut capacity on Mild Steel 17.6 in
(448 mm)
• 1/4 inch (6.4 mm) @ 20A setting on 100 VAC &
120 VAC Units
• 3/8 inch (9.5 mm) @ 29A setting on 120 VAC, 200
VAC & 220 VAC Units
9. Pilot Circuitry 17 in
(432 mm)
Capacitor Discharge (CD), Pulsed DC
END
10. Gas Connection
PANEL
1/4 NPT Gas Fitting SIDE PANEL
11. Gas Requirements A-01671

CAUTION 9.75 in
(248 mm)

Air supply must be free of oil, moisture, and other

contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even com-
plete torch failure. Contaminants may cause poor 2.04 Options And Accessories
cutting performance and rapid electrode wear.
The following accessories are available for this Power
a. Type Gas Supply. Refer to Section 6, Parts Lists, for part numbers
and ordering information.
Compressed Air or Nitrogen (N2) Only
A. Single Stage Air Line Filter Kit

WARNING A Single Stage In-Line Air Filter which is a pneumatic

dryer/evaporator that installs in the compressed air
supply line. Filters moisture, oil, dirt, chips, rust par-
This cutting system must not be used with Oxy- ticles, and other contminants.
gen (O2).
B. High Pressure Regulators
b. Operating Pressure High pressure regulators are available for air and ni-
trogen. The regulators are used to set the proper pres-
50 psi (3.4 bar)
sure for the type gas being used.

CAUTION NOTE
Regulators should not be installed with In-Line Air
Maximum input gas pressure must not exceed 125 Filters.
psi (8.6 bar)
c. Flow
190 scfh (90 lpm)
scfh = standard cubic feet per hour
12. Weight
49 lbs (22.3 kg)

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2872

 SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
This section describes installation of the Power Supply.
These instructions apply to the Power Supply, Torch and
Leads Assemblies only; installation procedures for the
Options and Accessories are given in manuals specifically
provided for those units.
The complete installation consists of:
1. Site Selection
2. Unpacking
3. Electrical Connection
4. Gas Connections
5. Torch Connections
6. Operator Training
3.02 Site Location
Select a clean, dry location with good ventilation and ad-
equate working space around all components.
CAUTIONS
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
To prevent entry of cutting or other metal debris,
the power supply must not be operated in the hori-
zontal position. Operate the power supply in the
vertical position only with the handle in the up-
right position.
The power supply is cooled by air flow through the end
and side panels. Air flow must not be obstructed. Pro-
vide at least 12 inches (300 mm) clearance on each side.
Provide sufficient clearance above unit to allow access to
top panel controls (minimum 12 inches or 300 mm).
NOTE
Review the safety precautions in Section 1 of this
manual to be sure that the location meets all safety
requirements.
Manual 0-2872
3.03 Unpacking Procedure
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove any packing material.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system in-
stallation.
3.04 Electrical Connection
A. Power Requirements
1. Domestic Units
• Using 120 VAC Service
Unit will operate on single phase 120VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 30 amps. If
fused at 20 amps, the Power Supply Current
Control must be set for 20 amps or less. Using
a 15 amp circuit is insufficient for proper op-
eration of this Power Supply.
• Using 220 VAC Service
Unit will operate on single phase 220VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 20 amps.
2. CE Units
Unit will operate on single phase 220VAC ±10%,
50/60 Hz input power. The electrical service must
be fused for at least 20 amps.
3. Japan Units
• Using 100 VAC Service
Unit will operate on single phase 100VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 30 amps. If
fused at 20 amps, the Power Supply Current
Control must be set for 20 amps or less. Using
a 15 amp circuit is insufficient for proper op-
eration of this Power Supply.
• Using 200 VAC Service
Unit will operate on single phase 200VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 30 amps.
3-1 INSTALLATION PROCEDURES
B. Input Voltage Selection D. Power Connections
Input voltage selection switch is available on Domes-
tic and Japan Units only. CAUTION

The primary power source, power cable, and plug

WARNING all must conform to local electrical codes and rec-
ommended circuit protection and wiring require-
ments.
Do not switch input voltage when unit is powered
ON. • Domestic 220 VAC Service Only
Remove the 120V Plug that comes with the unit.
Set Input Voltage Selection Switch to the correct The attached AC input power cable is three con-
input voltage. This switch is located on the end ductor, 12 AWG. The input power connections
panel of the unit, near the bottom. can be made directly to a properly fused discon-
nect or by using a plug which conforms to the rec-
Domestic Japan ommended ratings.
• CE 220 VAC Service Only
The attached AC input power cable is three con-
ductor, 14/3 AWG. The input power connections
can be made directly to a properly fused discon-
nect or by using a plug which conforms to the rec-
ommended ratings.
• Japan 200 VAC Service Only
A-03261 A-03262
The attached AC input power cable is three con-
ductor, 12 AWG. The input power connections
C. Extension Cords can be made directly to a properly fused discon-
Extension cords can be used only with the following units: nect or by using a plug which conforms to the rec-
ommended ratings.
• 120 VAC Domestic Units
• 100 VAC Japan Units 3.05 Gas Connection
Extension cords must meet National Electric Code guide-
lines. Extension cords must have the same rating as the CAUTION
electrical service (20A for 20A service; 30A for 30A ser-
vice) and must have three-prong plugs. Refer to the fol- Maximum input gas pressure must not exceed 125
lowing table for recommended cord sizes: psi (8.6 bar)
This subsection includes information for connecting the
Extension Cord Wire Gauge Requirements gas supply to the Power Supply. The information is
Cord Length 20A Service 30A Service grouped in paragraphs for different type gases and op-
50 ft (15.2 m) or Less 12 10 tions per the following:
100 ft (30.5 m) 10 8 A. Using Shop Air
150 ft (45.7 m) 8 6
B. Using High-Pressure Gas Cylinders
Refer to the appropriate paragraph(s) for the desired ap-
plication to be used.

INSTALLATION PROCEDURES 3-2 Manual 0-2872

A. Using Shop Air
An air line filter, capable of filtering to at least 5 microns,
is required when using air from a compressor to insure
that moisture and debris from the supply hose does not
enter the torch.
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even com-
plete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
Install the Optional Air Line Filter and connect the gas
supply per the following procedure:
A-01658
AIR FLOW
Filter Cap
Top Panel
Gas Fitting Air Line Filter
Assembly
Figure 3-1 Shop Air Gas Connection
NOTE
DO NOT use teflon tape on gas fittings.
1. Connect the air line filter assembly to the female
1/4 NPT gas input fitting at the front panel of
the power supply. The air filter is supplied with
1/4 NPT gas couplings. A quick disconnect fit-
ting is recommended on the filter body cap to al-
low easy connection to the compressed air source.
2. Connect the air supply hose to the inlet fitting on
the air line filter body cap.
CAUTION
When connecting a gas fitting to the filter cap, hold
the cap flats with a wrench. Over tightening the
cap on the filter body can damage the filter car-
tridge or cap gasket.
Manual 0-2872
B. Using High Pressure Gas Cylinders
NOTE
Do not use an air line filter with high pressure gas
cylinders.
To use air or nitrogen from a high pressure gas cylinder:
1. Connect the gas supply hose to the female 1/4
NPT gas input fitting at the front panel of the
power supply.
NOTE
For a secure seal, apply thread sealant to the fit-
ting threads, according to the maker's instructions.
Do Not use Teflon tape as a thread sealer, as small
particles of the tape may break off and block the
small gas passages in the torch.
AIR FLOW
Top Panel A-01657
Gas Fitting
Supply Hose From
Gas Cylinder Regulator
Figure 3-2 High Pressure Gas Cylinder Connection
2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate-
rial. Momentarily open each cylinder valve to
blow out any dust which may be present.
3. Each cylinder must be equipped with an adjust-
able high-pressure regulator capable of pressures
up to 50 psi (3.5 bar) minimum and flows of up to
190 scfh (90 lpm).
NOTE
Refer to the manufacturer’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
4. Connect the gas supply hose to the high-pressure
regulator at the gas cylinder.
5. Set the tank regulator to 75 psi (5.3 bar). This is
the required output pressure for the tank regula-
tor.
6. Use the regulator on the front of the power sup-
ply to adjust the operating gas pressure to the unit.
3-3 INSTALLATION PROCEDURES
3.06 Torch Connection 6. Remove the nylon screw holding the protective
insulating sheet to the bulkhead.
The Torch is installed to the Power Supply when ordered
as part of the system. Use the following procedure only
if the Power Supply and Torch were ordered separately:
Nylon Screw
1. Open the Power Supply per Section 5.08-A. Bulkhead
Area
2. Locate the torch bulkhead directly behind the
torch lead panel strain relief.

Bulkhead Area

A-03235

A-03237

Figure 3-4 Nylon Screw

Figure 3-3 Torch Bulkhead Location 7. Connect the Torch Negative Lead to the fitting in
the brass torch bulkhead.
NOTE
Note that all wires are outside the protective insu-
Torch Lead
lating sheet.
Fitting
3. Remove the strain relief nut from the strain relief Torch Negative
on the Torch Leads Assembly. Lead

4. Feed the ends of the Torch Leads Assembly

through the hole in the Power Supply Panel.
5. Place the strain relief nut back over the end of the
Torch Leads and secure the strain relief to the
panel with the nut.

Bulkhead

A-03236

Figure 3-5 Negative Torch Lead Connection

INSTALLATION PROCEDURES 3-4 Manual 0-2872

 8. Close the protective insulating sheet back over the
torch bulkhead and secure with the nylon screw
removed earlier (see CAUTION).

CAUTION

Be sure all wires are outside the protective insulat-

ing sheet when the nylon screw is reinstalled. High
voltage is present on the torch negative lead.
9. Connect the two torch control connectors and the
pilot wire to the Main PC Board Assembly con-
nections.

Torch Control
Connectors

Pilot Wire
Connection

A-03234

Figure 3-6 Wiring Connections

10. Close the Power Supply by reinstalling the Power

Supply panel.

Manual 0-2872 3-5 INSTALLATION PROCEDURES

INSTALLATION PROCEDURES 3-6 Manual 0-2872
 6. CURRENT Control
SECTION 4:
Adjusts output current from 12 to 29 amps.
OPERATION
Units (100 or 120 VAC) fused for 20A input power
should be limited to a maximum of 20 amps output.
4.01 Introduction 7. Pressure Gauge
This Section provides a description of the Power Supply Displays input gas pressure to the torch.
followed by operating procedures.
8. PRESSURE Control
4.02 Operating Controls Adjusts gas pressure from the regulator. Pull knob
out and turn clockwise to increase gas pressure to
desired level. Push Knob in to lock setting.
9 1 6 7 8 11 10
INPUT POWER AC POWER
TM
OPERATING PRESSURE
50 PSI (3.4 BAR)
WORK
9. Input Power Cable
OFF ON

PRESSURE
Strain relief and input power cable for main AC
Gas
Electrode Distributor Tip
Torch Head Assembly
Standard
Shield Cup
AC GAS DC
OVER
TEMP
20
Maximum
20A at 115V
TORCH power to the unit.
Proper Assembly of Torch Head Components
REPLACEMENT
TORCH PARTS Examine for elongated,
0.1 in (2.5 mm) cratered, or oversized orifice 12 29
Check the electrode and tip for excessive wear.
Replace electrode if worn back more than 0.1"
(2.5 mm). Check tip orifice for out-of-round wear.

Part Description Catalog No.

CURRENT
10. WORK Cable Input
Standard Electrode 9-6506
Gas Distributor 9-6507
Tip 9-6501
Standard Shield Cup 9-6003

GAS
SUPPLY
Recommended operating pressure for clean, dry
Air or Nitrogen is 50 PSI (3.5 BAR).
This system is not for use with Oxygen (O2).

Made in the USA

Input for the work cable on the system.
A-01672
11. TORCH Cable Input
2 3 4 5 12
Input for interfacing the Torch to the Power Supply.
Figure 4-1 Front Panel Controls and Indicators
12. Gas Input Fitting

1. AC POWER ON/OFF Switch Input gas fitting (1/4 NPT) to connect the desired
gas supply to the Power Supply.
ON position supplies AC power to activate all sys-
tem circuits. OFF position deactivates circuits. 13. Input Power Selection Switch

2. AC Indicator NOTE

Green light indicates AC input power is present in Input voltage selection switch is available on Do-
the system when the ON/OFF switch is in ON posi- mestic and Japan Units only.
tion. Indicator will flash for 3-5 seconds when first
Input Power selection switch to set the correct AC
turned on until the power circuits are ready.
input voltage for the Power Supply. The switch is
located on the end panel of the unit, near the bottom.
3. GAS Indicator
Domestic Japan
Green light indicates minimum gas pressure (35 psi
or 2.5 bar) flowing to the torch when torch is acti- 13 13
vated.
4. DC Indicator
Green light indicates adequate DC power output for
main arc when the torch is activated.
A-01674 A-01944

5. OVER TEMP Indicator Figure 4-2 Input Power Selection Switch

Indication is off during normal operation. Yellow

light indicates overheating; unit must be allowed to WARNING
cool. The indicator will also flash momentarily if
the torch is shorted.
Do not switch input voltage when unit is powered
ON.

Manual 0-2872 4-1 OPERATION

4.03 Getting Started
This procedure should be followed at the beginning of
each shift:
WARNING
Disconnect primary power at the source before as-
sembling or disassembling torch parts, or torch and
leads assemblies.
A. Torch Parts
Check the torch for proper assembly. Install proper
torch parts for the desired application (refer to
Manual supplied with the Torch for proper Torch
Parts Selection).
NOTE
The power supply will not operate unless the torch
shield cup is fully seated against the PIP (Parts in
Place) pins in the torch head.
B. Input Power
1. Check that Input Voltage Selection Switch is set
for proper input voltage (Domestic & Japan Units
only).
2. Make sure the power source meets circuit protec-
tion and wiring requirements per Section 3.04.
3. Plug unit in and close main disconnect switch to
supply primary power to the system.
C. Work Cable
Check for a solid work cable connection to the work-
piece.
D. Gas Supply
Select desired gas supply, air or nitrogen (N2). Make
sure gas source meets the gas requirements (refer to
Section 2.03, Specifications & Design Features).
Check connections and turn gas supply on.
E. Purge System
On the Power Supply place the ON/OFF switch to
the ON position. An automatic gas purge (PreFlow)
will remove any condensation that may have accu-
mulated in the torch and leads.
OPERATION
F. Checking Air Quality
To check the quality of the air, press then release torch
switch then place a welding filter lens in front of the
torch. Any oil or moisture in the air will be visible on
the lens. Do not initiate an arc!
G. Current Output Level
1. Domestic Units
• For 220VAC, 20 Amp Input Circuits and
120VAC, 30 Amp Input Circuits:
At the Power Supply set the desired current
output level for the desired operation (12 to 29
amps).
• For 120VAC, 20 Amp Input Circuits:
At the Power Supply set the desired current
output level between 12-20 amps. Setting
above 20 amps is likely to blow wall fuses or
circuit breakers.
2. CE Units (220VAC, 20 Amp Input Circuit)
At the Power Supply set the desired current out-
put level for the desired operation (12 to 29 amps).
3. Japan Units
• For 200VAC, 30 Amp Input Circuit:
At the Power Supply set the desired current
output level for the desired operation (12 to 29
amps).
• For 100VAC, 30 Amp Input Circuits:
Set desired current between 12-20 Amps. Set-
ting above 20 Amps will cause excessive fuse
blowing and reduce the reliability of the unit.
H. Pressure Settings
Press then release torch switch. While gas flows, ad-
just gas PRESSURE control to 50 psi (3.5 bar).
I. Ready for Operation
The system is now ready for operation.
NOTE
Refer to Appendix 1 for a detailed block diagram of
the Sequence Of Operation.
4-2 Manual 0-2872
4.04 Recommended Cutting Speeds
Cutting speed depends on the type of material, material
thickness and operator ability to accurately follow the de-
sired cut line. The following factors may have an impact
on system performance:
• Torch parts wear
• Air quality
• Operator experience
• Torch standoff height
• Proper work cable connection
• Alloy content of material
For complete cutting speed data refer to Appendix 3.
NOTE
The information represents realistic expectations
using recommended practices and well maintained
systems. Actual speeds may vary from those shown
in the chart depending on the alloy content of the
selected material.

Manual 0-2872 4-3 OPERATION

OPERATION 4-4 Manual 0-2872

SECTION 5:
SERVICE
5.01 Introduction
This section describes basic maintenance procedures that
can be performed by operating personnel, and advanced
procedures that can be performed by properly trained
personnel. No other adjustments or repairs other than
those described are to be attempted.
WARNINGS
Disconnect primary power at the source before dis-
assembling the torch or torch leads.
Frequently review the Important Safety Precau-
tions in Section 1. Be sure the operator is equipped
with proper gloves, clothing, eye and ear protec-
tion. Make sure no part of the operator’s body
comes into contact with the workpiece while the
torch is activated.
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
Handle torch leads with care and protect them from
damage.
5.02 General Maintenance
A. Cleaning Power Supply
The only routine maintenance required for the power sup-
ply is a thorough cleaning and inspection, with the fre-
quency depending on the usage and the operating envi-
ronment.
Refer to Appendix 2, Maintenance Schedule, for specific
procedures.
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
Manual 0-2872
To clean the unit, open the enclosure (refer to Section 5.08-
A, Opening Enclosure) and use a vacuum cleaner to re-
move any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents that are rec-
ommended for cleaning electrical apparatus may be used.
CAUTIONS
Do not blow air into the power supply during clean-
ing. Blowing air into the unit can cause metal par-
ticles to interfere with sensitive electrical compo-
nents and cause damage to the unit.
When cleaning care must be taken not to move or
damage the electronic components.
B. Optional Single Stage In-Line Air Filter
NOTE
Refer to Section 6, Parts Lists, for replacement parts
and ordering information.
The Optional Single Stage In-Line Air Filter cartridge
should be replaced every 30 days, depending on the con-
dition of the compressed air. If a noticeable drop in air
pressure occurs, the filter may have become filled with
contaminants and must be replaced.
Replace the cartridge per the following procedure:
1. Unscrew the filter cap from filter body.
2. Slide the old cartridge out of the filter body.
3. Insert the new filter cartridge into the filter body.
The filter cartridge will go in only one way.
4. Reinstall the filter cap and only hand tighten.
NOTE
Supply hoses must be at least #4 hose (1/4 inch or
6.4 mm minimum inside diameter).
5.03 Common Operating Faults
The following lists the more common cutting faults and
what is the possible cause:
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuine Thermal Dynamics Torch Parts
5-1 SERVICE
2. Main Arc Extinguishes
a. Cutting speed too slow or cutting current too high
b. Torch standoff too high from workpiece
c. AC line too low - reduce output current
d. Work cable disconnected
e. Worn torch parts
f. Non-Genuine Thermal Dynamics Torch Parts
3. Excessive Dross Formation
a. Cutting speed too slow (bottom dross)
b. Cutting speed too fast (top dross)
c. Torch standoff too high from workpiece
d. Worn torch parts
e. Improper cutting current
f. Non-Genuine Thermal Dynamics Torch Parts
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
f. Output current too high
g. Torch tip contacting workpiece
h. Damaged or loose torch head components
i. Non-Genuine Thermal Dynamics Torch Parts
5. Poor Pilot Starting
a. Non-Genuine Thermal Dynamics Torch Parts
b. Worn torch parts
c. Damaged or loose torch head parts
5.04 Troubleshooting Guides
There are two Troubleshooting Guides, Basic and Ad-
vanced, provided in this Instruction Manual. The Basic
Troubleshooting Guide uses symptom, cause, and rem-
edy for fault isolation. The Advanced Troubleshooting
Guide uses Flow Charts and test procedures for fault iso-
lation.
SERVICE
Basic troubleshooting is limited to non-power checks and
external Power Supply faults. Advanced troubleshoot-
ing requires fault isolation to the Power Supply or Torch,
Power Supply disassembly, voltage measurements and
major component replacement.
The guides are as follows:
Section 5.05 - Basic Troubleshooting Guide
Section 5.06 - Advanced Troubleshooting Guide
Depending on the level of repair to be done, refer to the
desired troubleshooting guide.
5.05 Basic Troubleshooting Guide
A. General
Basic troubleshooting of the Pak Master 38XL plasma cut-
ting system can be performed without special equipment
or knowledge, and without opening the enclosure.
This basic troubleshooting guide covers input power, gas
supply, and torch problems.
For problems not covered here, refer to the Advanced
Troubleshooting Guide or contact your authorized dis-
tributor.
If a product must be returned for service, contact your
authorized distributor. Materials returned to the Manu-
facturer without proper authorization will not be ac-
cepted.
B. How to use this Guide
The following information is a guide to help determine
the most likely causes for various symptoms.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
the unit is fully operational after any repairs.
A. AC Indicator OFF, Fan does not operate.
1. ON/OFF Switch not on.
a. Turn ON/OFF Switch to ON position.
2. No power from wall circuit.
a. Reset breaker or replace fuse. Refer to Section
3.04 for proper power requirements.
5-2 Manual 0-2872

B. Temperature (OVER TEMP) indicator ON.
1. Unit is overheated due to exceeding duty cycle.
a. Allow to cool, reduce duty cycle.
2. Unit is overheated due to obstructed air flow.
a. Provide at least 12 inch clearance around unit.
b. Clean unit (refer to Section 5.02).
3. Shorted torch; OVER TEMP Indicator lights momen-
tarily then unit stops cutting or piloting.
a. Check for proper torch parts assembly or
shorted torch head per Torch Manual supplied
with Torch.
4. Input voltage too high.
a. Check customer supplied voltage source. Re-
fer to Section 2.03-A-3.
C. AC Indicator blinks for 4 seconds when power is
turned on but no gas flows.
1. Gas not connected or turned on.
a. Check for proper gas supply.
2. Air filter or air line blocked.
a. Replace filter cartridge, check that air lines are
not kinked.
3. Torch leads or head blocked (Gas Pressure Indicator
lighted).
a. Check for twists or kinks in torch leads, check
torch parts. Check for plugged torch head.
4. Faulty gas solenoid or Main PCB.
a. Check for 24 VAC at J2-3 to J2-4 with torch
switch depressed. If present, replace solenoid,
otherwise repair or replace power supply.
D. AC indicator ON, OVER TEMP indicator dark, no
gas flow when torch switch pressed.
1. Shield cup not properly installed on torch.
a. Check that shield cup is fully seated against
torch head.
2. Faulty Torch Switch or PIP Assembly in torch holder.
a. Refer to Torch Manual supplied with Torch.
3. Faulty Main PC Board
a. Replace Power Supply
Manual 0-2872
E. AC indicator ON, OVER TEMP indicator dark,
GAS indicator ON, gas flows, DC indicator
ON. Torch does not pilot.
1. Faulty torch parts
a. Inspect torch parts and replace if necessary per
Torch Manual supplied with Torch.
2. Gas pressure too high.
a. Set pressure to 50 psi (3.5 bar).
F. Torch pilots but does not cut.
1. Work lead not connected.
a. Make sure work lead is connected securely to
bare metal.
2. AC input power too low
a. Use shortest service to breaker panel possible.
Refer to Section 3.04 for input power cable re-
quirements.
G. Gas flows continually even with power off.
1. Debris in solenoid holding piston open.
a. Replace Solenoid.
5.06 Advanced Troubleshooting
Guide
A. General
The troubleshooting covered in this Instruction Manual
requires Power Supply disassembly and live measure-
ments. It is helpful for solving the common problems
that may arise with the Power Supply Assembly.
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
If major complex subassemblies are faulty, the assembly
must be returned to an authorized service center for re-
pair.
Follow all instructions as listed and complete each in
the order presented.
5-3 SERVICE
The guide has two sections as follows:
Section 5.07 - Troubleshooting Flow Charts
Section 5.08 - Test Procedures
Specific test procedures have been grouped together, and
are referenced by the flowcharts.
B. How to use this Guide
The following information is a guide to help the Service
Technician determine the most likely causes for various
failures. This guide is set up in the following manner:
1. Use flowchart(s) to isolate problem to possible
circuit(s).
2. Perform the test procedures as required as noted on
flowcharts.
3. Repair as needed being sure to verify that unit is fully
operational after any repairs.

5.07 Troubleshooting Flow Charts

The following pages are flow charts to be used to isolate
problems in the Plasma Cutting System.

SERVICE 5-4 Manual 0-2872

 Chart #1: Main Power
AC Indicator OFF
on Front Panel

System Connect AC Power

AC POWER Power Cable
Operates No Yes No Input Cable to
Switch ON? Plugged In?
Properly? AC Source

Yes
No Yes

Faulty AC Indicator
Place AC POWER Check Main
Replace Power Supply
Switch to ON Power Disconnect

Place Main Power Main Power

No Disconnect ON? Yes
Disconnect to ON

Check Main Disconnect

Power Line Fuse

Check Main Disconnect Main Power Main Power

Install Proper Power Line Fuses For Yes Line Fuse No
No Line FuseOkay?
Fuse Proper Amperage Replaced
Once?

Yes
No Yes

Unplug Power Supply

From Main Power Source Replace Main Unplug Power Supply
Power Line Fuse From Main Power Source

Proceed to Chart #2B

Proceed to Chart #2A

Manual 0-2872 5-5 SERVICE

 Chart #2: Input Power Checks

B NOTE
This Condition could also result if the input
line voltage was low or using an extension
cable and the user was using a high standoff
while cutting.
Check Input Diode Bridge on
Heatsink/PC Board Assembly
Per Section 5.08-A

A
Diode Bridge Check FET Assemblies on
Yes Heatsink/PC Board Assembly
Check 1/2A Fuse (F1) on the Checks Okay? (See Note)
Heatsink/PC Board Assembly Per Section 5.08-C

1/2A Fuse
Yes No FET Assemblies
Checks Okay?
Check Okay?

No Yes

Unplug J2 Connector on the Check Capacitor

Heatsink/PC Board Assembly PC Board Assembly on
Replace Heatsink/PC Board Assembly
Power Supply Per Section 5.08-D

Replace Fuse (F1) and

Apply AC Power to the
Power Supply

Capacitor PC
Replace Capacitor
Board Assembly No
PCB per
Checks Okay?
Section 5.09-E
AC Indicator
No
Comes ON?
Yes

No Unit
Yes Operates Check unit for
Properly? proper operation

Replace
Pressure Gauge/Solenoid
Assembly Yes
Replace Cover
and follow
operating procedures

SERVICE 5-6 Manual 0-2872

 Chart #3: Temperature Indicator Checks

AC and Gas Indicators are ON

Temperature Indicator Either
ON or Blinks Once
When Torch Switch is Pressed

Temp Indicator
ON Steady
No Proceed to Chart #4
When Torch Switch (blinks once)
is Pressed

Yes

Fan Duty Cycle Allow Power Supply

No Operating? No Exceeded? Yes
To Cool

Yes

Temperature Use Proper Temperature

Indicator Still No No
Operating Procedures Indicator ON?
ON?

Yes Yes

Replace Power Supply

Assembly

Manual 0-2872 5-7 SERVICE

 Chart #4: Shorted Torch or Resistor (R3) Checks

AC and Gas Indicators are ON

DC Indicator Blinks or Momentary ON
When Torch Switch is pressed

Check Pilot Wire

per Section 5.08-E

Pilot Wire Replace

Check Correct? No
Leads Assembly

Yes

Check Resistor (R3) Assembly

per Section 5.08-F

Resistor R3 Replace Resistor (R3)

Check Okay? No
Assembly
per Section 5.08-F

Yes

Replace Power Supply

SERVICE 5-8 Manual 0-2872

 Chart #5: Faulty Torch

A B

AC and Gas Indicators are ON AC Indicator ON

DC Indicator OFF No GAS Flow When Torch
When Torch Switch is Depressed Switch is Depressed

Gas Supply Connect

No
Okay? Gas Supply

Check Torch And Leads

per Torch Manual
Yes

Check Torch Switch

Torch per Section 5.08-G
Check Correct? No Replace Torch

Yes

Replace Power Supply

Manual 0-2872 5-9 SERVICE

 Chart #6: Possible Shipping Damage

CURRENT Control Knob Turns Completely

Around And Doesn't Stop At Minimum Or
Maximum Positions

Check Shaft Of CURRENT

Control Is Not Loose Or
Broken From PC Board

Is Control
Shaft Okay? No Make Claim
Against Freight Carrier
Replace Power Supply

Yes

Replace CURRENT Control

Knob per Section 5.09-A

SERVICE 5-10 Manual 0-2872

5.08 Test Procedures 3. Set digital volt/ohm meter to diode test scale.
4. Using the Figures for each test, check each diode
The checks in these test procedures are all made with the
in the module. Each diode must be checked in
main power disconnected.
forward bias (plus to negative) and reverse bias
(negative to plus) direction.
WARNING 5. Connect the volt/ohm meter positive lead to the
anode of the diode and the negative lead to the
cathode of the diode for forward bias testing. A
Disconnect primary power to the system at the properly functioning diode will conduct in the for-
source before opening the Power Supply. ward bias direction and indicate between 0.3 to
0.9 volts.
A. Opening Power Supply
6. Reverse the meter leads across the diode for re-
1. Lay the unit down on its side (side without the verse bias testing. A properly functioning diode
leads wrap) and remove the six screws on the side will block in the reverse bias direction and de-
of the unit and six screws on the ends of the unit. pending on the meter function will indicate an
(refer to Section 6.03 Power Supply Replacement open or "OL".
Parts, for exploded view of unit.)
NOTE
AC AC
Do not remove the four screws holding the handle
to the case. Do not remove the single screw on the
bottom panel.
2. Slide the cover straight up and off the power sup-
ply. Pivot the cover over the torch lead, work lead,
( ) (+)
and power cord and rest the cover beside the
power supply.
NOTE
( ) AC
Make certain not to strain the ground wire con-
nection to the cover of the power supply.
B. Checking Input Diode Bridge
(+)
Testing of diode modules requires a digital volt/ohm
meter that has a diode test scale or an analog VOM with AC A-01274
1X or X10 scale. Remember that even if the diode mod-
ule checks good, it may still be bad. If in doubt, replace
the Power Supply. Figure 5-2 Input Diode Diagram
1. Open the Power Supply per paragraph ‘A’ above.
2. Make a visual check of the Input Diode Bridge
for damage.

Input Diode
A-01273

Figure 5-1 Input Diode Location

Manual 0-2872 5-11 SERVICE

 C. Checking FET Assemblies
A-00307 1. Open the Power Supply per paragraph ‘A’ above.
2. Using an ohmmeter set on the Rx1 scale make the
0.75 following checks:

Forward Bias
Diode Conducting
Capacitor
PC Board

Diode Test Symbol

VR COM A
+ _ Wire #3
Anode

(-) Terminal (+) Terminal

Cathode

Figure 5-3 Testing Diode Forward Bias

7. For an analog meter, use the meter set on X1 or

X10 scale to measure the resistance of each diode
in both directions. The readings should differ by A-03248

at least a factor of 10. If they do not differ (either

high or low in both directions) then replace the
diode module.
8. If the diode has visible damage or is shorted, the
diode is faulty. Replace the Power Supply. Figure 5-5 FET Assembly Check
A-00306
a. Measure from Capacitor PC Board (+) to Main
Transformer Wire #3. If the meter indicates a
OL
short the FET Assemblies are faulty.
b. Measure from Capacitor PC Board (-) to Main
Transformer Wire #3. If the meter indicates a
Reverse Bias short the FET Assemblies are faulty.
Diode Not Conducting

VR COM A
+ _
Cathode

Anode
Figure 5-4 Testing Diode Reverse Bias

SERVICE 5-12 Manual 0-2872

D. Checking Capacitor PC Board 3. Using an ohmmeter set on the Rx1 scale make the
following checks:
1. Open the Power Supply per paragraph ‘A’ above.
a. Measure from the Torch Block and the end of
the Pilot Wire. The meter should indicate an
Capacitor PC
open.
Board
b. Measure from Pilot Wire to torch tip. Should
measure short (less than 1 ohm).
4. Reinstall the Pilot Wire back onto the stud termi-
nal on the Main PC Board.
F. Checking Resistor R3 (11k ohms)
1. Open the Power Supply per paragraph ‘A’ above.
A-03249 2. Using a pair of needle nose pliers, remove the red
wire from the terminal on Resistor R3.
Figure 5-6 Capacitor PC Board Location

2. Using an ohmmeter set on the Rx1 scale make the

following check:
a. Measure from Capacitor PC Board (+) to (-)
terminals. The meter should increase in resis-
tance as the capacitors charge. If the meter
indication does not increase the Capacitor PC
Board is faulty.
E. Checking Pilot Wire
1. Open the Power Supply per paragraph ‘A’ above.
A-03250 Resistor (R3)
2. Remove the Pilot Wire from the stud terminal on
the Main PC Board.

Figure 5-8 Resistor R3 Location

3. Using an ohmmeter set on the Rx100 scale make

the following check:
a. Measure the Resistance of the Resistor R3. The
meter should indicate 11K ohms.
4. Reinstall the wire back onto the Resistor termi-
nal.
5. Check that the other ends of both red and blue
wires are properly attached.

Pilot Wire
Connection

A-03243

Figure 5-7 Pilot Wire Location

Manual 0-2872 5-13 SERVICE

G. Checking Torch Switch
1. Open the Power Supply per paragraph 'A' above.
2. Disconnect the Torch Control Connectors from the
wiring harness of the J3 connector on the Main
PC Board
Torch Control
Connectors
Connector
J3
A-03245
Figure 5-9 Torch Control Connectors Location
3. Using an ohmmeter set on the Rx1 scale make the
following check:
a. Measure across the Torch Control Connectors.
The meter should indicate an open when the
Torch Switch is not pressed. When the Torch
Switch is pressed the meter should indicate a
short. If faulty, replace Torch & Leads or re-
pair Torch components per Manual supplied
with the Torch.
NOTE
The Shield Cup must be installed to complete the
circuit through the Parts-In-Place (PIP) contacts.
4. Reconnect the Torch Control Connectors back to
the wiring harness of the J3 connector on the Main
PC Board.
SERVICE
5.09 Power Supply Component
Replacement Procedures
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
A. Current Knob Replacement
1. Using a small blade screwdriver loosen the screw
securing the knob to the CURRENT Control ad-
justment shaft.
2. Turn the CURRENT Control adjustment shaft
fully clockwise. This will represent the maximum
position.
3. Slide the replacement knob onto the shaft.
4. Turn the knob so that the line on the knob points
towards the wide end of the current control sym-
bol.
5. Tighten the screw in the knob to secure the knob
to the shaft.
6. Turn the knob fully counterclockwise.
7. The line should now line up with beginning of
the CURRENT Control adjustment symbol.
8. Adjust the knob as required to align the minimum
and maximum reference points.
B. Fuse Replacement
The 1/2A Fuse is located on the Main PC Board inside
the Power Supply. The Fuse is next to the terminal block
on the left side of the Power Supply.
NOTE
Removal of the Fuse requires the use of a pair of
needle nose pliers.
Remove the Fuse per the following procedure:
1. Open the Power Supply per Section 5.08-A.
2. Using a pair of needle nose pliers carefully remove
the Fuse.
3. Replace the Fuse only with the properly rated and
type fuse. Fuse F1, is next to the Terminal Block
and is a 1/2 amp 250V fuse.
5-14 Manual 0-2872
 D. Air Regulator Assembly Replacement
The Air Regulator Assembly includes the Air Regulator,
Pressure Switch, Pressure Gauge, and Solenoid Assem-
blies and is removed from the Power Supply as a com-
plete assembly. Remove the assembly per the following
procedure:
1. Open the Power Supply per Section 5.08-A.
2. Disconnect the ground wire from the cover, and
Fuse
Location set the cover aside.
3. Refer to paragraph 'G' below to disconnect the
Torch Leads from inside the Power Supply.
4. Disconnect the work cable from the stud termi-
nal on the Main PC Board.

F1

Torch Control
Connectors
A-01704

Terminal
Block Work Cable
Connection
Figure 5-10 Fuse F1 Location

4. Reinstall the Power Supply Cover.

C. AC POWER Switch Replacement
NOTE Pilot Wire
Make sure power cord is unplugged. Connection

1. Open the Power Supply per Section 5.08-A.

A-03246
2. Remove the two nuts securing ON/OFF Switch
to the panel.
Figure 5-12 Connection Locations
AC (Black)

5. Remove the AC input power and ground connec-

tions to the Main PC Board.
Blue Wire #3 6. Remove the four screws from the side of the Power
Supply and the single screw on the bottom of the
Power Supply.
A-01705 7. Push back the regulator hose fitting clamp and
slide the complete Heatsink/Main PC Board As-
AC (White) sembly back and up out of the way.
Blue Wire #19
8. Remove retaining nut from front of the regulator
assembly, and remove complete assembly with
Figure 5-11 Power Switch Connections
wiring.

3. Remove wires from Switch. 9. Remove the faulty Air Regulator, Pressure Switch,
Pressure Gauge, or Solenoid Assembly and install
4. Install the replacement AC Power Switch by re- the replacement assembly.
versing the above procedure.

Manual 0-2872 5-15 SERVICE

 10. Install complete Air Regulator Assembly by re-
versing the above procedure.
NOTE
Properly route the pressure switch and gas sole-
noid wires and secure with cable ties.
E. Capacitor PC Board Replacement
Procedure
1. Open the Power Supply per Section 5.08-A.
5. Remove the two wires connected to the Pilot Re-
sistor noting the locate of each.
6. Install the replacement Pilot Resistor by revers-
ing the above procedure.
G. Torch and Leads Replacement Procedure
1. Open the Power Supply per Section 5.08-A.
2. Locate the torch bulkhead directly behind the
torch lead panel strain relief.

2. Remove the three nuts and star washers securing

the Capacitor PC Board to the Heatsink/PC Board
Assembly. The nuts are located at terminals (+), Bulkhead Area
(-), and (N).
3. Pull the Capacitor PC Board up from the three
plastic PC Mounting Standoffs. Squeeze stand-
offs with needlenose pliers.
4. Remove the black pad on top of the capacitors
from the faulty Capacitor PC Board.
5. Install the replacement Capacitor PC Board by re-
versing the above procedure and noting the fol-
lowing: A-03237

a. Place the black pad removed from the faulty

PC Board on top of the capacitors on the re-
placement PC Board. Figure 5-13 Torch Bulkhead Location
b. Refer to the following CAUTION and torque
the three nuts on terminals (+), (-), and (N) to NOTE
15 inch-lbs (1.695 Nm) Note that all wires are outside the protective insu-
lating sheet.
CAUTION
3. Loosen the torch lead strain relief nut inside the
front panel. Do not remove the strain relief from
DO NOT over torque the nuts on the terminals as
the leads. Replacement torch leads are provided
the PC Board may be damaged.
with strain reliefs.
F. Pilot Resistor Replacement Procedure 4. Disconnect the two torch control connectors and
1. Open the Power Supply per Section 5.08-A. the pilot wire from the Main PC Board Assembly
connections.
2. Locate the Pilot Resistor near the Heatsink/PC
Board Assembly.
NOTE
There are two resistors mounted to this area, Pilot
Resistor (15 ohms) and Damping Resistor (30
ohms). The Pilot Resistor is mounted on the bot-
tom.
3. Using a phillips screwdriver remove the two
screws securing the Pilot and Damping Resistors
to the Heatsink/PC Board Assembly.
4. Pull the Pilot Resistor out far enough to gain ac-
cess to the two wiring connections.

SERVICE 5-16 Manual 0-2872

 CAUTION

Be sure all wires are outside the protective insulat-

ing sheet as noted above when it is reinstalled. High
voltage is present on the torch negative lead.

Torch Control
Connectors Torch Lead
Fitting
Torch Negative
Lead

Pilot Wire
Connection

A-03234

Figure 5-14 Wiring Connections

5. Remove the nylon screw holding the protective Bulkhead

insulating sheet to the bulkhead.

Nylon Screw A-03236

Bulkhead
Area

Figure 5-16 Negative Torch Lead Connection

7. Install the replacement Torch and Leads Assem-

bly by reversing the above steps.

A-03235

Figure 5-15 Nylon Screw

6. Use a 3/8 inch (9.5 mm) open end wrench to

loosen the torch lead fitting from the brass torch
bulkhead. This fitting must be removed from the
Torch Lead and installed on the replacement lead.

Manual 0-2872 5-17 SERVICE

SERVICE 5-18 Manual 0-2872
 SECTION 6:
PARTS LISTS

6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. Power Supply and Torch Assembly are field
serviceable, so a complete breakdown of parts is provided.
The parts lists are arranged as follows:

Section 6.03 Power Supply Replacement Parts

Section 6.04 Complete Assembly Replacements
Section 6.05 Options And Accessories
NOTE
Parts listed without item numbers are not illus-
trated, but may be ordered by the catalog numbers
shown.
B. Returns
If a product must be returned for service, contact your
authorized distributor. Materials returned without proper
authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the de-
scription column of the Parts List. Also include the model
and serial number of the torch. Address all inquiries to
your authorized distributor.

Manual 0-2872 6-1 PARTS LISTS

6.03 Power Supply Replacement Parts
Item # Qty Descript!ion Catalog #
1 1 Cover, with Labels
Domestic and CE Units 9-4611
Japan Units 9-6380
2 1 Base, with Labels 9-4612
3 1 Knob 9-4146
4 1 Fuse, 1/2 Amp, 250V (F1) 9-6395
5 1 Air Regulator Assembly Includes: 9-6897
1 Air Regulator 8-4382
1 Pressure Gauge Kit 9-7018
1 Pressure Switch 9-1044
1 Solenoid With Wiring 9-4605
6 1 Handle (does not include screws/washers) 9-4606
7 1 Resistor (R3), 11K ohms, 40W 9-7701
8 1 ON/OFF Switch 8-4248
9 1 Capacitor PC Board Assembly 9-4607
10 1 Pilot Resistor (R1), 15 ohms 55W 9-6323
11 1 Work Cable with Clamp
10 ft (3 m) Length 9-6298
15 ft (4.6 m) Length 9-6595
20 ft (6.1 m) Length 9-6596
25 ft (7.6 m) Length 9-6597
12 1 Leads Wrap (with label) 9-7650
13 1 Torch and Leads Assembly
PCH-42R RPT 70° Hand Torch, 20 ft (6.1 m) Leads 7-4226
PCH-42R RPT 90° Hand Torch, 20 ft (6.1 m) Leads 7-4227
14 1 Voltage Selection Switch (Non-CE Units Only) 9-3325

The following items are not shown:

Gas Connector
1 1/4 NPT FEM Elbow 9-4595
1 Nipple, Hex, 1/4 NPT-1/4 NPT 9-4482
1 AC Input Power Cord
Domestic and Japan Units 9-7651
With Ferrite Beads For CE Units 8-3162
1 Hardware (screws, washers) for cover, handle 9-6376

PARTS LISTS 6-2 Manual 0-2872

 12

9
Non-CE Units
6
14

11
8
CE Units

13 10

A-03259

Manual 0-2872 6-3 PARTS LISTS

6.04 Complete Assembly Replacement
Description Catalog #
Domestic Systems including:
Power Supply, Torch with Leads, Spare Parts Kit, AC Input Power Cable and Work Lead with Clamp
70° Torch with 20 ft (6.1 m) Leads 1-3851
90° Torch with 20 ft (6.1 m) Leads 1-3853

Power Supply, Torch with Leads, Spare Parts Kit, AC Input Power Cable, Work Lead with Clamp and Optional
Air Line Filter Installed
70° Torch with 20 ft (6.1 m) Leads 1-3951
90° Torch with 20 ft (6.1 m) Leads 1-3953
CE Systems including:
Power Supply, Torch with Leads (Unshielded), Spare Parts Kit, AC Input Power Cable with Filtering Beads,
Work Lead with Clamp and Optional Air Line Filter Installed
70° Torch with 20 ft (6.1 m) Leads 1-8851
90° Torch with 20 ft (6.1 m) Leads 1-8853
Japan Systems including:
Power Supply, Torch with Leads, Spare Parts Kit, AC Input Power Cable, Work Lead with Clamp and Optional
Air Line Filter Installed
70° Torch with 20 ft (6.1 m) Leads 1-3951J
90° Torch with 20 ft (6.1 m) Leads 1-3953

Power Supply Only

120/220 VAC - Domestic Units 3-3850

220 VAC - CE Units 3-8850
100/200 VAC - Japan Units 3-3950J

6.05 Options and Accessories

Qty Description Catalog #
1 Single Stage In-Line Air Filter 7-0250A
Replacement Cartridge 7-0252
High Pressure Regulators
1 Air 9-3022
1 Nitrogen (N2) 9-2722
1 Torch Spare Parts Kit Includes: 5-4204
5 Tip, Air
5 Electrode, 40A SureLok
1 Distributor, Gas
1 Shield Cup, Standard
1 Box, Utility
1 Adhesive Hang Tab
1 Label, Spare Parts Kit

PARTS LISTS 6-4 Manual 0-2872

 APPENDIX 1: SEQUENCE OF OPERATION BLOCK
DIAGRAM

ACTION ACTION ACTION ACTION

RUN/SET Switch to SET RUN/SET switch
Plug in ON/OFF switch RESULT to RUN
Power Cord to ON. Gas solenoid open, RESULT
gas flows to set Gas flow stops.
RESULT RESULT pressure. GAS indicator off.
Gas indicator ON Power circuit ready.
Power to system. AC Indicator flashes for if above 35 psi
3 seconds then stays on.

Fan on.

ACTION
ACTION Torch moved away
from work (while
Protect eyes and still activated).
activate torch
RESULT
RESULT
Main arc stops.
Gas flows Pilot arc auto-
GAS indicator ON PILOT ARC matically restarts.
After gas pre-flow:

DC indicator on.
Power supply enabled.
Pilot arc established

ACTION
Torch moved within
transfer distance of
workpiece.
RESULT

Main arc transfer.

ACTION Pilot arc off.

Torch deactivated by torch DC indicator still on.

switch release.

RESULT

Main arc stops. Pilot stops.

(Power supply enable signal removed.)
DC indicator off.
ACTION
ACTION
After post-flow: ON/OFF switch
to OFF Unplug
Gas solenoid closes. Gas flow stops. Power Cord
GAS indicator OFF. RESULT
RESULT
All indicators off.
NOTE - If torch is activated during Power supply No power to system.
post-flow, pilot arc will immediately restart. fan off.
If torch is within transfer distance (1/8 in) of
workpiece, main arc will transfer.
A-00788

Manual 0-2872 A-1 APPENDIX

 APPENDIX 2: ROUTINE MAINTENANCE SCHEDULE
This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the
parts listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/flow.
4. Purge plasma gas line to remove any moisture build-up.
5. Inspect input power cable for damage or exposed wires, replace if necessary.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air flow.
2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as required
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, replace if necessary.

APPENDIX A-2 Manual 0-2872

 APPENDIX 3: RECOMMENDED CUTTING SPEEDS
NOTE
Cutting speeds are for use with PCH-42 RPT Torch.

Pak Master 38XL Cutting Speeds (Air Pressure @ 50 psi for all settings)
Recommended
Recommended Maximum Cut
Cut
Material Thickness Cut Speed @29 Standoff
Speed @ 29
Speed @ 20 Amps Amps
Amps
26 Gauge 250 310 385 drag-1/8"
20 Gauge 125 245 310 drag-1/8"
1/16" 85 140 208 drag-1/8"
Mild Steel 1/8 " 25 55 85 drag-1/8"
3/16 " 15 30 55 drag-1/16"
1/4 " 8 16 27 drag-1/16"
3/8 " NR 10 14 drag-1/16"
24 Gauge 150 310 385 drag-1/8"
1/16" 40 80 115 drag-1/8"
Stainless Steel 1/8 " 25 44 70 drag-1/8"
3/16 " 10 19 27 drag-1/16"
1/4 " NR 14 20 drag-1/16"
24 gauge 100 290 360 drag-1/8"
20 gauge 75 228 310 drag-1/8"
Galvanized Steel
18 gauge 65 172 233 drag-1/8"
16 gauge 45 140 203 drag-1/8"
1/16 " 150 223 280 drag-1/8"
3/32 " 25 105 172 drag-1/8"
Aluminum
1/8 " 10 60 85 drag-1/8"
3/16 " NR 20 30 drag-1/8"
NR = Not Recommended

Manual 0-2872 A-3 APPENDIX

 APPENDIX 4: NON-CE SYSTEM SCHEMATIC

A-01675

APPENDIX A-4 Manual 0-2872

 NOTE
Refer to Appendix 5 for CE Power Supplies.

A-01675

Manual 0-2872 A-5 APPENDIX

 APPENDIX 5: CE SYSTEM SCHEMATIC

A-01933

APPENDIX A-6 Manual 0-2872

 NOTE
Refer to Appendix 4 for all other Power Supplies.

A-01933

Manual 0-2872 A-7 APPENDIX

APPENDIX A-8 Manual 0-2872