63_9901 PakMaster XL Plus Series

PakMaster XL PLUSSeriesPLUS the new SureLok™ Torch!

• New SureLok Torch Technology

• New SureLok™ Electrode Design

• Ergonomic Torch Handle

PakMaster™ 50XL PLUSGENUINE CUT 1⁄2” (12.7mm)

SEVERANCE CUT 3⁄4” (19.1mm)

PakMaster™ 100XL PLUSGENUINE CUT 1” (25.4mm)

SEVERANCE CUT 11⁄4” (31.8mm)

PakMaster™ 75XL PLUSGENUINE CUT 3⁄4” (19.1mm)

SEVERANCE CUT 1” (25.4mm)

PAK ™MASTERXL PLUS

3 Year Warranty

Air Plasma CuttingSystems

Over 40 Years of Plasma Cutting Innovation

PLASMA CUTTING SERIES


2 THERMAL DYNAMICS w w w . t h e r m a l - d y n a m i c s . c o m © T h e r m a l D y n a m i c s C o r p . , 2 0 0 0

SURELOK™ TORCHSureLok™ torch technology is an innovation in plasma torchdesign. Our patented electrode locking mechanism results inprecise tip and electrode positioning and more efficient oper-ation, resulting in improved consumable life. The electrode isalso easier to install, with no tools required.

SMART LOGIC™This circuit prevents damage to the unit should it be connect-ed to high line voltage while it is linked for low voltage.

SMART START™ — AUTO PILOT RESTARTInstantly reignites the pilot arc when the cutting arc is inter-rupted, such as when cutting expanded metal. This featurekeeps the arc on when cutting over holes or moving fromone cut to another without having to restart the torch, animportant feature for maintaining productivity.

TIP SAVER — CURRENT FOLD BACK CIRCUITAccidental contact between tip and material while cuttingor gouging at higher output levels can be expensive withsome competitive systems. Our Tip Savercircuit protects consumable parts andeliminates down time by reducing thecutting current while the tip is in contactwith the material, saving time and money.

TRIGGER LATCHPrevents hand fatigue during long cuts byallowing the torch switch to be releasedafter the cutting arc is established. The arcwill remain on until the cutting arc is bro-ken at the edge of the metal or if the torch

is lifted away from the work piece. This feature can be de-selected by the front panel switch for automated applicationsor hand applications where the operator needs to be able tostop the arc by release of the torch switch.

UNIVERSAL INPUT POWERBy a simple change over procedure and use of the appropriateinput cable/plug, the units can accept input power from 208 to460 VAC ± 10%, single or three phase, 50 or 60 hertz. Anoptional transformer is available for use on 575 VAC.

IP-23C PROTECTION CERTIFIEDThermal Dynamics® uses this test to check the unit’s abili-ty to perform in difficult conditions. Where other manu-facturers use a simple water drip test, Thermal Dynamicsuses a high pressure spray test to check the unit’s ability tostand up to outdoor weather.

FLOW THROUGH COOLING DESIGNAll of the semi-conductor devices are mounted on aheatsink. The cooling air is channeled through the fins onthe opposite side of the heatsink so that dirty environmen-tal air does not flow directly over the switching devices.This helps to prevent build up of foreign material whichcould otherwise limit duty cycle or component life.

CSA NRTL/C APPROVEDThe Canadian Standards Association is recognized world-wide as a premier testing laboratory. Thermal Dynamics is

proud to comply with the rigorousstandards of CSA 22.2 No. 60 forelectrical equipment.

3 YEAR WARRANTYPROTECTIONPakMaster XL PLUS units comewith excellent warranty protection– Power supply components arewarranted for 3 years; labor, torchand leads for 1 full year.

Features and Benefits



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The SureLok™ AdvantageThermal Dynamics® SureLok torch technology is used throughout thePakMaster XL PLUS family. SureLok torches and consumable parts offerimportant advantages for hand or mechanized plasma cutting.

• Tapered shield cup and small torch head – Allow excel-lent control when beveling and gouging. SureLok’s size,shape and long arc also make PakMaster XL PLUS anexcellent tool for cutting and gouging in tight spaceswhere other torches will not fit

• Long arc length – SureLok torches produce excellent cutsacross a wide range of cutting conditions, from drag cut-ting with the tip directly on the material, to beveling andgouging, where the tip must be held further away frommaterial. SureLok’s strong pilot arc and focused cuttingpower produce a long arc that gives operators more flexi-bility and control in demanding situations.

• Improved cutting performance - The patented electrodeinsertion design results in exact positioning of consum-able parts, every time, with no special tools. This meansa precise, well-defined cutting arc and more precise cuts.

• Improved torch cooling – Means longer consumableparts life and lower operating costs.

• Extended tip – For maximum visibility and optimum per-formance in drag cutting. The extended tip provides aclear view of the cut in stand-off or drag cutting. Dragcutting with the tip in contact with the metal results in anarrow kerf, helps eliminate dross and results in greaterprecision on sheet metal.

Cut QualityPakMaster XL PLUS power supplies deliver exceptionallysmooth, powerful cutting current. Combined with the fea-tures of the SureLok torch, this makes PakMaster XLPLUS the leader in cut quality.

Sheet Metal – PakMaster XL PLUS systems excel at dragcutting at current levels below 35 amps. The tip directlytouches the metal, resulting in clean cuts, narrow kerf anda very small Heat Affected Zone (HAZ). This quality can-not be achieved with torches that have a bulky shield cupand recessed tip.

Stand-off cutting – Hold the torch tip 1⁄8 - 3⁄8 inches awayfrom the work for cutting at higher amperage levels.PakMaster XL PLUS systems provide a precise, well-defined arc that results in less top edge rounding, less bevelalong the cut edge and a smoother cut surface. Our TipSaver™ fold-back circuit protects consumable parts fromdamage caused by accidental contact with the work.

Gouging – PakMaster XL PLUS systems can be used forprecision gouging with a simple change of consumableparts. With adjustable current settings and the SureLoktorch features, PakMaster XL PLUS systems deliver thepower and control you need for backgouging welds, sepa-rating welded parts or removing hardfacing metals. OurTip Saver™ fold-back circuit protects your consumableparts life and makes the torch an easy to use gouging tool.

PakMaster™ 50 XL PLUS cut on 7 guage mildsteel using the optional cutting guide kit



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70° Hand Torch 90° Hand Torch 180° Machine Torch

SYSTEM 20 ft. (6.1m) 50 ft. (15.2m) 20 ft. (6.1m) 50 ft. (15.2m) 25 ft. (7.6m) 50 ft. (15.2m)

PakMaster 50XL PLUS 1-5045-V 1-5046-V 1-5047-V 1-5048-V 1-5049-V 1-5050-V



70° Hand Torch 90° Hand Torch 180° Machine Torch20 ft. Leads 50 ft. Leads 20 ft. Leads 50 ft. Leads 25 ft. Leads 50 ft. Leads

PCH/M-62 7-6220 7-6221 7-6222 7-6223 7-6224 7-6225

PCH/M-102 7-7530-SL 7-7532-SL 7-7531-SL 7-7533-SL 7-7536-SL 7-7537-SL

System Ordering Information: The standard systems include power supply with 20’ work cable and clamp, torch andleads and spare parts kit. Machine torch systems include phenolic mounting tube and pinch block assembly. RemotePendant or CNC Cable are not included with systems, see Remote Options below for ordering information.

V=Voltage Suffix:1 208/230vac 1ph setting with 50 amp input cable and plug 2 460vac 3ph setting –No input cable or plug

Torch & Lead Combinations (Included with Systems)

Remote Options:

Computer Control (CNC) Cable: 25 ft (7.6m) 8-555750 ft (15.2m) 8-5558

Hand Pendant Control with 25 ft (7.6m) Cable: 7-3114Extension Cable 25 ft (7.6m) for Hand Pendant Control: 7-7744Metal Mounting Tube with Pinion Assembly 7-7745

Which PakMaster XL PLUS System Do I Need?Several factors should be considered when selecting a plasma system.

What is the thickest material to be cut?Genuine cut ratings mean that the system can cut a specificthickness of mild steel at approximately 10 inches perminute and achieve excellent cut quality. Severance cut rating means the system will cut this thickness of mild steelat a slower rate with some loss in cut quality. Aluminum andstainless steel generally require more power to cut, and cutratings may vary by as much as 25%.

What will I need to pierce? Pierce ratings should be calculated at 50% of genuine cut ratings.

How fast do I want to cut?Operator comfort and control is the real determinant of cut speed in hand cutting. More cutting power translates

directly to faster cutting speeds. Mechanized system cutting speeds can be limited by the mechanized posi-tioner capability.

What voltage input power is available?PakMaster XL PLUS systems accept 208-460 volts, sin-gle or 3 phase power.

XL™ PLUS IN PERFORMANCE


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PakMaster™ 50XL PLUS PCH/M-62Spare Parts Kits

Standard VIPCat. Number Part Description #5-6203 #5-6205

9-8407 Electrode, Maximum Life 3 259-8402 Electrode, General Purpose 0 09-8411 Tip, 40 Amp, Drag 2 209-8412 Tip, 40 Amp, Stand-off 5 309-8416 Tip, 40 Amp, Gouging 0 09-8401 Gas Distributor, 40 Amp 0 19-8400 Shield Cup, 40 Amp 0 18-0532 O-Ring 1 09-7501 Coil Spring 1 29-8415 Stand-off Cutting Guide 1 1


PakMaster™ 75XL PLUS PCH/M-102 (60 Amp)Spare Parts Kits

Standard VIP GougingCat. Number Description #5-7509 #5-7510 #5-0011

9-8407 Electrode, Maximum Life 5 20 109-8402 Electrode, General Purpose 0 0 08-7503 Tip, 40 Amp, Cutting 2 10 09-7726 Tip, 60 Amp, Cutting 5 40 08-7506 Tip, Gouging 0 0 158-7501 Gas Distributor, Cutting 0 2 08-7508 Gas Distributor, Gouging 0 0 28-7500 Shield Cup, Cutting 0 1 28-0532 O-Ring 1 5 59-7501 Coil Spring 1 3 38-7575 Stand-off Cutting Guide 1 1 08-7507 Shield Cup, Crown 0 1 0

PakMaster™ 100XL PLUS PCH/M-102 (80 Amp)Spare Parts Kits

Standard VIP GougingCat. Number Description #5-0009 #5-0010 #5-0011

9-8407 Electrode, Maximum Life 5 20 109-8402 Electrode, General Purpose 0 0 08-7503 Tip, 40 Amp, Cutting 2 10 09-7726 Tip, 60 Amp, Cutting 0 0 09-7728 Tip, 80 Amp, Cutting 5 40 08-7506 Tip, Gouging 0 0 158-7501 Gas Distributor, Cutting 0 2 08-7508 Gas Distributor, Gouging 0 0 28-7500 Shield Cup, Cutting 0 1 28-0532 O-Ring 1 5 59-7501 Coil Spring 1 3 38-7575 Stand-off Cutting Guide 1 1 08-7507 Shield Cup, Crown 0 1 0

SureLok™ Plasma Torches


ACCESSORIES

PAKMASTER XL™ PLUS PRODUCT SPECIFICATIONSPAKMASTER™ 50 XL PLUS PAKMASTER™ 75 XL PLUS PAKMASTER™ 100 XL PLUSCutting System Specification Cutting System Specification Cutting System Specification

Power SupplyCapacity: 1⁄2” (12.7mm) Genuine 3⁄4” (19.1mm) Genuine 1” (25.4mm) Genuine

3⁄4” (19.1mm) Severance 1” (25.4mm) Severance 11⁄4” (31.8mm) SeveranceOutput: 15-40 Amps - Continuously variable 15-60 Amps - Continuously variable 15-80 Amps - Continuously variableInput Power: 208-460 VAC (+/-10%) 208-460 VAC (+/-10%) 208-460 VAC (+/-10%)

1/3 Phase, 50/60Hz 1/3 Phase, 50/60Hz 1/3 Phase, 50/60Hz40/22 Amps 1 Phase 60/30 Amps 1 Phase 91/46 Amps 1 Phase20/11 Amps 3 Phase 31/16 Amps 3 Phase 48/26 Amps 3 Phase

Duty cycle: 100% @ 40 Amps 65% @ 60 Amps / 100% @ 55 Amps 40% @ 80 Amps / 100% @ 60 AmpsPanel Controls: On/Off Switch On/Off Switch On/Off Switch

RUN/SET/LATCH Switch RUN/SET/LATCH Switch RUN/SET/LATCH SwitchOutput Current Potentiometer Output Current Potentiometer Output Current Potentiometer

Panel Indicators: AC Power AC Power AC PowerTemperature Temperature TemperatureGas Pressure Gas Pressure Gas PressureDC Output DC Output DC Output

Dimensions: Height: 16” (406mm) Height: 16” (406mm) Height: 16” (406mm)Width: 13” (330mm) Width: 13” (330mm) Width: 13” (330mm)Length: 24.8” (630mm) Length: 24.8” (630mm) Length: 24.8” (630mm)

Weight: 66 lbs. (29.9 Kg) 71 lbs. (32.2 Kg) 75 lbs. (34 Kg)Work Cable Length: 20 ft (6.1m) 20 ft (6.1m) 20 ft (6.1m)

TorchModel PCH/M-62 PCH/M-102 PCH/M-102Gas: Air, Nitrogen Air, Nitrogen Air, NitrogenGas Pressure: 70 PSI ( 4.8 Bar) 60 PSI ( 4.1 Bar) 70 PSI ( 4.8 Bar)Gas Flow: 200 SCFH / 3.3CFM (95 lpm) 300 SCFH / 5CFM (142 lpm) 400 SCFH / 6.6CFM (190 lpm)Pilot: CD Start/ Pulsed DC CD Start/ Pulsed DC CD Start/ Pulsed DCControl: Hand switch Hand switch Hand switch

Remote Pendant Remote Pendant Remote PendantCNC Interface Cable CNC Interface Cable CNC Interface Cable

Torch Lead length:Hand 20 ft (6.1m) 20 ft (6.1m) 20 ft (6.1m)

50 ft (15.2m) 50 ft (15.2m) 50 ft (15.2m)Machine 25 ft (7.6m) 25 ft (7.6m) 25 ft (7.6m)

50 ft (15.2m) 50 ft (15.2m) 50 ft (15.2m)

575 Volt Power Transformer Cat. No. 9-7500For use with XL PLUS systems that require 575 Volt 3 ph input power

Air Filter KitCat. No. 7-7507All Systems.85 MicronParticulate Filter for use on compressed shop air systems

Cutting Guide KitCat. No. 7-8910All SystemsEasy add-on attachments to allow for straight line,circlecutting and beveling for all XL PLUS Systems

Cutting Guide Cat. No. 7-7501All SystemsManual circle cutting guide, 2" to 16" circles

Smart CartCat. No. 7-7777All SystemsRugged steel cart withlarge rubber wheels to maximize systemportability

International Customer Service Thermadyne Canada Thermadyne UK Thermadyne Asia Sdn. Bhd. Cigweld AustraliaOakville, Ontario, Canada Oakville, Ontario Canada Chorley, England Kuala Lumpur, Malaysia Melbourne, Australia

Ph: (1) 905-827-9777 Ph: (1) 905-827-1111 Ph: (44) 1257-261755 Ph: (603) 6092-2988 Ph: (61) 3-9474-7400Fax: (1) 905-827-9797 Fax: (1) 905-827-3648 Fax: (44) 1257-224800 Fax: (603) 6092-1085 Fax: (61) 3-9474-7510

Thermadyne do Brasil Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Thermadyne EuropeRio de Janeiro, Brazil Dubai, United Arab Emirates Mexico City, Mexico Osaka, Japan Milan, ItalyPh: (55) 21-485-8859 Ph: (971) 4-332-9060 Ph: (52) 5696-7407 Ph: (81) 6-4809-8411 Ph: (39) 039-204-991Fax: (55) 21-485-8735 Fax: (971) 4-332-5484 Fax: (52) 5696-7757 Fax: (81) 6-4809-8412 Fax: (39) 039-204-9922

U.S. CUSTOMER SERVICE: Industrial Park #2 • West Lebanon, NH 03784(1) 603-298-5711 • FAX (1) 603-298-5720

International Offices

Form No. 63-9901 (1/01) © Thermal Dynamics Corp., 2001 www.thermal-dynamics.com Printed in U.S.A.

WORLD HEADQUARTERS: 101 S. Hanley Road • St. Louis, MO 63105 • 314-721-5573 • FAX 314-746-2161

Documents

63_9901 PakMaster XL Plus Series