Thermal Dynamics PAK Master 150XL User manual

Service Manual
November 18, 2005 Manual No. 0-2825
TM
TM
A-02861
Automated Plasma
Cutting Power Supply
PAK Master
®
150XL™

WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, 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.
Automated Plasma Cutting Power Supply
Pak Master®150XL
Service Manual Number 0-2825
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
©Copyright 2000 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: November 18, 2005
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 ................................................................................................................... 1
2.01 Scope Of Manual ............................................................................................. 1
2.02 General Service Philosophy ............................................................................. 1
2.03 Service Responsibilities ................................................................................... 1
SECTION 3:
DESCRIPTION ................................................................................................................... 3-1
3.01 Scope of Manual ........................................................................................... 3-1
3.02 Power Supply General Description ................................................................ 3-1
3.03 Specifications/Design Features ..................................................................... 3-2
3.04 Power Supply Options and Accessories ....................................................... 3-3
2.05 Theory Of Operation ...................................................................................... 3-3
SECTION 4:
SERVICE .......................................................................................................................... 4-1
4.01 Introduction ................................................................................................... 4-1
4.02 Periodic Inspection & Procedures ................................................................. 4-1
4.03 System Theory ............................................................................................. 4-3
4.04 Common Operating Problems ....................................................................... 4-5
4.05 Troubleshooting Guide - General Information ................................................. 4-6
4.06 Circuit Fault Isolation .................................................................................... 4-7
4.07 Main Input and Internal Power Problems ....................................................... 4-8
4.08 Pilot Arc Problems ....................................................................................... 4-10
4.09 Main Cutting Arc Problems ..........................................................................4-12
4.10 Test Procedures ........................................................................................... 4-13
SECTION 5:
REPLACEMENT PROCEDURES ...................................................................................... 5-1
5.01 Introduction ................................................................................................... 5-1
5.02 Anti-Static Handling Procedures ................................................................... 5-1
5.03 Parts Replacement - General Information ...................................................... 5-1
5.04 Major External Parts Replacement ............................................................... 5-2
5.05 Access Panel Parts Replacement ................................................................ 5-3
5.06 Left Side Center Chassis Parts Replacement ............................................... 5-4
5.07 Right Side Center Chassis Parts Replacement ............................................. 5-8
5.08 Base Parts Replacement ............................................................................. 5-13
5.09 Rear Panel Parts Replacement ....................................................................5-16

TABLE OF CONTENTS (Continued)
SECTION 6:
PARTS LISTS .................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ...................................................................................... 6-1
6.03 Major External Replacement Parts ............................................................... 6-2
6.04 Access Panel Replacement Parts ................................................................ 6-3
6.05 Left Side Center Chassis Replacement Parts ............................................... 6-4
6.06 Right Side Center Chassis Replacement Parts ............................................ 6-6
6.07 Base Replacement Parts ............................................................................. 6-8
6.08 Rear Panel Replacement Parts ................................................................... 6-10
6.09 Options and Accessories ............................................................................ 6-12
APPENDIX 1: INPUT WIRING REQUIREMENTS ....................................................................... A-1
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ............................................ A-2
APPENDIX 3: POT/LED PC BOARD LAYOUT .......................................................................... A-3
APPENDIX 4: LOGIC PC BOARD LAYOUT ............................................................................... A-4
APPENDIX 5: GATE DRIVE PC BOARD LAYOUT..................................................................... A-6
APPENDIX 6: PILOT/OUTPUT PC BOARD LAYOUT AND WIRING CONNECTION DIAGRAM .. A-8
APPENDIX 7: CD PC BOARD LAYOUT .................................................................................. A-10
APPENDIX 8: INPUT PC BOARD LAYOUT ............................................................................. A-11
APPENDIX 9: FET PC BOARD LAYOUT ................................................................................. A-12
APPENDIX 10: CAPACITOR PC BOARD LAYOUT .................................................................. A-14
APPENDIX 11: CURRENT SENSOR PC BOARD LAYOUT ..................................................... A-15
APPENDIX 12: 36VAC CIRCUIT DIAGRAM ............................................................................. A-16
APPENDIX 13: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE
FOR LIQUID COOLED PLASMA CUTTING SYSTEMS .................................................... A-17
APPENDIX 14: TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM ........................... A-18
APPENDIX 15: POWER SUPPLY CNC INTERFACE DIAGRAM
WITHOUT STANDOFF CONTROL ................................................................................... A-19
APPENDIX 16: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM ... A-20
APPENDIX 17: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES .......... A-21

TABLE OF CONTENTS (Continued)
APPENDIX 18: FILTER/VOLTAGE DIVIDER PC BOARD LAYOUT .......................................... A-22
APPENDIX 19: SYSTEM SCHEMATIC for Units to Rev AH ..................................................... A-24
APPENDIX 20: SYSTEM SCHEMATIC for Units Rev AJ and Later ........................................... A-26

Date: November 15, 2004 1-1 GENERAL INFORMATION
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.
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.”

GENERAL INFORMATION 1-2 Date: November 15, 2004
• 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.
PLASMAARC 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

Date: November 15, 2004 1-3 GENERAL INFORMATION
6. ANSIStandard Z49.2,FIRE PREVENTIONIN THEUSE OF
CUTTINGAND WELDING PROCESSES, obtainable from
AmericanNational Standards Institute,1430 Broadway,New
York, NY 10018
7. AWS StandardA6.0, 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. NFPAStandard 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 StandardAWSF4.1, 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
Danscemanuel,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.
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.

GENERAL INFORMATION 1-4 Date: November 15, 2004
FUMÉEet GAZ
La fumée et les gaz produits par le procédé de jet de plasma
peuvent présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration.
Gardezvotretête 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.
• Lessortes de gaz et de fumée provenantde l’arc de plasma
dépendent du genre de métal utilisé, des revêtements se
trouvantsur lemétaletdes différentsprocédés. Vousdevez
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
sécuritéde santé enCalifornieet la codesécuritéSec. 25249.5
et seq.)
CHOCELECTRIQUE
Leschocs électriques peuvent blesseroumême tuer.Leprocédé
aujet de plasma requiertetproduit de l’énergie électriquehaute
tension.Cette énergieélectriquepeut produiredeschocs graves,
voire mortels, pour l’opérateur et les autres personnes sur le
lieude travail.
• 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
couperles alliages en aluminiumsousl’eau ou sur unetable
d’eau à moins que le gas hydrogène peut s’échapper ou se
dissiper. Legashydrogèneaccumuléexploserasienflammé.

Date: November 15, 2004 1-5 GENERAL INFORMATION
RAYONSD’ARCDEPLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos
yeuxetbrûlervotrepeau. Le procédé à l’arc de plasma produit
une lumière infra-rouge et des rayons 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
muniesde parois latérales ou des lunettes de protectionou
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.
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. NormeA6.0 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
PROCÉDÉSASSOCIÉS, disponible auprès de la National
FireProtectionAssociation,BatterymarchPark, Quincy, MA
02269
9. Norme 70 de la NFPA,CODE ELECTRIQUE NATIONAL,
disponible auprès de la National Fire ProtectionAssocia-
tion,BatterymarchPark, Quincy,MA02269

GENERAL INFORMATION 1-6 Date: November 15, 2004
10. Norme 51B de la NFPA,LESPROCÉDÉS DE COUPE ET
DESOUDAGE, disponibleauprès delaNational FirePro-
tectionAssociation,BatterymarchPark,Quincy, MA02269
11. BrochureGCAP-1,LAMANIPULATIONSANSRISQUE
DES GAZ COMPRIMÉS EN CYLINDRES, disponible
auprèsdel’AssociationdesGaz Comprimés(Compressed
GasAssociation), 1235 Jefferson Davis Highway, Suite
501,Arlington, VA22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE
SOUDAGE ET LA COUPE, disponible auprès de
l’AssociationdesNormesCanadiennes,Standards Sales,
178RexdaleBoulevard, Rexdale, Ontario, Canada, M9W
1R3
13. LivretNWSA,BIBLIOGRAPHIESURLASÉCURITÉDU
SOUDAGE,disponible auprèsdel’Association Nationale
deFournituresdeSoudage (NationalWeldingSupplyAs-
sociation), 1900Arch Street, Philadelphia, PA19103
14. NormeAWSF4.1 del’AssociationAméricainede Soudage,
RECOMMANDATIONSDEPRATIQUESSURESPOUR
LAPRÉPARATIONÀLACOUPEETAUSOUDAGE DE
CONTENEURSET TUYAUXAYANT RENFERMÉ DES
PRODUITSDANGEREUX,disponibleauprèsdelaAmeri-
can Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. NormeANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

Date: November 15, 2004 1-7 GENERAL INFORMATION
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.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and
associated accessories.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment
* 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 tips, if equipped with properly installed stand-
off guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing 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: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

GENERAL INFORMATION 1-8 Date: November 15, 2004
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

Manual 0-2825 2-1 INTRODUCTION
2.03 Service Responsibilities
The Service Technician should be familiar with the equip-
ment and its capabilities and should be prepared to rec-
ommend arrangements of components which will pro-
vide the most efficient layout, utilizing the equipment to
its best possible advantage.
Maintenance work should be accomplished in a timely
manner. If problems are encountered, or the equipment
does not function as specified, contact Technical Services
Department at West Lebanon for assistance.
SECTION 2:
INTRODUCTION
2.01 Scope Of Manual
This Manual provides Service Instructions for Thermal
Dynamics PAK Master®150XLAutomated Plasma Power
Supply.
Refer to Operating Manual (0-2824) for individual oper-
ating procedures. Information in this edition is therefore
particularly applicable to the Troubleshooting and Repair
of the equipment, and is intended for use by properly
trained Service Technicians familiar with this equipment.
Read this manual and the Operating Manual thoroughly.
A complete understanding of the capabilities and func-
tions of the equipment will assure obtaining the perfor-
mance for which it was designed.
2.02 General Service Philosophy
Several key points are essential to properly support the
application and operation of this equipment.
A. Application
The equipment should satisfy the customer’s require-
ments as supplied and as described in Section 3 of this
manual. Be sure to confirm that the equipment is capable
of the application desired.
B. Modifications
No physical or electrical modifications other than selec-
tion of standard options and accessories are to be made
to this equipment.
C. Customer/Operator Responsibilities
It is the customer/operator's responsibility to maintain
the equipment and peripheral accessories provided by
Thermal Dynamics in good operating order in accordance
with the procedures outlined in the Operating Manual,
and to protect the equipment from accidental or mali-
cious damage.
D. Repair Restrictions
The electronics consists of Printed Circuit Board Assem-
blies which must be carefully handled, and must be re-
placed as units. No replacement of printed circuit sol-
der-mounted components is allowed except as noted in
this manual.
Printed Circuit Board Assemblies to be returned must be
properly packaged in protective material and returned
intact per normal procedures.

INTRODUCTION 2-2 Manual 0-2825

Manual 0-2825 3-1 DESCRIPTION
SECTION 3:
DESCRIPTION
3.01 Scope of Manual
The information in this section has two purposes:
• To familiarize the service technician with the capa-
bilities and limitations of the equipment,
• To provide an overall understanding which will al-
low the technician, in turn, to properly train
customer's operating personnel.
3.02 Power Supply General
Description
Power Supply is designed to cut most metals up to 1-1/2
inches (38 mm) using air, nitrogen, or argon/hydrogen
as the plasma gas. This system is also capable of satisfy-
ing many mechanized gouging applications.
The Automated Power Supply provides 120 amp maxi-
mum output current and includes all control circuitry,
electrical and gas inputs and outputs, pilot circuitry, torch
leads receptacle and a 20 ft (6.1 m) work cable with ring
lug.
The torch used with the Power Supply is available in the
following configuration:
• 180° Machine Torch Head (PCM) with 1-3/8 inch
(34 mm) diameter Mounting Tube with Rack and
Pinion Assembly
Automated system include a machine torch with shielded
leads and a CNC Interface Cable.
NOTES
The power supply can be ordered in various con-
figurations with various options factory installed.
Refer to the supplied Torch Instruction Manual for
more information on the Torch.
Refer to Section 3.04 for list of Power Supply Op-
tions and Accessories.
TM
TM
A-02862
Power Supply
Torch & Leads
Work Cable With
Ring Lug
Figure3-1 AutomatedPakMaster150XLSystem
TheExtra-CoolTM Coolant suppliedwiththePowerSupplycan
be used in ambient temperatures down to 10° F (-12° C). For
lowertemperatures, Ultra-CoolTM Coolant shouldbeused. This
coolant can be used in areas where the ambient temperature
drops to -27° F (-33° C).
A. Typical System
A typical system configuration will contain the follow-
ing:
• Automated Power Supply
• 20 ft (6.1 m) Work Cable with Ring Lug
• PCM Torch with 25 ft (7.6 m) or 50 ft (15.2 m) Leads
length as ordered
• PCM Torch Spare Parts Kit
• CNC Interface Cable, 25 ft (7.6 m) or 50 ft (15.2 m)
length as ordered
• Standard Thermal Arc Coolant - 3 gallons (11.4 li-
ters)
NOTE
Refer to Section 3.04 for complete list of Power Sup-
ply Options and Accessories.
B. Requirements to Complete System
To complete the system, the user needs to provide the
following:
• Primary Input Power Cable
• Gas Supplies

DESCRIPTION 3-2 Manual 0-2825
3.03 Specifications/Design
Features
A. Power Supply Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
• ON/OFF and RUN/SET Switches
• Output Current Control
• Work Cable Connection
• Torch Leads Connection
2. Front Panel LED Indicators
•AC
• TEMP
• GAS Pressure/Coolant Flow
• DC Output
3. Rear Panel
• Primary Input Power Cable Strain Relief
• Plasma Gas Supply Connection
• Plasma Gas Regulator/Filter Assembly with Gas
Pressure Gauge and Pressure Adjustment
• Secondary Gas Supply Connection
• Secondary Gas Regulator/Filter Assembly with Gas
Pressure Gauge and Pressure Adjustment
• Two Stage Air Line Filter
• CNC Control Connector
4. Input Power (see NOTES)
208/230/460 VAC (±10%), 50/60 Hz, Three-Phase
220/380-415 VAC (±10%), 50/60 Hz, Three-Phase
575 VAC (±10%), 50/60Hz, Three-Phase
NOTES
Refer to Appendix 1 for suggested input wiring
size, current ratings and circuit protection require-
ments.
Units using 575 VAC input power require instal-
lation of Optional 575V Transformer Assembly.
5. Output Power
Continuously variable from 30 to 120 amps (±5%)
6. Duty Cycle
60% @ 128 vdc output at 120 amps
7. Cut Capacity on Carbon Steel
• Genuine Cut Capacity: 1-1/2 inch (38 mm)
• Severance Cut: 1- 3/4 inch (44 mm)
• Pierce Rating: 5/8 inch (15.9 mm)
8. Pilot Circuitry
Capacitive Discharge (CD), Pulsed DC
9. CNC Interface Signals
Start/Stop, OK-To-Move and Arc Voltage
10. Coolant Pressure
Internal Service Adjustable (Factory Only)
130 psi (8.8 bar) at zero flow
120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)
11. Coolant Flow Rate
0.5 gpm (1.9 lpm) with 150 feet (45.7 m) of total torch
and torch leads at 70°F (21°C)
NOTE
The flow rate varies with lead length, torch con-
figuration, ambient temperature, amperage level,
etc.
12. Cooling Capacity
4,000 to 10,000 BTU
NOTE
Maximum value based on “free flow” condition.
13. Coolant Reservoir Capacity
2 gallons (Use Thermal Arc®coolant only)
Capable of handling a total of 150 feet (45.7 m) of torch
lead length
14. Overall Dimensions
Height: 45-3/8 inches (1.2 m)
Width: 24-1/2 in (0.6 m)
Depth: 35 inches (0.9 m)
15. Weight
Power Supply with Torch: 275 lbs (125 kg)
Shipping Weight: 350 lbs (158.8 kg)
16. Used With Torch
• PCM-120 Automated Machine Torch

Manual 0-2825 3-3 DESCRIPTION
B. Gas Regulator/Filter Assembly
Specifications
The following specifications apply to the Gas Regulator/
Filter Assembly only:
1. Gas Regulator Maximum Gauge Pressure
Plasma: 160 psi (11.3 bar)
Secondary: 160 psi (11.3 bar)
2. Maximum Input Gas Pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
C. Gas Requirements
1. Plasma
Gases: Compressed Air, Nitrogen, Argon/Hydrogen
Operating Pressure: 65 psi (4.5 bar)
Cold Flow:
Cutting: 50 - 78 scfh (23.6 - 36.8 lpm)
Gouging: 85 - 95 scfh (40.1 - 44.8 lpm)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar).
2. Secondary
Gases: Compressed Air, Carbon Dioxide (C02), Ni-
trogen
Operating Pressure: 60 psi (4.1 bar)
Cold Flow:
Cutting: 340 scfh (160.4 lpm)
Gouging: 235 scfh (110.9 lpm)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar).
D. Two Stage Air Line Filter
The Two Stage Air Line Filter will remove moisture
and contaminants from the air stream when using
compressed air. The filter is capable of filtering to at
least 5 microns.
3.04 Power Supply Options and
Accessories
The following accessories are available for the Power
Supply. Refer to Section 6, Parts Lists, for part numbers
and ordering information.
A. Primary Input Power Cable
The following input power cables are available:
• 230VAC, (2AWG) 10 ft (3 m)
• 460VAC, (6AWG) 10 ft (3 m)
B. High Pressure Regulators
High pressure regulators are available for air, nitro-
gen, and argon-hydrogen. The regulators are used to
set the proper pressure for the type of gas being used.
C. 575V Transformer
This 575 VAC to 460 VAC Step-down Transformer al-
lows the Power Supply to operate on 575 VAC three-
phase input power.
D. Standoff Control (SC11)
Optional Standoff Control automatically finds height
and maintains torch standoff with a high speed torch
lifter motor. Refer to Standoff Control (SC11) Manual,
0-2556, for more information.
E. Remote Pendant Control
Control used to manually start and stop cutting op-
erations from a location up to 20 ft. (6.1 m) from the
Plasma Power Supply.

DESCRIPTION 3-4 Manual 0-2825
2.05 Theory Of Operation
A. Plasma Arc Cutting and Gouging
Plasma is a gas which is heated to an extremely high tem-
perature and ionized so that it becomes electrically con-
ductive. The plasma arc cutting process uses this plasma
gas to transfer an electric arc to a workpiece. The metal
to be cut is melted by the intense heat of the arc and then
blown away by the flow of gas.
With a simple change of torch parts, the system can also
be used for plasma arc gouging. Plasma arc gouging uses
the same process to remove material to a controlled depth
and width.
B. Input and Output Power
The unit converts AC input power to DC power for the
main cutting arc. The negative output is connected to
the torch electrode through the negative torch lead, and
the positive output connects to the workpiece through
the work cable.
C. Pilot Arc
When the torch is activated there is a 2 second (service
adjustable) gas pre-flow, followed by an uninterrupted
pulsed DC pilot arc established between the electrode and
tip. The pilot arc is initiated by a momentary high fre-
quency pulse from the Power Supply. The pilot creates a
path for the main arc to transfer to the work. When the
main arc is established, the pilot arc shuts off. The pilot
automatically restarts when the main arc stops, as long
as the torch remains activated.
D. Main Cutting Arc
The power supply converts the AC input power to DC
power for the main cutting arc. The negative output is
connected to the torch electrode through the negative
torch lead. The positive output is connected to the work-
piece via the work cable and clamp connection.
E. RF Shielding
Automated systems using CNC Interface Cables are
shielded to minimize radio frequency (RF) interference
which results from the high frequency arc initiation. These
shielded systems are designed with features such as a
wire for establishing an earth ground and shielded torch
and control leads. The CNC control signals are filtered
on an internal PC Board.
F. Interlocks
The system has several built-in interlocks to provide safe
and efficient operation. When an interlock shuts down
the system, the fault condition must be remedied and the
system recycled using the applicable control device.
1. Parts-In-Place (PIP) Interlock
The Power Supply has a built-in parts-in-place in-
terlock that prevents accidental torch starting
when torch parts are not properly installed. Aflow
switch on the coolant return lead detects reduced
coolant flow caused by improper torch assembly.
If not satisfied, the switch interrupts power to the
tip and electrode.
2. Gas Pressure Interlock
A pressure switch acts as an interlock for the
plasma gas supply. If the plasma gas supply pres-
sure falls below minimum requirements the pres-
sure switch will open, shutting off the power to
the contactors, and the GAS indicator will go out.
When adequate plasma supply pressure is avail-
able the pressure switch will close, allowing power
to be resumed for cutting.
NOTE
There is no gas pressure interlock for secondary
gas.