PAK. PakMaster XL PLUS-CE Series. PLUS The New SureLok Torch! Air Plasma Cutting Systems. Over 40 Years of Plasma Cutting Innovation

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1 MASTERXL PLUS- Air Plasma Cutting Systems 3 Year Warranty PakMaster 50XL PLUS-CE GENUINE CUT 12.7mm ( 1 2 ) SEVERANCE CUT 19.1mm ( 3 4 ) PakMaster 75XL PLUS-CE GENUINE CUT 19.1mm ( 3 4 ) SEVERANCE CUT 25.4mm (1 ) PakMaster 100XL PLUS-CE GENUINE CUT 25.4mm (1 ) SEVERANCE CUT 31.8mm (1 1 4 ) PakMaster XL PLUS-CE Series PLUS The New SureLok Torch! New Patented SureLok Torch Technology New SureLok Electrode Design Ergonomic Torch Handle Over 40 Years of Plasma Cutting Innovation

2 Features and Benefits SURELOK TORCH SureLok torch technology is an innovation in plasma torch design. Our patented electrode locking mechanism results in precise tip and electrode positioning and more efficient operation, resulting in improved consumable life. The electrode is also easier to install, with no tools required. SMART LOGIC This circuit prevents damage to the unit should it be connected to high line voltage while it is linked for low voltage. SMART START AUTO PILOT RESTART Instantly reignites the pilot arc when the cutting arc is interrupted, such as when cutting expanded metal. This feature keeps the arc on when cutting over holes or moving from one cut to another without having to restart the torch, an important feature for maintaining productivity. after the cutting arc is established. The arc will remain on until the cutting arc is broken 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 applications or hand applications where the operator needs to be able to stop the arc by release of the torch switch. IP-23C PROTECTION CERTIFIED Thermal Dynamics uses this test to check the unit s ability to perform in difficult conditions. Where other manufacturers use a simple water drip test, Thermal Dynamics uses a high pressure spray test to check the unit s ability to stand up to outdoor weather. FLOW THROUGH COOLING DESIGN All of the semi-conductor devices are mounted on a heatsink. The cooling air is channeled through the fins on the opposite side of the heatsink so that dirty environmental air does not flow directly over the switching devices. This helps to prevent build up of foreign material which could otherwise limit duty cycle or component life. TIP SAVER CURRENT FOLD BACK CIRCUIT Accidental contact between tip and material while cutting or gouging at higher output levels can be expensive with some competitive systems. Our Tip Saver circuit protects consumable parts and eliminates down time by reducing the cutting current while the tip is in contact with the material, saving time and money. TRIGGER LATCH Prevents hand fatigue during long cuts by allowing the torch switch to be released CSA NRTL/C APPROVED The Canadian Standards Association is recognized worldwide as a premier testing laboratory. Thermal Dynamics is proud to comply with the rigorous standards of CSA 22.2 No. 60 for electrical equipment. 3 YEAR WARRANTY PROTECTION PakMaster XL PLUS-CE units come with excellent warranty protection Power supply components are warranted for 3 years; labor, torch and leads for 1 full year. 2 THERMAL DYNAMICS Thermal Dynamics Corp., 2001

3 The SureLok Advantage Thermal Dynamics SureLok torch technology is used throughout the PakMaster XL PLUS-CE family. SureLok torches and consumable parts offer important advantages for hand or mechanized plasma cutting. Improved cutting performance - The patented electrode insertion design results in exact positioning of consumable parts, every time, with no special tools. This means a precise, well-defined cutting arc and more precise cuts. Improved torch cooling Means longer consumable parts life and lower operating costs. Extended tip For maximum visibility and optimum performance in drag cutting. The extended tip provides a clear view of the cut in stand-off or drag cutting. Drag cutting with the tip in contact with the metal results in a narrow kerf, helps eliminate dross and results in greater precision on sheet metal. Tapered shield cup and small torch head Allow excellent control when beveling and gouging. SureLok s size, shape and long arc also make PakMaster XL PLUS-CE an excellent tool for cutting and gouging in tight spaces where other torches will not fit Long arc length SureLok torches produce excellent cuts across a wide range of cutting conditions, from drag cutting with the tip directly on the material, to beveling and gouging, where the tip must be held further away from material. SureLok s strong pilot arc and focused cutting power produce a long arc that gives operators more flexibility and control in demanding situations. Cut Quality PakMaster XL PLUS-CE power supplies deliver exceptionally smooth, powerful cutting current. Combined with the features of the SureLok torch, this makes PakMaster XL PLUS-CE the leader in cut quality. Sheet Metal PakMaster XL PLUS-CE systems excel at drag cutting at current levels below 35 amps. The tip directly touches the metal, resulting in clean cuts, narrow kerf and a very small Heat Affected Zone (HAZ). This quality cannot be achieved with torches that have a bulky shield cup and recessed tip. Stand-off cutting Hold the torch tip 3.2mm - 9.6mm ( ) away from the work for cutting at higher amperage levels. PakMaster XL PLUS-CE systems provide a precise, well-defined arc that results in less top edge rounding, less bevel along the cut edge and a smoother cut surface. Our Tip Saver fold-back circuit protects consumable parts from damage caused by accidental contact with the work. Gouging PakMaster XL PLUS-CE systems can be used for precision gouging with a simple change of consumable parts. With adjustable current settings and the SureLok torch features, PakMaster XL PLUS-CE systems deliver the power and control you need for backgouging welds, separating welded parts or removing hardfacing metals. Our Tip Saver fold-back circuit protects your consumable parts life and makes the torch an easy to use gouging tool. PakMaster 50 XL PLUS-CE cut on 7 gauge mild steel using the optional cutting guide kit 3

4 - Which PakMaster XL PLUS-CE 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 specific thickness of mild steel at approximately 254mm (10 ) per minute and achieve excellent cut quality. Severance cut rating means the system will cut this thickness of mild steel at a slower rate with some loss in cut quality. Aluminum and stainless steel generally require more power to cut, and cut ratings 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 XL PLUS-CE IN PERFORMANCE directly to faster cutting speeds. Mechanized system cutting speeds can be limited by the mechanized positioner capability. What voltage input power is available? PakMaster XL PLUS-CE systems accept 380/415 volts, 50/60Hz., 3-phase power. System Ordering Information: The standard systems include a power supply with 6.1m (20 ) work cable and clamp, torch and leads and spare parts kit. Machine torch systems include phenolic mounting tube and pinch block assembly. Remote Pendant or CNC Cable are not included with systems, see Remote Options below for ordering information. 70 Hand Torch 180 Machine Torch SYSTEM 6.1m (20 ft.) 15.2m (50 ft.) 7.6m (25 ft.) 15.2m (50 ft.) PakMaster 50XL PLUS-CE * * PakMaster 75XL PLUS-CE * * PakMaster 100XL PLUS-CE * * *Remote Control is not included. Order appropriate control from options below. Torch & Lead Combinations (Included with Systems) 70 Hand Torch 180 Machine Torch TORCH 6.1m Leads 15.2m Leads 7.6m Leads 15.2m Leads PCH/M PCH/M SL SL SL SL REPLACEMENT TORCH HEADS ONLY PCH/M PCH/M Remote Options: Computer Control (CNC) Cable: 7.6m (25 ft.) m (50 ft.) Hand Pendant Control with 7.6m (25 ft.) Cable: Extension Cable 7.6m (25 ft.) for Hand Pendant Control: Metal Mounting Tube with Pinion Assembly call (39) for more information 4

5 SureLok Plasma Torches PakMaster 50XL PLUS-CE PCH/M-62 Standard Spare Parts Kit Cat. Number Part Description # O-Ring Electrode (SureLok), General Purpose Gas Distributor, 40 Amp Tip, 40 Amp, Drag Tip, 40 Amp, Stand-off Tip, 40 Amp, Gouging Coil Spring Shield Cup, 40 Amp Stand-off Cutting Guide 1 PakMaster 75XL PLUS-CE PCH/M-102 (60 Amp) Standard Spare Parts Kit Cat. Number Description # O-Ring Electrode (SureLok), General Purpose Gas Distributor, Cutting Gas Distributor, Gouging Tip, 60 Amp, Cutting Tip, 40 Amp, Cutting Tip, Gouging Coil Spring Shield Cup, Cutting Shield Cup, Crown Stand-off Cutting Guide Fuse (0.8A, 600V) Adapter Fitting 1/4 Hose to 1/4 NPT Lubricant Box, Utility 1 PakMaster 100XL PLUS-CE PCH/M-102 (80 Amp) Standard Spare Parts Kit Cat. Number Description # O-Ring Electrode (SureLok), General Purpose Gas Distributor, Cutting Gas Distributor, Gouging Tip, 80 Amp, Cutting Tip, 60 Amp, Cutting Tip, 40 Amp, Cutting Tip, Gouging Coil Spring Shield Cup, Cutting Shield Cup, Crown Stand-off Cutting Guide Fuse (0.8A, 600V) Adapter Fitting 1/4 Hose to 1/4 NPT Lubricant Box, Utility 1 call (39) for more information 5

6 PRODUCT SPECIFICATIONS MASTER 50 XL PLUS-CE MASTER 75 XL PLUS-CE MASTER 100 XL PLUS-CE Cutting System Specification Cutting System Specification Cutting System Specification Power Supply Capacity: 12.7mm Genuine 19.1mm Genuine 25.4mm Genuine 19.1mm Severance 25.4mm Severance 31.8mm Severance Output: Amps - Continuously variable Amps - Continuously variable Amps - Continuously variable Input Power: 220/ VAC (+/-10%) 380/415 VAC (+/-10%) 380/415 VAC (+/-10%) 1/3 Phase, 50/60Hz 3 Phase, 50/60Hz 3 Phase, 50/60Hz 11 Amps, 3 Phase 16 Amps, 3 Phase 25 Amps, 3 Phase Duty cycle: 40 Amps 60 Amps / 55 Amps 80 Amps / 60 Amps Panel Controls: On/Off Switch On/Off Switch On/Off Switch RUN/SET/LATCH Switch RUN/SET/LATCH Switch RUN/SET/LATCH Switch Output Current Potentiometer Output Current Potentiometer Output Current Potentiometer Panel Indicators: AC Power AC Power AC Power Temperature Temperature Temperature Gas Pressure Gas Pressure Gas Pressure DC Output DC Output DC Output Dimensions: Height: 406mm Height: 406mm Height: 406mm Width: 330mm Width: 330mm Width: 330mm Length: 630mm Length: 630mm Length: 630mm Weight: 31.3 Kg 32.2 Kg 34 Kg Work Cable Length: 6.1m 6.1m 6.1m Torch Model PCH/M-62 PCH/M-102 PCH/M-102 Gas: Air Air Air, Nitrogen Gas Pressure: 4.8 bar (70 psi) 4.1 bar (60 psi) 4.8 bar (70 psi) Gas Flow: 95 lpm (200 SCFH / 3.3CFM) 142 lpm (300 SCFH / 5CFM) 190 lpm (400 SCFH / 6.6CFM) Pilot: CD Start/ Pulsed DC CD Start/ Pulsed DC CD Start/ Pulsed DC Control: Hand switch Hand switch Hand switch Remote Pendant Remote Pendant Remote Pendant CNC Interface Cable CNC Interface Cable CNC Interface Cable Torch Lead length: Hand 6.1m 6.1m 6.1m 15.2m 15.2m 15.2m Machine 7.6m 7.6m 7.6m 15.2m 15.2m 15.2m ACCESSORIES Air Filter Kit Cat. No Micron Particulate Filter for use on compressed shop air systems Cutting Guide Cat. No Manual circle cutting guide, 2" to 16" circles Cutting Guide Kit Cat. No Easy add-on attachments to allow for straight line,circle cutting and beveling for all XL PLUS-CE Systems Multi-Purpose Cart Cat. No Rugged steel cart with large rubber wheels, swivel casters and extra shelf to maximize system portability WORLD HEADQUARTERS: 101 S. Hanley Road St. Louis, MO FAX EUROPEAN CUSTOMER SERVICE: Via Rio Fabbiani, 8A Rastignano (Bologna) - ITALY (39) FAX (39) International Offices International Customer Service Thermadyne Canada Thermadyne UK Thermadyne Asia Sdn. Bhd. Cigweld Australia Oakville, Ontario, Canada Oakville, Ontario Canada Chorley, England Kuala Lumpur, Malaysia Melbourne, Australia Ph: (1) Ph: (1) Ph: (44) Ph: (603) Ph: (61) Fax: (1) Fax: (1) Fax: (44) Fax: (603) Fax: (61) Thermadyne do Brasil Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Thermadyne Europe Rio de Janeiro, Brazil Dubai, United Arab Emirates Mexico City, Mexico Osaka, Japan Milan, Italy Ph: (55) Ph: (971) Ph: (52) Ph: (81) Ph: (39) Fax: (55) Fax: (971) Fax: (52) Fax: (81) Fax: (39) Form No (1/03) Thermal Dynamics Corp., Printed in U.S.A.