PAK

MASTER XL PLUS-
™

Air Plasma Cutting

Systems

3 Year
Warrant
y

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 (11⁄4”)
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

PLASMA CUTTING SERIES
PAK
MASTER XL PLUS-CE™
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 oper-
ation, 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 connect-
ed 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 inter-
rupted, 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.
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
2 THERMAL DYNAMICS www.thermal-dynamics.com
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 appli-
cations 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 abili-
ty to perform in difficult conditions. Where other manu-
facturers 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 environmen-
tal 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.
CSA NRTL/C APPROVED
The Canadian Standards Association is recognized world-
wide 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 war-
ranted for 3 years; labor, torch and
leads for 1 full year.
©Thermal Dynamics Corp., 2001
PLASMA CUTTING SERIES

PAK
MASTER XL PLUS-CE
™

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 consum-
able 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 per-
formance 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 excel-
lent 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 cut-
ting 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 flexi-
bility and control in demanding situations.

Cut Quality
PakMaster XL PLUS-CE power supplies deliver excep-
tionally 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 (1⁄8” -

3
⁄8”) 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, sepa- PakMaster™ 50 XL PLUS-CE cut on 7 gauge mild
rating welded parts or removing hardfacing metals. Our Tip steel using the optional cutting guide kit
Saver™ fold-back circuit protects your consumable parts
life and makes the torch an easy to use gouging tool.

3
PLASMA CUTTING SERIES

PAK
MASTER XL PLUS-CE
™
-

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 rat-
ing means the system will cut this thickness of mild steel at
a slower rate with some loss in cut quality. Aluminum and
XL™ PLUS-CE IN
stainless steel generally require more power to cut, and cut
ratings may vary by as much as 25%.
PERFORMANCE
What will I need to pierce? directly to faster cutting speeds. Mechanized system
Pierce ratings should be calculated at 50% of genuine cutting speeds can be limited by the mechanized posi-
cut ratings. tioner capability.

How fast do I want to cut? What voltage input power is available?

Operator comfort and control is the real determinant of PakMaster XL PLUS-CE systems accept 380/415 volts,
cut speed in hand cutting. More cutting power translates 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 1-5845 1-5846 1-5849* 1-5850*
PakMaster 75XL PLUS-CE 1-7865 1-7866 1-7869* 1-7870*
PakMaster 100XL PLUS-CE 1-0885 1-0886 1-0889* 1-0890*
*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-62 7-6220 7-6221 7-6224 7-6225
PCH/M-102 7-7530-SL 7-7532-SL 7-7536-SL 7-7537-SL
REPLACEMENT TORCH HEADS ONLY
PCH/M-62 9-8410 9-8408
PCH/M-102 9-8405 9-8403

Remote Options:
Computer Control (CNC) Cable: 7.6m (25 ft.) 8-5557
15.2m (50 ft.) 8-5558
Hand Pendant Control with 7.6m (25 ft.) Cable: 7-3114
Extension Cable 7.6m (25 ft.) for Hand Pendant Control: 7-7744
Metal Mounting Tube with Pinion Assembly 7-7745

call (39) 051-742-692 f o r m o r e i n f o r m a t i o n 4

PLASMA CUTTING SERIES

PAK
MASTER XL PLUS-CE SureLok
™
™
Plasma Torches
PakMaster™ 50XL PLUS-CE PCH/M-62
Standard Spare Parts Kit
Cat. Number Part Description #5-6209
8-0532 O-Ring 1
9-8402 Electrode (SureLok™), General Purpose 3
9-8401 Gas Distributor, 40 Amp 0
9-8411 Tip, 40 Amp, Drag 2
9-8412 Tip, 40 Amp, Stand-off 5
9-8416 Tip, 40 Amp, Gouging 0
9-7501 Coil Spring 1
9-8400 Shield Cup, 40 Amp 0
9-8415 Stand-off Cutting Guide 1

PakMaster™ 75XL PLUS-CE PCH/M-102 (60 Amp)

Standard Spare Parts Kit
Cat. Number Description #5-7509
8-0532 O-Ring 1
9-8402 Electrode (SureLok™), General Purpose 5
8-7501 Gas Distributor, Cutting 0
8-7508 Gas Distributor, Gouging 0
9-7726 Tip, 60 Amp, Cutting 5
8-7503 Tip, 40 Amp, Cutting 2
8-7506 Tip, Gouging 0
9-7501 Coil Spring 1
8-7500 Shield Cup, Cutting 0
8-7507 Shield Cup, Crown 0
8-7575 Stand-off Cutting Guide 1
9-7526 Fuse (0.8A, 600V) 1
8-4264 Adapter Fitting 1/4” Hose to 1/4” NPT 1
8-4025 Lubricant 1
8-3141 Box, Utility 1

PakMaster™ 100XL PLUS-CE PCH/M-102 (80 Amp)

Standard Spare Parts Kit
Cat. Number Description #5-0009
8-0532 O-Ring 1
9-8402 Electrode (SureLok™), General Purpose 5
8-7501 Gas Distributor, Cutting 0
8-7508 Gas Distributor, Gouging 0
9-7728 Tip, 80 Amp, Cutting 5
9-7726 Tip, 60 Amp, Cutting 0
8-7503 Tip, 40 Amp, Cutting 2
8-7506 Tip, Gouging 0
9-7501 Coil Spring 1
8-7500 Shield Cup, Cutting 0
8-7507 Shield Cup, Crown 0
8-7575 Stand-off Cutting Guide 1
9-7526 Fuse (0.8A, 600V) 1
8-4264 Adapter Fitting 1/4” Hose to 1/4” NPT 1
8-4025 Lubricant 1
8-3141 Box, Utility 1

call (39) 051-742-692 f o r m o r e i n f o r m a t i o n 5

PLASMA CUTTING SERIES

PAKMASTER XL™ PLUS-CE PRODUCT SPECIFICATIONS

PAKMASTER™ 50 XL PLUS-CE PAKMASTER™ 75 XL PLUS-CE PAKMASTER™ 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: 15-40 Amps - Continuously variable 15-60 Amps - Continuously variable 15-80 Amps - Continuously variable
Input Power: 220/380-415 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: 100% @ 40 Amps 65% @ 60 Amps / 100% @ 55 Amps 40% @ 80 Amps / 100% @ 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 Cutting Cutting Multi-Purpose Cart
Cat. No. 7-7507 Guide Guide Kit Cat. No. 7-8888
All Systems Cat. No. 7-7501 Cat. No. 7-8910 All Systems
.85 Micron All Systems All Systems Rugged steel
Particulate Manual circle Easy add-on cart with
Filter for use on cutting guide, attachments to allow large rubber
compressed shop 2" to 16" circles for straight line,circle wheels,
air systems cutting and beveling swivel casters
for all XL PLUS-CE and extra shelf
Systems to maximize
system portability

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

EUROPEAN CUSTOMER SERVICE:

International Customer Service
Oakville, Ontario, Canada
Ph: (1) 905-827-9777
Fax: (1) 905-827-9797
Thermadyne do Brasil
Rio de Janeiro, Brazil
Ph: (55) 21-2-485-8859
Fax: (55) 21-2-485-8735
Form No. 9963-9901 (1/03)
Via Rio Fabbiani, 8A - 40067 Rastignano (Bologna) - ITALY
(39) 051-742-692 • FAX (39) 051-743-786
International Offices
Thermadyne Canada Thermadyne UK Thermadyne Asia Sdn. Bhd. Cigweld Australia
Oakville, Ontario Canada Chorley, England Kuala Lumpur, Malaysia Melbourne, Australia
Ph: (1) 905-827-1111 Ph: (44) 1257-261755 Ph: (603) 6092-2988 Ph: (61) 3-9474-7400
Fax: (1) 905-827-3648 Fax: (44) 1257-224800 Fax: (603) 6092-1085 Fax: (61) 3-9474-7510
Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Thermadyne Europe
Dubai, United Arab Emirates Mexico City, Mexico Osaka, Japan Milan, Italy
Ph: (971) 4-332-9060 Ph: (52) 5696-7407 Ph: (81) 6-4809-8411 Ph: (39) 039-204-991
Fax: (971) 4-332-5484 Fax: (52) 5696-7757 Fax: (81) 6-4809-8412 Fax: (39) 039-204-9922
© Thermal Dynamics Corp., 2003 www.thermal-dynamics.com Printed in U.S.A.