2818 PCH&M-102 SureLok Torch (I)

PLASMA
CUTTING TORCH
Model PCH - 102 Hand Torch
Model PCM - 102 Machine Torch
Instruction Manual
December 6, 2004
Manual No. 0-2818
WARNINGS
Read and understand this entire Manual and your employers 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.
Plasma Cutting Torch

Model PCH - 102 & PCM - 102
Instruction Manual Number 0-2818
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2000 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission 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: December 6, 2004
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
1.02
1.03
1.04
1.05
1.06
1.07
1.08
Notes, Cautions and Warnings .....................................................................

Important Safety Precautions ........................................................................
Publications ..................................................................................................
Note, Attention et Avertissement ...................................................................
Precautions De Securite Importantes ............................................................
Documents De Reference .............................................................................
Declaration of Conformity ..............................................................................
Statement of Warranty ..................................................................................
1-1
1-1
1-2
1-3
1-3
1-5
1-7
1-8
SECTION 2:
INTRODUCTION ................................................................................................................ 2-1
2.01
2.02
2.03
2.04
2.05
Scope of Manual ...........................................................................................

General Description ......................................................................................
Specifications & Design Features .................................................................
Options And Accessories ..............................................................................
Introduction to Plasma ..................................................................................
2-1
2-1
2-1
2-2
2-2
SECTION 3:
INSTALLATION .................................................................................................................. 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
Introduction ...................................................................................................
Site Location ................................................................................................
Unpacking ....................................................................................................
Setting Up Hand Torch ..................................................................................
Setting Up Machine Torch .............................................................................
Connecting Torch ..........................................................................................
Gas Connection ............................................................................................
3-1
3-1
3-1
3-1
3-1
3-2
3-6
SECTION 4:
OPERATION ...................................................................................................................... 4-1
4.01
4.02
4.03
4.04
4.05
4.06
4.07
4.08
4.09
4.10
Introduction ...................................................................................................
Functional Overview ......................................................................................
Getting Started .............................................................................................
Torch Parts Selection ....................................................................................
Cut Quality ...................................................................................................
General Cutting Information ...........................................................................
Hand Torch Operation ...................................................................................
Machine Torch Operation ..............................................................................
Recommended Cutting Speeds .....................................................................
Gouging ........................................................................................................
4-1
4-1
4-1
4-2
4-2
4-3
4-4
4-6
4-7
4-7
TABLE OF CONTENTS (continued)

SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01
5.02
5.03
5.04
5.05
5.06
5.07
5.08
Introduction ................................................................................................... 5-1

General Torch Maintenance .......................................................................... 5-1
Common Operating Faults ............................................................................ 5-2
Inspection and Replacement Consumable Torch Parts .................................. 5-2
Troubleshooting Guide .................................................................................. 5-3
Torch & Leads Troubleshooting ..................................................................... 5-5
Servicing Hand Torch (PCH) Components ..................................................... 5-6
Servicing Machine Torch (PCM) Components ............................................... 5-10
SECTION 6:
PARTS LISTS .................................................................................................................... 6-1
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
6.09
Introduction ................................................................................................... 6-1

Ordering Information ...................................................................................... 6-1
Replacement Hand Torch Parts (Ergonomic Handle) ..................................... 6-2
Replacement Machine Torch With Pinch Block Mounting Parts .................... 6-4
Replacement Machine Torch Lead Parts ....................................................... 6-6
Complete Assembly Replacement ................................................................ 6-8
Options & Accessories ................................................................................. 6-8
Torch Consumables .................................................................................... 6-10
Torch Spare Parts Kits ................................................................................. 6-11
APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM ................ A-1

APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS A-2
APPENDIX 3: GENERAL APPLICATION NOTES ...................................................................... A-4
APPENDIX 4: CUTMASTER 75 SYSTEM DATA ........................................................................ A-6
APPENDIX 5: CUTMASTER 80XL SYSTEM DATA .................................................................... A-8
APPENDIX 6: CUTMASTER 100 SYSTEM DATA .................................................................... A-10
APPENDIX 7: PAK MASTER 75XL PLUS SYSTEM DATA ...................................................... A-12
APPENDIX 8: PAK MASTER 100XL PLUS SYSTEM DATA ..................................................... A-14
APPENDIX 9: CE PAK MASTER 75XL PLUS SYSTEM DATA ................................................. A-16
APPENDIX 10: CE PAK MASTER 100XL PLUS SYSTEM DATA ............................................. A-18
APPENDIX 11: TORCH CONNECTION DIAGRAMS ................................................................ A-20
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
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.
Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These highlights are categorized as follows:
Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.
NOTE
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 metals which may contain one or more of the following:
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
Antimony
Arsenic
Barium
Beryllium
Cadmium
A procedure which, if not properly followed, may

cause damage to the equipment.
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
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 information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
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.
1.02 Important Safety Precautions
Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.
WARNINGS
Do not use the plasma torch in an area where combustible 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.
OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DANGEROUS 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. Persons who work near plasma arc cutting applications should consult their medical health professional 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 instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: January 27, 2004
This product, when used for welding or cutting,

produces fumes or gases which contain chemicals
known to the State of California to cause birth defects 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 operator 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, Publications.
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 helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
Disconnect power source before performing any

service or repairs.
Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
Read and follow all the instructions in the Operating Manual.
Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.
FIRE AND EXPLOSION
Protect others in the work area from the arc rays.

Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.
Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:
Arc Current
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
Noise levels should be measured to be sure the decibels (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
12
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 workpiece.
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 underwater 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 dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
400 - 800*
Do not cut or weld on containers that may have

held combustibles.
Suggested
Shade No.
300 - 400*
Ventilate all flammable or explosive vapors from

the workplace.
Minimum Protective
Shade No.
Less Than 300*
Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
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 Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 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. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
1-2
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
ATTENTION
Toute procdure pouvant rsulter
lendommagement du matriel en cas de nonrespect de la procdure en question.
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
AVERTISSEMENT
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
Toute procdure pouvant provoquer des blessures

de loprateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procdure en question.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
1.05 Precautions De Securite

Importantes
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
AVERTISSEMENTS
LOPRATION ET LA MAINTENANCE DU
MATRIEL DE SOUDAGE LARC AU JET
DE PLASMA PEUVENT PRSENTER DES
RISQUES ET DES DANGERS DE SANT.
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
Coupant larc au jet de plasma produit de lnergie

lectrique haute tension et des missions
magntique qui peuvent interfrer la fonction
propre dun pacemaker cardiaque, les appareils
auditif, ou autre matriel de sant electronique.
Ceux qui travail prs dune application larc au
jet de plasma devrait consulter leur membre
professionel de mdication et le manufacturier de
matriel de sant pour dterminer sil existe des
risques de sant.
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS 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
Il faut communiquer aux oprateurs et au personnel TOUS les dangers possibles. Afin dviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les prcautions de scurit
et toutes les consignes avant dutiliser le matriel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
1.04 Note, Attention et

Avertissement
Dans ce manuel, les mots note, attention, et
avertissement sont utiliss pour mettre en relief des
informations caractre important. Ces mises en relief
sont classifies comme suit :
NOTE
Toute opration, procdure ou renseignement
gnral sur lequel il importe dinsister davantage
ou qui contribue lefficacit de fonctionnement
du systme.
FUME et GAZ
La fume et les gaz produits par le procd de jet de
plasma peuvent prsenter des risques et des dangers de
sant.
1-3
GENERAL INFORMATION
Eloignez toute fume et gaz de votre zone de respiration. Gardez votre tte hors de la plume de fume
provenant du chalumeau.
Utilisez un appareil respiratoire alimentation en air
si laration fournie ne permet pas dliminer la fume
et les gaz.
Les sortes de gaz et de fume provenant de larc de
plasma dpendent du genre de mtal utilis, des
revtements se trouvant sur le mtal et des diffrents
procds. Vous devez prendre soin lorsque vous
coupez ou soudez tout mtal pouvant contenir un ou
plusieurs des lments suivants:
antimoine
argent
arsenic
baryum
bryllium
cadmium
chrome
cobalt
cuivre
manganse
mercure
nickel
plomb
slnium
vanadium
Lisez toujours les fiches de donnes sur la scurit

des matires (sigle amricain MSDS); celles-ci
devraient tre fournies avec le matriel que vous
utilisez. Les MSDS contiennent des renseignements
quant la quantit et la nature de la fume et des gaz
pouvant poser des dangers de sant.
Pour des informations sur la manire de tester la
fume et les gaz de votre lieu de travail, consultez
larticle 1 et les documents cits la page 5.
Ne touchez jamais une pice sous tension ou vive;

portez des gants et des vtements secs. Isolez-vous
de la pice de travail ou des autres parties du circuit
de soudage.
Rparez ou remplacez toute pice use ou
endommage.
Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
Montez et maintenez le matriel conformment au
Code lectrique national des Etats-Unis. (Voir la page
5, article 9.)
Dbranchez lalimentation lectrique avant tout travail dentretien ou de rparation.
Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent rsulter des scories
chaudes, des tincelles ou de larc de plasma. Le procd
larc de plasma produit du mtal, des tincelles, des
scories chaudes pouvant mettre le feu aux matires combustibles ou provoquer lexplosion de fumes
inflammables.
Utilisez un quipement spcial tel que des tables de

coupe dbit deau ou courant descendant pour
capter la fume et les gaz.
Soyez certain quaucune matire combustible ou inflammable ne se trouve sur le lieu de travail. Protgez
toute telle matire quil est impossible de retirer de la
zone de travail.
Nutilisez pas le chalumeau au jet de plasma dans une

zone o se trouvent des matires ou des gaz combustibles ou explosifs.
Procurez une bonne aration de toutes les fumes

inflammables ou explosives.
Le phosgne, un gaz toxique, est gnr par la fume

provenant des solvants et des produits de nettoyage
chlors. Eliminez toute source de telle fume.
Ce produit, dans le procder de soudage et de coupe,
produit de la fume ou des gaz pouvant contenir des
lments reconnu dans Ltat de la Californie, qui
peuvent causer des dfauts de naissance et le cancer.
(La scurit de sant en Californie et la code scurit
Sec. 25249.5 et seq.)
Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matires combustibles.
Prvoyez une veille dincendie lors de tout travail dans
une zone prsentant des dangers dincendie.
Le gas hydrogne peut se former ou saccumuler sous
les pices de travail en aluminium lorsquelles sont
coupes sous leau ou sur une table deau. NE PAS
couper les alliages en aluminium sous leau ou sur
une table deau moins que le gas hydrogne peut
schapper ou se dissiper. Le gas hydrogne accumul
explosera si enflamm.
CHOC ELECTRIQUE
Les chocs lectriques peuvent blesser ou mme tuer. Le
procd au jet de plasma requiert et produit de lnergie
lectrique haute tension. Cette nergie lectrique peut
produire des chocs graves, voire mortels, pour loprateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION
RAYONS DARC DE PLASMA

Les rayons provenant de larc de plasma peuvent blesser
vos yeux et brler votre peau. Le procd larc de
plasma produit une lumire infra-rouge et des rayons
1-4
ultra-violets trs forts. Ces rayons darc nuiront vos

yeux et brleront votre peau si vous ne vous protgez
pas correctement.
Pour protger vos yeux, portez toujours un casque ou
un cran de soudeur. Portez toujours des lunettes de
scurit munies de parois latrales ou des lunettes de
protection ou une autre sorte de protection oculaire.
Portez des gants de soudeur et un vtement protecteur
appropri pour protger votre peau contre les
tincelles et les rayons de larc.
Maintenez votre casque et vos lunettes de protection
en bon tat. Remplacez toute lentille sale ou
comportant fissure ou rognure.
Protgez les autres personnes se trouvant sur la zone
de travail contre les rayons de larc en fournissant des
cabines ou des crans de protection.
Utilisez la nuance de lentille qui est suggre dans le
recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc
Nuance Minimum
Protective Numro
Nuance Suggere
Numro
Moins de 300*
300 - 400*
12
400 - 800*
10
14
* Ces valeurs sappliquent ou larc actuel est observ

clairement. Lexperience a dmontrer que les filtres
moins foncs peuvent tre utiliss quand larc est
cach par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de loue.
Les procds de soudage larc de plasma peuvent
provoquer des niveaux sonores suprieurs aux limites
normalement acceptables. Vous d4ez vous protger les
oreilles contre les bruits forts afin dviter une perte
permanente de loue.
Pour protger votre oue contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protgez galement les autres personnes
se trouvant sur le lieu de travail.
Il faut mesurer les niveaux sonores afin dassurer que
les dcibels (le bruit) ne dpassent pas les niveaux
srs.
Pour des renseignements sur la manire de tester le
bruit, consultez larticle 1, page 5.
1.06 Documents De Reference

Consultez les normes suivantes ou les rvisions les plus
rcentes ayant t faites celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DE
PROTECTION DE LA SANT, 29CFR 1910,
disponible auprs du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SCURIT DES
OPRATIONS DE COUPE ET DE SOUDAGE,
disponible auprs de la Socit Amricaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SCURIT ET LA SANT LORS DES
OPRATIONS DE COUPE ET DE SOUDAGE
LARC ET AU GAZ, disponible auprs du Superintendent 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 TRAVAIL ET DANS LES ECOLES, disponible de lInstitut
Amricain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprs
de lAmerican National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRVENTION DES INCENDIES
LORS DE LEMPLOI DE PROCDS DE COUPE ET
DE SOUDAGE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York,
NY 10018
7. Norme A6.0 de lAssociation Amricaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERM DES PRODUITS
COMBUSTIBLES, disponible auprs de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de lAssociation Amricaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCDS ASSOCIS, disponible auprs de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
1-5
GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCDS DE
COUPE ET DE SOUDAGE, disponible auprs de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMS EN CYLINDRES,
disponible auprs de lAssociation des Gaz
Comprims (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SCURIT POUR
LE SOUDAGE ET LA COUPE, disponible auprs
de lAssociation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SCURIT DU SOUDAGE, disponible auprs de
lAssociation Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de lAssociation Amricaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRPARATION LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT
RENFERM
DES
PRODUITS
DANGEREUX , disponible auprs de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprs de lAmerican
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION
1-6
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" (European 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.
* 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
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 Thermals 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 Thermals 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
PAK Units, Power Supplies
XL Plus &
CutMaster Series
Parts
Cougar/Drag-Gun
Parts
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,

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
Consoles, Control Equipment, Heat

Exchanges, And Accessory Equipment
1 Year
Torch And Leads

Maximizer 300 Torch
SureLok Torches
1 Year
All Other Torches
180 Days
180 Days
180 Days
180 Days
90 Days
90 Days
90 Days
None
Repair/Replacement Parts
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
customers risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: November 15, 2001
GENERAL INFORMATION
1-8
SECTION 2:
INTRODUCTION
2.03 Specifications & Design

Features
NOTE
Refer to Appendix Pages for additional specifications as related to the Power Supply used.
2.01 Scope of Manual

This manual contains descriptions, operating instructions and
maintenance procedures for the PCH/M-102 Torch using the
SureLok electrode design. Service of this equipment is restricted
to properly trained personnel; unqualified personnel are strictly
cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
A. Torch Configurations and Dimensions

1. Hand Torch
Available with torch head at 70 or 90 to the torch
handle. The hand torches include a torch handle
and torch switch assembly.
Read this manual thoroughly. A complete understanding of the

characteristics and capabilities of this equipment will assure
the dependable operation for which it was designed.
2. Machine Torch
The standard machine torch has a fiberglass positioning tube with rack & pinch block assembly.
2.02 General Description
Available options include a kit with metal mounting tube with rack & pinion assembly or a kit with
the pinion assembly only.
NOTE
Refer to Section 2.05, Introduction To Plasma, for
a more detailed description on plasma theory.
The Torch provides cutting capacity of up to 1 inch (25.4 mm) at
100 amperes. In the torch, a single torch lead provides compressed air from a single source to be used as both the plasma
and secondary gas. The air flow is divided inside the torch
head. Single-gas operation provides a smaller sized torch and
inexpensive operation.
10.5 in
(267 mm)
3.0 in
(76.2 mm)
Plasma torches are similar in design to the common automotive

spark plug. They consist of negative and positive sections
which are separated by a center insulator. Inside the torch, the
pilot arc is initiated in the gap between the negatively charged
electrode and the positively charged tip. Once the pilot arc has
ionized the plasma gas, the superheated column of gas flows
through the small orifice in the torch tip, which is focused on
the metal to be cut.
1.1in
(28 mm)
10.0 in
(254 mm)
3.4 in
(86.4 mm)
1.1in
(28 mm)
14.1 in
(358 mm)
1.4 in
(35.6 mm)
0.62 in
(15.2 mm)
13.5 in (343 mm) Max

3.7 in (94 mm) Min
1.1 in
(28 mm)
5.1 in
0.75 in
(129.5 mm)
(19 mm)
A-02804
Figure 2-1 Torch Configurations and Dimensions
Manual 0-2818
2-1
INTRODUCTION
B. Torch Leads Lengths
2.04 Options And Accessories
Hand Torches
These items can be used to customize a standard system

for a particular application or to further enhance performance (refer to Section 6 for ordering information).
20 ft (6.1 m) or 50 ft (15.2 m)
Machine Torches
Spare Parts Kits - Various kits containing replacement front-end torch parts for various applications.
25 ft (7.6 m) or 50 ft (15.2 m)
C. Torch Parts
Circle Cutting Guide Kit - Easy add-on attachments

to allow for straight line, circle cutting, and beveling
with a hand torch. The guide fits both the 70 and
90 hand torches.
Gas Distributor, Electrode, Tip, Shield Cup
D. Parts-In-Place (PIP)
Standoff Cutting Guide - Simple push-on attachment

to allow for torch dragging without risk of touching
tip to workpiece.
Torch Head has built-in contacts

12 vdc circuit rating
1 - 3/8" Metal Mounting Tube with Rack & Pinion

Assembly
E. Type Cooling
Combination of ambient air and gas stream through torch
Pinion Assembly
Computer Control (CNC) Cable 25 Ft (7.6 m) or 50 Ft
(15.2 m)
F. Torch Ratings
Hand Pendant Control Assembly - Used for machine applications. Hand Pendant Control has
20 ft. (6.1 m) cable which provides ON & OFF
signals to the Power Supply.
Torch Ratings
Ambient
Temperature
104 F
(40 C)
Duty Cycle
100% @ 100 Amps @ 400 scfh
Maximum Current
100 Amps
Voltage (Vpeak)
500V
Arc Striking Voltage
12 kV
G. Plasma Power Supply Used With
Extension Cable for Hand Pendant Control - 25 ft

(7.6 m) cable which can be added to the Hand Pendant Control cable to provide a total control cable
length of 50 ft (15.2 m).
2.05 Introduction to Plasma

A. Plasma Gas Flow
Plasma is defined as a gas which has been heated to
an extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc cutting and gouging process use this plasma to transfer
an electrical arc to the workpiece. The metal to be cut
or removed is melted by the heat of the arc and then
blown away.
CutMaster 75
CutMaster 80XL
CutMaster 100
Pak Master 75XL Plus
Pak Master 100XL Plus
CE Pak Master 75XL Plus
While the goal of plasma arc cutting is separation of

the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
CE Pak Master 100XL Plus
H. Direct Contact Hazard
In a Plasma Cutting Torch a cool gas enters Zone B

(refer to Figure 2-2), where a pilot arc between the electrode and the torch tip heats and ionizes the gas. The
main cutting arc then transfers to the workpiece
through the column of plasma gas in Zone C.
For exposed tip the recommended standoff is 1/8 3/8 inch or 3 - 9.5 mm.
INTRODUCTION
2-2
Manual 0-2818
;;
;;
;;
;;
;;
;;
D. Capacitive Discharge
Because direct current (DC) alone is not sufficient to strike
and maintain the pilot arc, capacitive discharge is also used.
The high voltage jumps between the tip and electrode with
the DC following.
E. Main Cutting Arc
Power
Supply
+
DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the
torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot
wire.
F. Interlocks
One pressure switch acts as an interlock for the gas supply. If supply pressure falls below minimum requirements
the pressure switch will open, shutting off the DC power,
and the GAS indicator will go off. When adequate gas
supply pressure is available the pressure switch will close,
allowing power to be resumed for cutting.
Workpiece
A-00002
Figure 2-2 Typical Torch Head Detail
By forcing the plasma gas and electric arc through a small

orifice, the torch delivers a high concentration of heat to a
small area. The stiff, constricted plasma arc is shown in
Zone C (Figure 2-2). Direct current (DC) straight polarity is
used for plasma cutting, as shown in the illustration.
G. Parts-In-Place (PIP)
The torch head has built-in contacts called Parts-In-Place
(PIP). These two contacts are made through the canted
coiled spring inside the shield cup when it is installed. The
torch will fail to operate if these contacts are not made.
Zone A (Figure 2-2) is used as a secondary gas that cools

the torch. This gas assists the high velocity plasma gas in
blowing the molten metal out of the cut allowing for a fast,
slag-free cut.
Torch Switch
B. Gas Distribution
To Control
Cable Wiring
The single gas used is internally split into plasma and secondary gases.
PIP Pin
Shield Cup
PIP Pin
A-00458
The plasma gas flows into the torch through the negative
lead, through the gas distributor, around the electrode,
and out through the tip orifice.
Figure 2-3A Parts-In-Place (PIP) Diagram - Machine

Torch
The secondary gas flows down around the outside of the

torch gas distributor, and out between the tip and shield
cup around the plasma arc.
To Control
Cable Wiring
C. Pilot Arc
Torch Switch
PIP Switch
When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates
a path for the main arc to transfer to the work.
Manual 0-2818
Torch Trigger
Shield Cup
A-03761
Figure 2-3B Parts-In-Place (PIP) Diagram - Hand

Torch
2-3
INTRODUCTION
INTRODUCTION
2-4
Manual 0-2818
SECTION 3:
INSTALLATION
3.05 Setting Up Machine Torch

WARNING
3.01 Introduction
This section describes installation of the Torch. These
instructions apply to the Torch and Leads Assemblies
only; installation procedures for the Power Supply, Options and Accessories are given in Manuals specifically
provided for those parts.
The complete installation consists of:
Disconnect primary power at the source before disassembling the torch or torch leads.
The machine torch is factory assembled to the Power Supply and includes a fiberglass positioning tube with rack
and pinch block assembly. A metal mounting tube with
rack & pinion assembly or the pinion assembly only are
available as options.
Site Selection
1. Mount the torch assembly on the cutting table.
Unpacking
2. To obtain a clean vertical cut, use a square to align

the torch perpendicular to the surface of the workpiece.
Setting Up Torch
Connecting Torch
Gas Connection
3.02 Site Location

Pinch Block
Assembly
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Square
Each component of the system is packaged and protected

with a carton and packing material to prevent damage
during shipping.
Workpiece
A-02585
1. Unpack each item and remove all packing material.

2. Locate the packing list 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
installation.
Figure 3-1 Machine Torch Set-Up
3.04 Setting Up Hand Torch
3. The proper torch parts (shield cup, tip, gas distributor, and electrode) must be installed for the
type of operation. Refer to Section 4.04, Torch
Parts Selection for more information.
The hand torch is factory assembled to the Power Supply

and requires no special set up. The proper torch parts
(shield cup, tip, gas distributor, and electrode) must be
installed for the type of operation. Refer to Section 4.04,
Torch Parts Selection for more information.
Manual 0-2818
3-1
INSTALLATION
3. Secure the Through-hole Protector with the retaining nut removed earlier.
3.06 Connecting Torch

The instructions for connecting the Torch Leads to the
Power Supply are different depending on the type of
leads. This sub-section covers connecting the Torch for
the following applications:
A. Hand Systems
4. Connect the torch Negative & Plasma Lead to the bulkhead connection inside the Power Supply.
Note: Actual Bulkhead

configuration may
differ from that shown.
B. Machine Systems (Unshielded Leads)

C. Machine Systems (Shielded Leads)
Adapter
Connector
Negative/Plasma
Lead Connection
D. Remote Pendant Control (Optional)

The Torch Leads must be properly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the Torch
Bulkhead Panel for the desired application.
Adapter
Control Circuit
Connectors
NOTE
Pilot Lead Stud
Equipment ordered as a system will have the Torch

factory connected to the Power Supply.
Pilot Lead
Negative/Plasma
Lead
A. Hand Systems
Torch Lead
Assembly
or ATC Adapter
WARNING
Figure 3-3 Hand Torch Lead Connections
1. Remove the retaining nut from the Through-hole
Protector.
Remove Tie Wrap,

Remove Insulator,
Disconnect Wires
A-03542
5. Connect the Cables to the mating connectors on the

Adapter supplied on the Power Supply.
6. Remove the top nut and washer from the Pilot Stud.
7. Place the lug on the Pilot Control Wire onto the stud
and secure with the nut and washer removed in the
above Step.
Torch Leads
Assembly
Through - Hole
Protector
8. Tighten the Through-hole Protector onto the Torch

Leads.
9. Check the torch for proper parts assembly.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Selection.
Through - Hole
Protector Nut
Art #A-03848
Figure 3-2 Retaining Nut Removal

2. Feed the torch lead ends and the Through-hole
Protector into the hole in the unit.
INSTALLATION
3-2
Manual 0-2818
B. Machine Systems (Unshielded Leads)

1. Remove the Through-hole Protector Nut from the
Through-hole Protector.
Control Connector
Control Connector
Plug
Torch Leads
Assembly
Thru - Hole Protector
Negative/Plasma
Lead Connection
Shield Connectors
(Not Used)
Control (PIP) Circuit
Connectors
Pilot Lead
Stud
Pilot Lead
Remote
Cable
Connector
Art # A-03847
Negative/Plasma
Lead
Thru - Hole
ProtectorNut
A-02843
Torch Lead
Assembly
Figure 3-4 Through-hole Protector Nut Removal

Figure 3-5A Unshielded Machine Torch Lead
Connections
2. The Adapter supplied with the Power Supply

must be installed as follows:
a. Inside the Power Supply Bulkhead area, route
the connector on the free end of the Adapter
through the Through-hole Protector Nut.
Shield Connectors (Not Used)
b. Continue routing the connector out the hole

in the front of the Power Supply.
Power Supply Adapter
c. Feed the end of the torch lead and the

Through-hole Protector into the hole in the unit
while routing the single black wire into the
notch of the Through-hole Protector.
Control Circuit
Connectors
d. Tighten the Through-hole Protector Nut to

secure the Through-hole Protector to the
Power Supply.
Remote Pendant
Connector
Pilot Lead
Negative/Plasma
Lead Connection
Torch Lead
Assembly
Negative/Plasma Lead
Art # A-04323
Figure 3-5B Unshielded Machine Torch Connection Detail
Manual 0-2818
3-3
INSTALLATION
3. Connect the torch Negative / Plasma Lead to the bulkhead connection inside the Power Supply.
C. Machine Systems (Shielded Leads)
4. Connect the Control (PIP) Circuit Connectors to the

mating connectors on the Adapter supplied on the
Power Supply (see Warning).
1. Remove the Through-hole Protector Nut from the

Torch Leads
Assembly
Through - Hole
Protector
WARNING
The Adapter supplied with the Power Supply has
two additional Shield Connectors that are used for
Shielded Systems only. These two connectors are
not used and need to be taped out of the way to
prevent contacting the Negative & Plasma or Pilot Leads.
Through - Hole
Protector Nut
5. Remove the top nut and washer from the Pilot

Stud.
6. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
Leads.
Art # A-03849
Figure 3-6 Through-hole Protector Nut Removal

2. The Adapter supplied with the Power Supply must be
installed per the following:
a. Inside the Power Supply Bulkhead area, route the
connector on the free end of the Adapter through
the Through-hole Protector Nut.
b. Continue routing the connector out the hole in the
front of the Power Supply.
CAUTION
c. Feed the end of the torch lead and the Throughhole Protector into the hole in the unit while routing the single black wire into the notch of the

d. Tighten the Through-hole Protector Nut to secure

the Through-hole Protector to the Power Supply.
INSTALLATION
3-4
Manual 0-2818
D. Remote Pendant Control (Optional)

In machine type operations the Power Supply has an
Adapter that has a cable connector supplied at each
end of the Adapter. One end is connected at the factory to the mating connector on the Power Supply
Bulkhead area. The other end allows connection of a
Remote Pendant. The remote pendant lead connector allows connection to a remote pendant or CNC
cable while using PIP connections in the Torch Assembly.
Adapter Connector
Adapter
(Supplied With
Power Supply)
Negative/Plasma
Lead Connection
Control (PIP) Circuit

Connectors
Shield Connectors
Pilot Lead
Stud
Connect the remote pendant control cable to the connector provided on the Adapter from the Power Supply.
Pilot Lead
Negative/Plasma
Lead
Torch Control
Cable Connector
Remote Pendant/CNC
Cable Connector
A-02829
Torch Lead
Assembly
3
Control
PIP
Circuit
3. Connect the torch Negative & Plasma Lead to the bulkhead connection inside the Power Supply.
12
14
14
13
OK-To-Move
12
Figure 3-7 Shielded Machine Torch Lead Connections
13
4. Connect the PIP and Shield Cables to the mating connectors on the Adapter supplied on the Power Supply.
5. Remove the top nut and washer from the Pilot Stud.
A-01366
6. Place the lug on the Pilot Control Wire onto the stud
and secure with the nut and washer removed in the
above Step.
Figure 3-8 Remote Pendant Connector Diagram

Leads.
NOTE
Refer to Appendix 2, Torch Control Cable Wiring
Diagram For Mechanized Systems, for detailed
schematic of the Adapter.

CAUTION
Manual 0-2818
3-5
INSTALLATION
3.07 Gas Connection

A. Connection
Connect the gas, compressed air only, to the Power
Supply as described in the Manual supplied with the
Power Supply.
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 complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
B. Checking Air Quality

To test the quality of air, place a welding filter lens in
front of the torch and turn on the gas. Any oil or
moisture in the air will be visible on the lens. Do not
initiate an arc!
C. Filtering
An in-line pneumatic dryer & evaporator type air filter, capable of filtering to at least 5 microns, is required
when using air from a compressor. This type filter
will insure that moisture, oil, dirt, chips, rust particles,
and other contaminants from the supply hose do not
enter the torch. For highly automated applications,
a refrigerated drier may be used.
INSTALLATION
3-6
Manual 0-2818
NOTE
SECTION 4:
OPERATION
Refer to Appendix Pages for additional information as related to the Power Supply used.
E. Power On
4.01 Introduction
Place the ON - OFF Switch on the Power Supply to

the ON position. If the RUN - SET - or RUN - SET LATCH switch is in SET position, gas will flow. If
the switch is in RUN position there will be no gas
flow.
This section provides a description of the PCH & M-102

Torch Assembly followed by operating procedures.
4.02 Functional Overview

The Torch is designed to operate with various Power Supplies to provide a plasma cutting system which can cut
most metals from gauge thickness up to 1 inch (25.4 mm).
Using gouging torch parts the torch can be used for
plasma arc gouging up to 1/4 inch (6.4 mm) wide and
3/16 inch (4.8 mm) deep in a single pass on carbon steel.
F. RUN - SET or RUN - SET - LATCH Switch

If the RUN - SET or RUN - SET - LATCH switch is in
SET position, gas will flow. If the switch is in RUN
position there will be no gas flow.
G. Current Output Level

At the Power Supply, set the desired current output
level to a maximum of 100 amperes. For drag cutting set the control at 35 amps or less only.
NOTE
H. Pressure Settings
4.03 Getting Started
Place the RUN - SET or RUN - SET - LATCH switch

to the SET position. Adjust the gas pressure control
on the Power Supply for the proper gas pressure (see
Note).
This procedure should be followed at the beginning of

each shift:
NOTE
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
I.
Return the RUN - SET or RUN - SET - LATCH switch

to RUN position.
A. Torch Parts
NOTES
Check the torch for proper assembly. Install proper

torch parts for the desired application (refer to Section 4.04, Torch Parts Selection).
For general cutting, use the RUN position which

provides normal torch operation where the torch
switch must be held throughout the main arc transfer.
B. Input Power
For specific applications, use the LATCH position

where the torch switch can be released after the main
arc transfer. The torch remains activated until the
main arc breaks from the workpiece.
Check the power source for proper input voltage.

Close main disconnect switch or plug unit in to supply primary power to the system.
C. Work Cable
Refer to Appendix 1 for a typical detailed block diagram of Sequence of Operation.
Check for a solid cable connection to the workpiece.
D. Gas Supply
Select desired single gas supply. Make sure gas
sources meet requirements (see Note). Check connections and turn gas supply on.
Manual 0-2818
Ready for Operation
The system is now ready for operation.

Start the pilot arc. On Hand Torches press the Torch Trigger. On Machine Torches press the switch on the Remote
Pendant or supply a Start Signal from the CNC control.
There is a 2 second pre-flow before the arc starts.
4-1
OPERATION
4.04 Torch Parts Selection
4.05 Cut Quality
Depending on the type of operation to be done determines

the torch parts to be used.
NOTES
Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and operator ability.
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Gas Distributor
NOTE
Change the torch parts for a different operation as follows:
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross-free cutting is important when finish cut
quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following figure:
NOTE
Kerf Width
The tip and gas distributor are held in place by the

shield cup. Position the torch with the shield cup
facing upward to prevent these parts from falling
out when the cup is removed.
Cut Surface
Bevel Angle
Top
Spatter
1. Unscrew and remove the shield cup from the torch

head.
Top Edge
Rounding
Torch Head Assembly

(70o Hand Torch Shown)
Dross
Build-Up
Electrode
Gas
Distributor
Cut Surface
Drag Lines
A-00007
Figure 4-2 Cut Quality Characteristics
A. Cut Surface
Tip
The desired or specified condition (smooth or rough)

of the face of the cut.
A-02793
Shield Cup
B. Nitride Build-Up
Figure 4-1 Torch Parts
Nitride deposits can be left on the surface of the cut

when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.
2. Tilt the torch head to remove the tip and gas distributor.
3. Remove the SureLok Electrode by pulling it straight
out of the Torch Head.
C. Bevel Angle
The angle between the surface of the cut edge and a
plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0 bevel
angle.
4. Install the desired SureLok Electrode by pushing it

straight into the torch head until it clicks.
5. Install the desired gas distributor and tip for the operation into the torch head.
D. Top-Edge Rounding
6. Hand tighten the shield cup until it is seated on the

torch head. If resistance is felt when installing the
cup, check the threads before proceeding.
OPERATION
4-2
Rounding on the top edge of a cut due to wearing

from the initial contact of the plasma arc on the workpiece.
Manual 0-2818
E. Bottom Dross Buildup
C. Edge Starting
Molten material which is not blown out of the cut

area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after cutting.
For edge starts, hold the torch perpendicular to the

workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the
cut is to start. When starting at the edge of the plate,
do not pause at the edge and force the arc to "reach"
for the edge of the metal. Establish the cutting arc as
quickly as possible.
F. Kerf Width
The width of the cut (or the width of material removed during the cut).
D. Direction of Cut
G. Top Spatter (Dross)
In the torches, the plasma gas stream swirls as it leaves

the torch to maintain a smooth column of gas. This
swirl effect results in one side of a cut being more
square than the other. Viewed along the direction of
travel, the right side of the cut is more square than
the left.
Top spatter or dross on the top of the cut caused by

slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.
4.06 General Cutting Information
Left Side
Cut Angle
WARNINGS
Right Side
Cut Angle
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operators body comes into contact with the workpiece while the torch is activated.
A-00512
Figure 4-3 Side Characteristics Of Cut

To make a square-edged cut along an inside diameter of a
circle, the torch should move counterclockwise around the
circle. To keep the square edge along an outside diameter
cut, the torch should travel in a clockwise direction.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
E. Dross
When dross is present on carbon steel, it is commonly
referred to as either high speed, slow speed, or top
dross. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed
dross" is normally present on the bottom edge of the
plate. It can vary from a light to heavy bead, but
does not adhere tightly to the cut edge, and can be
easily scraped off. "High speed dross" usually forms
a narrow bead along the bottom of the cut edge and
is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not
grinding.
NOTE
Handle torch leads with care and protect them from
damage.
A. Piloting
Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to
the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts
life.
B. Torch Standoff
Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as well
as shield cup life. Standoff may also significantly
affect the bevel angle. Reducing standoff will generally result in a more square cut.
Manual 0-2818
4-3
OPERATION
4. Once on, the main arc remains on as long as the Torch

Trigger is held down, unless the torch is withdrawn
from the work or torch motion is too slow. If the cutting
arc is interrupted, the pilot arc comes back on automatically.
4.07 Hand Torch Operation

A. Standoff Cutting With Hand Torch
NOTE
For best performance and parts life, always use
the correct parts for the type of operation.
NOTE
Most cutting is performed with the power supply
in the RUN position. For specific applications, the
LATCH position may be preferred where the Torch
Trigger can be released after the main arc transfer.
The torch remains activated until the main arc
breaks from the workpiece.
1. The torch can be comfortably held in one hand or

steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the back
end for maximum heat protection. Choose the holding
technique that feels most comfortable and allows good
control and movement.
5. To shut off the torch simply release the Torch Trigger. When the trigger is released a 20 second postflow will occur. If the Torch Trigger is pushed
during the post-flow, the cutting arc will restart
immediately when the torch is brought within
range of the workpiece.
NOTE
The tip should never come in contact with the
workpiece except during drag cutting operations.
2. Depending on the cutting operation, do one of the
following:
B. Crown Shield Cup With Straight Edge
a. For edge starts, hold the torch perpendicular

to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start.
b. For standoff cutting, hold the torch 1/8 - 3/8
in (3-9 mm) from the workpiece as shown below.
The crown shield cup can be used with a nonconductive straight edge to make straight cuts by hand.
WARNING
The straight edge must be non-conductive.
Torch
Torch
Crown Shield
Cup
Shield Cup
Non-Conductive
Straight Edge
Cutting Guide
Standoff
Distance 1/8" - 3/8"
A-02600
A-00024
Figure 4-5 Using Crown Shield Cup With Straight

Edge
Figure 4-4 Standoff Distance

3. With the torch in starting position, press and hold
the Torch Trigger. After an initial two second preflow, the pilot arc will come on and remain on
until the cutting arc starts.
OPERATION
4-4
The crown shield cup functions best when cutting

3/16 inch (4.7 mm) solid metal with relatively
smooth surface. Use drag cutting for thinner
metal.
Manual 0-2818
C. Drag Cutting With a Hand Torch
D. Piercing With Hand Torch

the torch head for maximum control or near the
back end for maximum heat protection. Choose
the technique that feels most comfortable and allows good control and movement.
Drag cutting works best on metal 3/16" (4.7 mm) thick or

less.
NOTE
For best parts performance and life, always use
the correct parts for the type of operation.
1. Install the drag cutting tip and set the output current
to 35 amps or less.
NOTE

the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.
The tip should never come in contact with the workpiece except during drag cutting operations.
2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather
than directly back into it until the pierce is complete.
3. In a portion of the unwanted metal start the pierce
off the cutting line and then continue the cut onto
the line. Hold the torch perpendicular to the workpiece after the pierce is complete.
3. Keep the torch in contact with the workpiece during the cutting cycle.
4. Press the Torch Trigger, and after an initial two
second pre-flow, the pilot arc will come on and
remain on until the cutting arc starts.
4. Clean spatter and scale from the shield cup and

the tip as soon as possible. Spraying the shield
cup in anti-spatter compound will minimize the
amount of scale which adheres to it.
5. Once on, the main arc remains on as long as the

Torch Trigger is held down, unless the torch is
withdrawn from the work or torch motion is too
slow. If the cutting arc is interrupted, the pilot
arc comes back on automatically.
NOTE
Most cutting is performed with the power supply
in the RUN position. For specific applications,
the LATCH position may be preferred where the
Torch Trigger can be released after the main arc
transfer. In the LATCH position, the torch remains
activated until the main arc breaks from the workpiece.
6. To shut off the torch simply release the Torch Trigger. When the Trigger is released a 20 second postflow will occur. If the Torch Trigger is pushed
during the post-flow, the cutting arc will restart
immediately when the torch is brought within
range of the workpiece.
Manual 0-2818
4-5
OPERATION
2. Leading Arc
4.08 Machine Torch Operation

A. Cutting With Machine Torch
The machine torch can be activated by remote control
pendant or by a remote interface device such as CNC.
1. Use a square to check that the torch is perpendicular to the workpiece to obtain a clean, vertical cut.
The leading arc is directed in the same direction as

torch travel. A five degree leading arc is generally
recommended for air plasma on mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite direction as torch travel. Generally recommended for
Nitrogen plasma.
Pinch Block
Assembly
Dir
Square
ect
ion
of T
orc
hT
rav
el
Standoff Distance
Workpiece
A-02585
Straight Arc
Trailing Arc
Figure 4-6 Checking Alignment

A-02586
2. To start a cut at the plate edge, position the center

of the torch along the edge of the plate (refer to
Figure 4-7).
Figure 4-7 Machine Torch Operation
B. Travel Speed
Proper travel speed is indicated by the trail of the arc
which is seen below the plate ( Figure 4-7). The arc
can be one of the following:
1. Straight Arc
A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended for the
best cut using air plasma on stainless or aluminum.
OPERATION
Leading Arc
4-6
For optimum smooth surface quality, the travel speed

should be adjusted so that only the leading edge of
the arc column produces the cut. If the travel speed
is too slow, a rough cut will be produced as the arc
moves from side to side in search of metal for transfer.
Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing
down the travel speed will result in a squarer cut.
The power source output should be reduced also.
Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
may be required.
Manual 0-2818
C. Piercing With Machine Torch
4.10 Gouging
To pierce with a machine torch, the arc should be started

with the torch positioned as high as possible above the
plate while allowing the arc to transfer and pierce. This
standoff helps avoid having molten metal blow back onto
the front end of the torch.
WARNINGS
Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that
all safety precautions at the front of this manual
have been followed. Make sure no part of the
operators body comes in contact with the workpiece when the torch is activated.
When operating with a cutting machine, a pierce or dwell

time is required. Torch travel should not be enabled until
the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended
1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut
quality. Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying or dipping the shield
cup in anti-spatter compound will minimize the amount of
scale which adheres to it.
Disconnect primary power to the system before

disassembling the torch, leads, or power supply.
CAUTIONS
4.09 Recommended Cutting

Speeds
Sparks from plasma gouging can cause damage to

coated, painted or other surfaces such as glass, plastic, and metal.
Cutting speed depends on material, thickness, and the operators

ability to accurately follow the desired cut line. The following
factors may have an impact on system performance:
Check torch parts. The torch parts must correspond

with the type of operation. Refer to Section 4.04,
Torch Parts Selection.
Torch parts wear

Air quality
A. Gouging Parameters
Line voltage fluctuations
Gouging performance depends on parameters such

as torch travel speed, current level, lead angle (the
angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).
Torch standoff height

Proper work cable connection
NOTES
This information represents realistic expectations
using recommended practices and well-maintained
systems. Actual speeds may vary up to 50% from
those shown.
B. Torch Travel Speed

NOTE
Refer to Appendix Pages for cutting speed chart

information as related to the Power Supply used.
Optimum torch travel speed is dependent on current

setting, lead angle, and mode of operation (hand or
machine torch).
C. Current Setting
Current settings depend on torch travel speed, mode
of operation (hand or machine torch), and the amount
of material to be removed.
Manual 0-2818
4-7
OPERATION
D. Lead Angle
The angle between the torch and workpiece depends on
the output current setting and torch travel speed. At 80
amps, the recommended lead angle is 35 (refer to Figure 48). At a lead angle greater than 45 the molten metal will
not be blown out of the gouge and may be blown back
onto the torch. If the lead angle is too small (less than 35),
less material may be removed, requiring more passes. In
some applications, such as removing welds or working
with light metal, this may be desirable.
Torch Head
35
Standoff Height
1/8 - 1/4"
Workpiece
A-00941
Figure 4-8 Gouging Angle and Standoff Distance
E. Standoff Distance
The tip to work distance affects gouge quality and depth.
Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for
smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge.
Standoff distances greater than 1/4 inch (6 mm) may result
in minimal metal removal or loss of transferred main arc.
F. Slag Buildup
Slag generated by gouging on materials such as carbon
and stainless steels, nickels, and alloyed steels, can be
removed easily in most cases. Slag does not obstruct the
gouging process if it accumulates to the side of the gouge
path. However, slag build-up can cause inconsistencies
and irregular metal removal if large amounts of material
build up in front of the arc. The build-up is most often a
result of improper travel speed, lead angle, or standoff
height.
OPERATION
4-8
Manual 0-2818
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
SECTION 5:
SERVICE
5.01 Introduction
Refer to Section 5.07, Servicing Hand Torch (PCH)

Components, or Section 5.08, Servicing Machine
Torch Components (PCM) for disassembling the
Torch and Leads Assembly.
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than properly
trained personnel.
CAUTION
WARNINGS
Dry the torch thoroughly before reinstalling.
B. Checking Center Insulator

The center insulator separates the negative and positive sections of the torch. If the center insulator does
not provide adequate resistance, current which is intended for the pilot arc may be dissipated into the
torch head, resulting in torch failure.
Frequently review the Important Safety Precautions at the front of this Manual. Be sure the operator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operators body comes into contact with the workpiece while the torch is activated.
WARNINGS
CAUTION

disassembling the torch or torch leads.
Sparks from the cutting process can cause damage

to coated, painted, and other surfaces such as glass,
plastic and metal.
DO NOT touch any internal torch parts while the

AC indicator light of the Power Supply is ON.
NOTE
1. Remove the shield cup, tip, gas distributor, and

electrode from the torch. Disconnect the torch
leads from the power supply to isolate the torch
from power supply circuits.
Handle torch leads with care and protect them from

damage.
5.02 General Torch Maintenance
2. Using an ohmmeter (set to 10K or higher), check

for continuity between the positive and negative
torch fittings. Infinite resistance (no continuity)
should be found. If continuity is found, refer to
Section 5.06, Torch and Leads Troubleshooting.
A. Cleaning Torch
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of
the torch.
C. O-Ring Lubrication
The external o-ring on the Torch Head Assembly
(shield cup) requires lubrication on a scheduled basis. This will allow the o-ring to remain pliable and
provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is
not used on a regular basis. This can lead to potential leaks of the secondary gas around the end of the
shield cup.
WARNINGS
Manual 0-2818
It is recommended to apply a very light film of oring lubricant (Catalog # 8-4025) to the o-ring on a
weekly basis.
5-1
SERVICE
NOTE
5.04 Inspection and Replacement

Consumable Torch Parts
DO NOT use other lubricants or grease, they may

not be designed to operate within high temperatures or may contain unknown elements that
may react with the atmosphere. This reaction can
leave contaminants inside the torch. Either of these
conditions can lead to inconsistent performance or
poor parts life.
WARNINGS
5.03 Common Operating Faults

The following lists the more common cutting faults and

possible causes:
1. Insufficient Penetration
Remove the consumable torch parts per the following

procedure:
a. Cutting speed too fast
NOTE
b. Torch tilted too much
The tip and gas distributor are held in place by the

shield cup. Position the torch with the shield cup
facing upward to prevent these parts from falling
out when the cup is removed.
c. Metal too thick

d. Worn torch parts
e. Cutting current too low
1. Unscrew and remove the shield cup from the torch.
f. Non - Genuine Thermal Dynamics Parts
NOTE
2. Main Arc Extinguishes
Slag built up on the shield cup that cannot be removed may effect the performance of the system.
a. Cutting speed too slow

b. Torch standoff too high from workpiece
2. Inspect the cup for damage. Wipe it clean or replace

if damaged.
c. Cutting current too high
Torch Head Assembly

(70o Hand Torch Shown)
d. Work cable disconnected

e. Worn torch parts
Electrode
Gas
Distributor

3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
Tip
c. Worn torch parts
A-02793
Shield Cup
d. Improper cutting current
Figure 5-1 Consumable Parts
e. Non - Genuine Thermal Dynamics 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
SERVICE
5-2
Manual 0-2818
3. Remove the tip. Check for excessive wear (indicated

by an elongated or oversized orifice). Clean or replace the tip if necessary.
Good Tip
Worn Tip
5.05 Troubleshooting Guide

This subsection covers troubleshooting that requires disassembly and electronic measurements. It is helpful for
solving many of the common problems that can arise with
this torch assembly.
How to Use This Guide

The following information is a guide to help the Customer
/ Operator determine the most likely causes for various
symptoms.
A-00942
Figure 5-2 Tip Wear
This guide is set up as follows:

X. Symptom (Bold Type)
4. Remove the gas distributor and check for excessive

wear, plugged gas holes, or discoloration. Replace if
necessary.
5. Remove the SureLok Electrode by pulling it straight
out of the Torch Head. Refer to the following figure
and check the face of the electrode for excessive wear.
New Electrode
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
unit is fully operational after any repairs.
Troubleshooting
A. Torch will not pilot when torch switch is activated
1. Power Supply RUN / SET / LATCH switch in SET
position
a. Place RUN / SET / LATCH switch to RUN position.
Worn Electrode
A-02794
2. Parts - In - Place (PIP) not satisfied.
Figure 5-3 Electrode Wear
a. Check canted coiled spring inside shield cup

3. Faulty Torch Switch
6. Reinstall the SureLok Electrode by pushing it straight

into the torch head until it clicks.
a. Check for continuity
7. Reinstall the desired gas distributor and tip into the

torch head.
4. Faulty torch parts

a. Inspect torch parts and replace if necessary. Refer to Section 5.04, Inspection and Replacement
Consumable Torch Parts
8. Hand tighten the shield cup until it is seated on the

torch head. If resistance is felt when installing the
cup, check the threads before proceeding.
5. Gas pressure too high

a. Set proper operating gas pressure.
6. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if necessary. Refer to Section 5.06, Torch & Leads
Troubleshooting.
7. Faulty components in power supply system components
a. Return for repair or have qualified technician
repair per Service Manual.
Manual 0-2818
5-3
SERVICE
5. Torch tip dragged across workpiece
B. No cutting output
1. Torch not properly connected to power supply
a. When the tip is dragged across the workpiece,

the amperage automatically cuts back to 35
amps (see Note).
a. Check that torch leads are properly attached

to power supply
NOTE
2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against
torch head (do not overtighten)
All power supplies may not have this feature.

E. No gas flow
3. Parts - In - Place (PIP) not satisfied.
1. Gas not connected or pressure too low
a. Check canted coiled spring inside shield cup
a. Check source for proper operating gas pressure

(refer to Appendix Page for Power Supply
used).

Troubleshooting.

Troubleshooting.


C. Limited output with no control

1. Poor input or output connections to power supply
F. Torch cuts but not adequately
a. Check all input and output connections.
1. Current set too low at power supply
a. Increase current setting
Troubleshooting.
D. Erratic or improper cutting output
2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix Page
for the Power Supply being used).
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3.2 mm) from clean surface while purging and observe oil or moisture
buildup (do not activate torch)
1. Poor input or output connections to power supply

a. Check all input and output connections.
2. Current set too low at power supply
a. Increase current setting.
3. Torch is being moved too fast across workpiece
a. Reduce cutting speed (refer to Appendix Page
for the Power Supply being used).
4. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3.2 mm) from clean surface while purging and observe oil or moisture
buildup (do not activate torch).
SERVICE
5-4
Manual 0-2818
A. General Information
4. Remove the torch head from the leads (refer to

the proper Section on servicing the Torch Components).
Failures in the Torch and Leads can be isolated to the Torch

Head or Torch Lead components. To properly isolate the
failed part requires the use of an ohmmeter and a Hi-Pot
Tester.
5. With the torch head disconnected from the leads,

measure the resistance between negative fitting
or cathode body of the torch head and the positive fitting or anode body of the torch head.
5.06 Torch & Leads Troubleshooting
No continuity (infinite resistance) should be measured between negative and positive sections of
the torch head.
WARNING
If there is continuity, torch head must be replaced.

If no continuity (infinite resistance) is found
proceed to Step 6.
The use of a Hi - Pot Tester should be performed

only by a qualified electronic technician.
In the Torch Head the center insulator separates the negative and positive charged sections of the torch. If the center insulator does not provide adequate resistance, current which is intended for the pilot arc may be dissipated
into the torch head, resulting in torch failure.
6. Check the torch leads by measuring the resistance

between the positive pilot lead connector and the
negative lead fitting.
If there is continuity, torch leads must be replaced.
In the Torch Leads the negative and positive leads are

isolated from each other. If there is not adequate resistance between the leads then torch failure may occur.

proceed to paragraph C (see NOTE).
B. Quick Check Procedure

NOTE
This quick check will identify major isolation failures in

the Torch Head or Torch Lead components using an ohmmeter.
The actual assembly and consumables may vary for different torches but the basic procedure is the same for all
torches. Make the quick check on the Torch Head and
Leads as follows:
WARNINGS
It is possible that the Torch Head and Torch Leads

will test properly with an ohmmeter. The Torch
Head and Torch Leads should be tested further for
insulation breakdown if no other fault can be found.
C. Checking Proper Isolation Resistance

Procedure
The Torch Head and Torch Leads should be tested further for insulation breakdown if no other fault has been
found. This procedure requires the use of a Hi-Pot Tester.
WARNING

This procedure should be performed only by a qualified electronic technician.
1. Remove the consumables from the torch.

2. Disconnect the torch leads from the power supply to isolate the torch from power supply circuits.
1. To test the Torch Head center insulator for insulation breakdown use the following procedure:
3. Using an ohmmeter (set to 10K or higher), check

for continuity between the positive and negative
torch fittings.
a. Remove the Torch Head Assembly from the

Torch Leads if not already done.
If there is continuity between the two torch fittings proceed to Step 4.
b. Remove the consumables from the Torch Head

Assembly if not already done.

between the two torch fittings proceed to paragraph C.
c. Connect a Hi-Pot Tester capable of producing

2500 VAC between the positive pilot lead and
the negative lead fittings.
Manual 0-2818
5-5
SERVICE
d. Increase the output of the Hi-Pot Tester to a

maximum of 2500 VAC
4. Check the pilot lead, negative lead and switch control wires for opens from one end of the torch leads
to the other.
If the voltage drops to 0 VAC or leakage

current is detected, then the Torch Head
center insulator is breaking down and the
Torch Head must be replaced.
If open, replace leads or open component of

the Torch Leads Assembly.
If not open, then proceed to Step 5.
5. Check the pilot and switch control wires for shorts
to other components in the Torch Leads.
If the Torch Head center insulator passes

the test, then proceed to Step 2.
2. To test the Torch Leads for insulation breakdown
use the following procedure:
If shorted, then replace Torch Leads.

If not shorted, then proceed to Step 6.
6. Carefully reassemble the components and recheck
the completed assembly per paragraph B, Step
3 to confirm that the components have been properly assembled.
a. Connect the Hi-Pot Tester between the positive pilot lead and the negative lead fittings.
The fitting on the other end of the Torch Leads
must be separated (isolated) from each other.
b. Increase the output of the Hi-Pot Tester to a
maximum of 2500 VAC.
If the voltage drops to 0 VAC or leakage
current is detected, then the insulation between the Torch Leads is breaking down
and the Torch Leads must be replaced.
This completes the checks for the proper operation of the

Torch Head and Torch Leads.
5.07 Servicing Hand Torch (PCH)

Components
If the Torch Leads passes the test, then proceed to Step 3.

3. Visually check that the PIP wires, torch switch
wires, pilot lead connection, and negative lead
connections are properly connected and in good
condition (no shorts or arcing).
WARNINGS
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
NEVER touch any internal torch parts while the
AC indicator light on the Power Supply is ON.
Torch Switch
To Control
Cable Wiring
A. Removing the Hand Torch Head Assembly
PIP Pin
Shield Cup
The removal of the Torch Head Assembly requires disassembly of the torch handle and leads per the following
procedure:
PIP Pin
A-00458
Figure 5-4A Torch Switch and PIP Schematic Machine Torch
To Control
Cable Wiring
Torch Switch
1. Remove the five screws from the Torch Handle

Assembly. Pull the halves apart and set aside.
Torch Trigger
A-02823
PIP Switch
Shield Cup
A-03761
Handle Half
Figure 5-4B Torch Switch and PIP Schematic - Hand

Torch
Handle Screws
(Five Places)
If problems are evident, repair or replace as required.

If there are no visual problems, then proceed
to Step 4.
SERVICE
5-6
Figure 5-5 Torch Handle Screw Removal
Manual 0-2818
2. Disconnect both torch head wire connectors.

3. Slide the insulation sleeve on the Pilot Lead back
towards the Lead.
B. Reassembling the Hand Torch Head

Assembly
4. Remove the screw and star washer securing the

Pilot Lead to the head assembly.
WARNING
5. Slide the insulation sleeving on the Negative /

Plasma Lead back towards the Lead.
NOTE
Some units may have shrink on tubing instead of
insulation sleeving. If this is the case, remove the
shrink on tubing from the Negative / Plasma Lead,
being careful not to damage the lead under the
shrink on tubing.
Negative / Plasma Lead

Insulation Sleeving Pilot Lead
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
To install the Torch Head Assembly use the following procedure:
IMPORTANT
The insulation sleevings are critical for safety. Be
sure both are properly installed and not damaged
during reassembly.
1. Slide the replacement insulation sleeving over the
Negative / Plasma Lead.
A-03544
Insulation
Sleeving
2. Connect the Negative / Plasma Lead to the replacement Torch Head Assembly.
Handle Shell
3. Carefully position the insulation sleeving over the

connectors as shown below.
Torch
Switch
Negative/Plasma
Lead Insulation Sleeving
Spring
Trigger
Handle Shell
Figure 5-6 Hand Torch Assembly

6. Disconnect the Negative / Plasma Lead from the
Torch Head.
7. Remove the defective Torch Head.
A-03545
Figure 5-7 Insulation Sleeving Position for the

4. Insert the screw through the Pilot Lead lug and
then install the star washer before securing it to
the Torch Head Assembly.
5. Carefully position the Insulation Sleeve over the
Pilot connection.
Manual 0-2818
5-7
SERVICE
d. Check the Torch Trigger for proper operation.

It should move freely and not bind. If the trigger binds, loosen the center screw only until
the Trigger moves freely.
Pilot Lead
Insulation Sleeving
A-02824
#2
Handle Half
#3
#1
Install Screws In
Sequence Shown
A-03546
Figure 5-9 Torch Handle Screw Installation
Figure 5-8 Insulation Sleeving Position for the Pilot

Connection
9. Install the front end torch parts.

6. Reconnect the two torch head wires to the mating
connectors in the leads assembly.
C. Removing Hand Torch Control Switch
7. Place the Torch Head Assembly in the handle shell

halves keeping in mind the following:
Place the Torch Head Assembly switch leads
so that no connectors or wires extend beyond
the edge of the handle.
To remove the Torch Control Switch Assembly requires gaining access to the switch wiring and partial disassembly of the torch handle per the following procedure:
1. Remove the five screws from the Torch Handle
Assembly. Pull the halves apart and set aside.
Allow sufficient slack in the leads to avoid pulling the leads tightly around the edge of the
handle.
Position Pilot Lead under the Negative /
Plasma Lead.
Position the Pilot Lead so that the screw will
not penetrate the Insulation Sleeve when the
handle halves are reassembled.
NOTE
A-02823
Handle Half
Handle Screws
(Five Places)
For safety reasons, do NOT use the sleeving if it is

damaged during reassembly. Replace sleeving if
damaged.
8. Place the torch handle halves together and install
the five assembly screws as follows:
Figure 5-10 Torch Handle Screw Removal
a. Insert the two screws at the Torch Head end

of the Handle and torque to 15 in-lbs.
b. Insert the two screws at the Torch Lead end of
the Handle and torque to 15 in-lbs.
c. Insert the center screw and torque to 15 in-lbs.
SERVICE
5-8
Manual 0-2818
2. Cut the Torch Switch leads between the butt

splices and the torch leads, and as close as possible to the splices.

Insulation Sleeving Pilot Lead
5. Replace the handle and secure with five screws

as follows:
a. Insert the two screws at the Torch Head end
of the Handle and torque to 15 in-lbs.
b. Insert the two screws at the Torch Lead end of
the Handle and torque to 15 in-lbs.
A-03544
Insulation
Sleeving
c. Insert the center screw and torque to 15 in-lbs.
Handle Shell
d. Check the Torch Trigger for proper operation.

It should move freely and not bind. If the trigger binds, loosen the center screw only until
the Trigger moves freely.
Torch
Switch
A-02824
#2
Spring
Trigger
Handle Half
Handle Shell
#3
#1
Figure 5-11 Hand Torch Assembly
Install Screws In
Sequence Shown
3. Remove the defective Torch Switch from the

handle.
Figure 5-12 Torch Handle Screw Installation
D. Reassembling Hand Torch Control Switch

Assembly
1. Strip back the insulation from the Torch Switch
leads approximately 3/16". Install heat-shrink
insulation on the Torch Switch leads. Crimp butt
splices onto the two Torch Switch leads and onto
the switch leads in the Torch Leads assembly.
Slide the sheat-shrink insulator over the butt
splices. Use a heat gun to shrink the heat-shrink
insulation into position on the butt splices.
2. Position Torch Head and Torch Control Switch in
handle, making sure all connectors and leads do
not extend beyond the edge of the handle.
3. Position Pilot Lead under the Negative / Plasma
Lead.
4. Position the Pilot Lead so that the screw will not
penetrate the Insulation Sleeving when the handle
halves are reassembled.
NOTE
For safety reasons, it is critical that the sleeving
not be used if it is damaged during reassembly.
Replace sleeving if damaged.
Manual 0-2818
5-9
SERVICE
5.08 Servicing Machine Torch (PCM)

Components
Negative/Plasma
Lead Connection
WARNINGS
Parts-in-Place
Wires

Pilot Lead
Connection
A. Removing Machine Torch Head

1. Unscrew the positioning tube from the Torch
Head.
2. Slide the positioning tube back over the leads to
expose the Negative / Plasma Lead connection,
Pilot Lead connection, and two PIP (parts-in-place
circuit) connectors.
A-02581
Figure 5-14 Torch Head Removal
B. Reassembling Machine Torch Assembly

1. Connect the two PIP lead connectors, the Negative / Plasma Lead and Pilot Lead.
NOTE
Pinch Block Assembly
Tape the PIP lead connectors to the leads covering.

2. Screw the positioning tube tightly onto the Torch
Head.
Positioning
Tube
A-02587
Machine Torch Head
Figure 5-13 Torch Mounting Assembly

3. Disconnect the Negative / Plasma Lead, Pilot
Lead and the PIP connectors to allow removal of
the Torch Head Assembly.
SERVICE
5-10
Manual 0-2818
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. Torch Assemblies are field serviceable, so a
complete breakdown of parts is provided. The parts lists
are arranged as follows:
Section 6.03: Replacement Hand Torch Parts
Section 6.04: Replacement Machine Torch Parts
Section 6.05: Replacement Machine Torch Leads
Section 6.06: Complete Assembly Replacements
Section 6.07: Options & Accessories
Section 6.08: Torch Consumable Parts
Section 6.09: Spare Parts Kits
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number 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 parts
list for each type item. Also include the model and serial
number of the torch. Address all inquiries to your authorized distributor.
Manual 0-2818
6-1
PARTS LISTS
6.03 Replacement Hand Torch Parts (Ergonomic Handle)

Item #
Qty
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
3
3
3
3
10
11
12
13
14
15
1
1
1
1
1
1
16
17
1
1
Description
Catalog #
Assembly, Torch Head (Includes items # 2 & 3)

PCH - 102 RPT 70 Torch Head
PCH - 102 RPT 90 Torch Head
# 6-32 x 3/16 Phillips Pan Head Screw
# 6 Internal Star Washer
Negative / Plasma Lead Insulation Sleeving
Pilot Wire Insulation Sleeving
Pin Housing (Used with item # 7)
Pin
Socket Housing (Used with item # 9)
Socket
Handle, Split, with Trigger (includes items # 10-14)
Trigger, Lexan, Orange
Handle
Spring
Torch Switch Assembly
Torch Handle Socket Head Cap Screw Kit (5 pieces # 6-32 x 1/2")
Lead Assembly, including items No. 11, 13, and 14
20 ft (6.1 m) Length
Through - Hole Protector with Nut (included in Item #17)
Adapter, Torch Control Cable (Includes Item #16)
9-8405
9-8404
See Note
See Note
9-8067
9-8057
9-8111
9-8101
9-8112
9-8102
9-8105
9-8059
9-8065
9-8061
9-8063
9-8062
4-7530
4-7529
9-7571
7-3447
NOTE: Item can be purchased locally.
PARTS LISTS
6-2
Manual 0-2818
Art # A-03550
8&9
4
11
13
6&7
12
1
10
14
11
16
15
17
Manual 0-2818
6-3
PARTS LISTS
6.04 Replacement Machine Torch With Pinch Block Mounting Parts

Item #
Qty
Assembly, Torch Head, PCM - 102 RPT (Includes items # 2-3)
# 6-32 x 3/16 Phillips Pan Head Screw
See Note
# 6 Internal Star Washer
See Note
Lead Assembly, Cable Complete
4A
Description
Catalog #
9-8403
Unshielded Lead Assembly

4B
4-7522
4-7523
Shielded Lead Assembly

4-7531
4-7532
Positioning Tube With Rack, Fiberglass
9-7835
Body, Mounting, Pinch Block Phenolic (Plastic)
9-4513
Pin, Mounting, Pinch Block
9-4521
Torch Holder Sleeve
7-2896
# 10-32 x 5/8" Phillips Pan Head Screw
See Note
10
# 10-32 x 32 x 1 - 1/4 Large Phillips Pan Head Screw
See Note
11
# 10-32 Regular Nylon Lock Nut
See Note
12
Through - hole protector, Notched (Supplied with Nut)
9-7016
13
Adapter, Torch Control Cable
7-3448
14
Pinch Block Mounting Kit (includes items #6-11)
7-3252
PARTS LISTS
6-4
Manual 0-2818
10
6
14
9
7
1
OR / OU
2
4A
12
13
4B
12
Art # A-03092
Manual 0-2818
6-5
PARTS LISTS
6.05 Replacement Machine Torch Lead Parts

Item #
Qty
Description
Catalog #
Nylon Sleeving
1
8-1000
8-7051
Through - hole protector, Notched (Supplied with Nut)
9-7016
Boot
9-7017
Lead, Pilot Return, 14 AWG

1
8-6460
8-6461
Lead, Gas Cooled, Negative, # 5

1
9-7665
9-7796
Assembly, Control Cable

Unshielded Leads
1
8-6462
8-6463
Shielded Leads
1
8-6456
8-6457
PVC Sleeving
1
8-6478
8-6479
Shield Braid
1
8-6458
PARTS LISTS
8-6459
6-6
Manual 0-2818
PCM - 102 Unshielded Torch Leads
1
5
4
2
A-02802
PCM - 102 Shielded Torch Leads
;;
7
1
5
A-02803
Manual 0-2818
6-7
PARTS LISTS
6.06 Complete Assembly Replacement

NOTE
The Complete Torch & Leads Assembly Replacement does not include the Torch Control Cable Adapter (refer to
Section 6.03 or 6.04)
Description
Catalog #
Hand Torches with Ergonomic Handle:

PCH - 102 RPT 70 Hand Torch, 20 ft (6.1 m) Leads
7-7530-SL
7-7532-SL

7-7531-SL
7-7533-SL
Machine Torches with Unshielded Leads (Fiberglass Mounting Tube with Rack & Phenolic Pinch Block Assembly):
PCM - 102 RPT Machine Torch, 25 ft (7.6 m) Leads
7-7536-SL
7-7537-SL
Machine Torches with Shielded Leads (Fiberglass Mounting Tube with Rack & Phenolic Pinch Block Assembly):
7-7538-SL
7-7539-SL
6.07 Options & Accessories

Qty
Description
Catalog #
Circle Cutting Guide
7-8910
Standoff Cutting Guide

For Use With 8-7500 Standard Shield Cup
8-7575
1
1
Remote Hand Pendant Control with 20 ft. Cable

Hand Pendant Extension - 25 ft
7-3460
7-7744
Computer Control (CNC) Cable

25 Ft (7.6 m)
50 Ft (15.2 m)
8-5557
8-5558
Kevlar Sleeving:
25 ft. (7.6 m)
50 ft. (15.2 m)
9-7905
9-7906
1
1
PARTS LISTS
6-8
Manual 0-2818
Item #
Qty
1
1
Description
Catalog #
1 - 3/8" Metal Positioning Tube with Rack & Pinion Assembly Kit
Pinion Assembly Only
7-7745
7-2827
Torch Holder Sleeve
7-2896
Pinion Gear-Short
8-6074
Handwheel (Torch Holder)
9-4514
Low Profile Torch Holder (1 - 3/8 Diameter) without Hardware 9-4515
Calibrated Torch Holder Bushing
5/32 Diameter x 5/8 Large Slotted Spring Pin
See Note
3/8 - 24 x 3/8 Socket Head Set Screw, Cup Point
See Note
1/4 - 20 x 5/8 Hex Socket Head Screw
See Note
# 10 - 24 x 3/8 Hex Socket Set Screw, Cup Point
See Note
9-4366
7
6
4
2
9
A-02737
5
1
Manual 0-2818
6-9
PARTS LISTS
6.08 Torch Consumables

The illustration shows all consumable parts for the PCH & M-102 torches. Refer to the section covering the
power supply being used to ensure proper selection for the application.
Cutting Consumables
Shield Cups
Tips
Air
SureLok
Electrodes
General Purpose
9-8402
Standard
8-7500
35/40 Amp
8-7503
Gas
Distributor
60 Amp
9-7726
Copper
8-7496
Body
8-7498
Copper
8-7497
Body
8-7498
Crown (Castle)
8-7499
8-7501
60/70 Amp
8-7505
Hi-Vis (Black)
8-7525
MaximumLife
9-8407
80 Amp
9-7728
A-03020
Crown (Castle)
8-7507
Gouging Consumables
SureLok
Electrodes
Shield Cups
A-03021
Gas
Distributor
Tip
Air
8-7508
General Purpose
9-8402
Orifice
8-7506
Standard
8-7500
MaximumLife
9-8407
Copper
8-7496
Body
8-7498
Copper
8-7497
Canted Coil Spring

Inside Shield Cups (All)
A-03022
PARTS LISTS
9-7501
6-10
Manual 0-2818
6.09 Torch Spare Parts Kits

A. For CutMaster 75 Applications
Qty
5
5
2
1
1
1
1
Description
Catalog #
Standard Spare Parts Kit Includes:

Electrode (SureLok), MaximumLife
Tip, Cutting, Air, 60 Amp
Tip, Cutting / Drag, Air, 40 Amp
O-Ring
Canted Coil Spring
Standoff Guide
Box, Utility
5-0018
9-8407
9-7726
8-7503
8-0532
9-7501
8-7575
8-3141
B. For CutMaster 80XL Applications

Qty
5
5
2
1
1
1
1
1
Description
Catalog #

Electrode (SureLok), General Purpose
Tip, Cutting / Drag, 40 Amp
O-Ring
Canted Coil Spring
Adapter Fitting 1/4" Hose to 1/4 NPT
Lubricant
Box, Utility
5-7580
9-8402
9-7726
8-7503
8-0532
9-7501
8-4264
8-4025
8-3141
C. For CutMaster 100 Applications

Qty
5
5
2
1
1
1
1
Manual 0-2818
Description
Catalog #

O-Ring
Canted Coil Spring
Standoff Guide
Box, Utility
6-11
5-0019
9-8407
9-7728
8-7503
8-0532
9-7501
8-7575
8-3141
PARTS LISTS
D. For Pak Master 75XL Plus Applications

1. For Non-CE Pak Master 75XL Plus Applications
Qty
Description
Catalog #
5
5
2
1
1
1
1
1
1

O-Ring
Canted Coil Spring
Adapter Fitting 1/4" Hose to 1/4" NPT
Lubricant
Box, Utility
Standoff Guide
5-7509
9-8407
9-7726
8-7503
8-0532
9-7501
8-4264
8-4025
8-3141
8-7575
20
40
10
2
1
1
5
3
1
VIP Spare Parts Kit Includes:

Gas Distributor
Standard Shield Cup
Shield Cup, Castle
O-Ring
Canted Coil Spring
Standoff Guide
5-7510
9-8407
9-7726
8-7503
8-7501
8-7500
8-7507
8-0532
9-7501
8-7575
10
15
2
2
5
3
1
Gouging Spare Parts Kit Includes:

Tip, Gouging, Air
Gas Distributor, Gouging
Standard Shield Cup
O-Ring
Canted Coil Spring
Box, Utility
5-0011
9-8407
8-7506
8-7508
8-7500
8-0532
9-7501
8-3141
2. For CE Pak Master 75XL Plus Applications

Qty
5
5
2
1
1
1
1
1
1
PARTS LISTS
Description
Catalog #

O-Ring
Canted Coil Spring
Lubricant
Box, Utility
Standoff Guide
6-12
5-7613
9-8402
9-7726
8-7503
8-0532
9-7501
8-4264
8-4025
8-3141
8-7575
Manual 0-2818
E. For Pak Master 100XL Plus Applications

1. For Non-CE Pak Master 100XL Plus Applications
Qty
Description
Catalog #
5
5
2
1
1
1
1
1
1

O-Ring
Canted Coil Spring
Lubricant
Box, Utility
Standoff Guide
5-0009
9-8407
9-7728
8-7503
8-0532
9-7501
8-4264
8-4025
8-3141
8-7575
20
40
10
2
1
1
5
3
1
VIP Spare Parts Kit Includes:

Gas Distributor
Standard Shield Cup
Shield Cup, Castle
O-Ring
Canted Coil Spring
Standoff Guide
5-0010
9-8407
9-7728
8-7503
8-7501
8-7500
8-7507
8-0532
9-7501
8-7575
10
15
2
2
5
3
1
Gouging Spare Parts Kit Includes:

Tip, Gouging, Air
Gas Distributor, Gouging
Standard Shield Cup
O-Ring
Canted Coil Spring
Box, Utility
5-0011
9-8407
8-7506
8-7508
8-7500
8-0532
9-7501
8-3141
2. For CE Pak Master 100XL Plus Applications

Qty
5
5
2
1
1
1
1
1
1
Manual 0-2818
Description
Catalog #

O-Ring
Canted Coil Spring
Lubricant
Box, Utility
Standoff Guide
6-13
5-7612
9-8402
9-7728
8-7503
8-0532
9-7501
8-4264
8-4025
8-3141
8-7575
PARTS LISTS
PARTS LISTS
6-14
Manual 0-2818
APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF

OPERATION BLOCK DIAGRAM
LATCH
ACTION
ACTION
ACTION
ACTION
Close external
disconnect switch.
ON/OFF switch
to ON.
RUN/SET/LATCH switch
to SET.
RUN/SET/LATCH
switch to RUN.
RESULT
RESULT
RESULT
RESULT
Power to system.
AC indicator blinks for 8

seconds then steady on.
Fans on.
Power circuit ready.
Gas solenoid open,

gas flows to set pressure.
GAS indicator on.
Gas flow stops.

GAS indicator off.
ACTION
ACTION
Protect eyes and
activate torch
Torch moved away

from work (while
still activated).
RESULT
RESULT
Gas flows (2 seconds).
Main arc stops.

Pilot arc automatically
restarts.
PILOT ARC
After gas pre-flow:

DC indicator on.
Pilot relay closes.
Pilot arc established
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
ACTION
Main arc transfer.

Pilot arc off.
Torch deactivated (by torch switch

release or by remote device).
RESULT
Main arc stops.
(Power supply enable signal removed.)
Gas flows (15 seconds)
NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
workpiece, main arc will transfer.
After post-flow:
Gas solenoid closes, gas flow stops.
GAS indicator off.
Manual 0-2818
ACTION
ON/OFF switch
to OFF
RESULT
All indicators off.
Power supply fans off.
A-1
ACTION
Torch Switch
can be released.
RESULT
Transfer will continue
until torch is removed
from workpiece.
ACTION
Open external
disconnect.
RESULT
No power to system.
A-02461
APPENDIX
APPENDIX 2: TORCH CONTROL CABLE WIRING

DIAGRAM FOR MECHANIZED SYSTEMS
To Torch
Control Device
Torch Control
Cable
Control Connector
Plug with Connectors
Torch Control
Connectors
To Power Supply
Control Connector
Control Shield
Connector
Torch Lead
Assembly
Lead Shield
Connector
Mate & Lock

Connectors
A-02821
Art # A-02801
Connectors only on
Shielded Leads
Torch Head
PIP Pin
Torch Leads
2
Shield
Return
Shield Cup
PIP Pin
Mate & Lock

Connectors
OK-To-Move
Relay
12
12
14
14
13
Power Supply
Control
13
Control
OK-To-Move
Remote Pendant/CNC
Cable Connector
Torch Control
Cable Connector
APPENDIX
Pendant Ground
A-2
Manual 0-2818
This Page Left Blank
Manual 0-2818
A-3
APPENDIX
APPENDIX 3: GENERAL APPLICATION NOTES

A. Electrode Selection
There are two SureLok Electrodes, General Purpose and MaximumLife. The information in this section is to help
determine which electrode to use for best performance.
General Purpose SureLok Electrode (Catalog No. 9-8402)
General Purpose- Good performance with all systems.
Design of electrode is similar to previous designed electrodes used in the PCH & M - 60, 75, 76, 80, and 100XL
Torches.
New patented locking design offers improved parts life, excellent piloting, improved arc transfer distance
and excellent arc characteristics as compared to older electrode designs.
The General Purpose electrode is the standard electrode offered with SureLok RPT Replacement Torches
providing good all around characteristics and performance.
MaximumLife SureLok Electrode (Catalog No. 9-8407)
New innovative patented fluted design.
Fluted design optimizes electrode cooling in most applications resulting in a significant improvement in
consumable parts life.
Suggested Applications
System
CutMaster 75
Electrode
General Purpose
MaximumLife
Catalog # 9-8402
Catalog # 9-8407
Optional
Suggested
CutMaster 80XL
Optional
CutMaster 100
Optional
Suggested
PakMaster 75XL Plus
Optional
Suggested
PakMaster 100XL Plus
Optional
Suggested
CE PakMaster 75XL Plus
Suggested
Optional
CE PakMaster 100XL Plus
APPENDIX
Suggested
Suggested
Optional
A-4
Manual 0-2818
B. Hand Cutting Versus Machine (Mechanized) Cutting Speeds
A-02947
Hand Cutting Speeds

(Shaded Area)
Speed
Machine Cutting
Speeds
Material Thickness
Hand cutting speeds can be much less than those obtained from Machine (Mechanized) Type applications. Hand
cutting application speeds mostly depend on operator experience. The cut quality obtained at slower speeds for a
Hand application is just as good as those obtained from a Machine application. As the cut speeds increase or decrease from the Machine applications the following may occur:
If cut speed is too fast the cut may exhibit one or more of the following: Insufficient Penetration, High Speed
Dross, Poor Consumable Life, Excessive Bevel Angle.
If cut speed is too slow the cut may exhibit one or more of the following: Main Arc Extinguishes, Slow Speed
Dross, Wandering (Unstable) Arc, Poor Consumable Life.
C. Frequently Asked Questions

Q. What Electrode can be used?
A. Only SureLok Electrodes, 9-8402 and 9-8407 may be used. Depending on the application and power supply
the General Purpose Electrode (9-8402) provides good all around characteristics and performance. The
MaximumLife Electrode (9-8407) design offers improved electrode cooling resulting in a significant improvement in parts life.
Q. Which Tip can be used?
A. All the Tips listed on the Appendix Page for the selected Power Supply application can be used. Select the
proper Tip for the desired application. It is recommended to use the Cutting / Drag Tip for general purpose
drag and light cutting applications. The Gouging Tip is recommended for gouging applications only. The
Standoff Tip can be used for standoff cutting applications for improved cut quality and speed.
Q. What if Electrode parts life is low?
A. Try using the MaximumLife Electrode.
Manual 0-2818
A-5
APPENDIX
APPENDIX 4: CUTMASTER 75 SYSTEM DATA

Cut Quality on Various Materials and
Thicknesses
Torch Specifications For

CutMaster 75 Power Supply
Cutting Range
Material
The following table defines the cut quality on various

materials and thicknesses:
Most Metals
Up to
3/4 inch (19 mm)
Speed
9 ipm (0.23 mpm)
Pierce Rating
Material
Thickness
Transfer Distance
Carbon Steel
3/8 inch (9.5 mm)
1/4 inch (6.3 mm)
Cut Quality on Various Materials

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
3/4 inch
Aluminum
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent
Gouging
Width
3/16 inch (4.76 mm)
Depth
1/8 inch (3.18 mm)
Number Passes
Speed
Single
20 ipm (0.5 mpm)
Bevel Cut Capability

Degrees
Material Thickness
Excellent - Minimum bevel (0 - 4), minimum kerf (2 x tip

orifice diameter), little or no dross, smooth cut
surface.
Good - Slight bevel (0 - 10), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed),
medium-smooth cut surface, slight top edge rounding.
0 to 45
1/2 inch (13 mm)
Gas Requirement
Type Gas
Description of Cut Characteristics:
Air
Operating Pressure
70 psi (4.8 bar)
Max Input Pressure

Cutting & Gouging
Total Flow
125 psi (8.6 bar)

400 scfh (190 lpm)
Consumable Matrix For CutMaster 75

Application
Drag Cutting
Electrode
9-8407
Gas Distributor
8-7501
Cutting (without Standoff Cup)
9-8407
8-7501
Cutting (with Standoff Cup)

Gouging
9-8407
9-8407
8-7501
8-7508
APPENDIX
A-6
Tip
8-7503
8-7503 (40A)
or 9-7726 (60A)
9-7726
8-7506
Shield Cup
8-7500
8-7500
8-7500
8-7500
Manual 0-2818
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 75

Type Torch: PCM-102
Type Plasma Gas: Air
Thickness
Type Material: Aluminum

Type Secondary Gas: Single Gas Torch
Tip
Output Volts Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
0.06
1.3
9-7726
100
60
370
9.40
0.19
4.8
70
4.8
80
387
0.19
mm
4.8
0.102
2.6
9-7726
103
60
195
4.95
0.19
4.8
70
4.8
80
387
0.19
4.8
1/4
6.4
9-7726
106
60
96
2.44
0.19
4.8
70
4.8
80
387
0.19
4.8
3/8
9.5
9-7726
111
60
52
1.32
0.19
4.8
70
4.8
80
387
0.19
4.8
1/2
12.7
9-7726
112
60
26
0.66
0.19
4.8
70
4.8
80
387
0.19
4.8
3/4
19.1
9-7726
117
60
12
0.30
0.19
4.8
70
4.8
80
387
NR
0.19
4.8

Type Torch: PCM-102
Type Material: Mild Steel

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
0.06
1.3
9-7726
95
60
350
8.89
0.19
4.8
70
4.8
80
387
0.19
4.8
0.102
2.6
9-7726
98
60
175
4.45
0.19
4.8
70
4.8
80
387
0.19
4.8
1/4
6.4
9-7726
102
60
80
2.03
0.19
4.8
70
4.8
80
387
0.19
4.8
3/8
9.5
9-7726
109
60
44
1.12
0.19
4.8
70
4.8
80
387
0.19
4.8
1/2
3/4
12.7
19.1
9-7726
9-7726
115
117
60
60
23
11
0.58
0.28
0.19
0.19
4.8
4.8
70
70
4.8
4.8
80
80
387
387
0
NR
0.19
0.19
4.8
4.8

Type Torch: PCM-102
Thickness
Type Material: Stainless Steel

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
0.06
1.3
9-7726
95
60
350
8.89
0.19
4.8
70
4.8
80
387
0.19
4.8
0.102
2.6
9-7726
98
60
162
4.11
0.19
4.8
70
4.8
80
387
0.19
4.8
1/4
6.4
9-7726
102
60
74
1.88
0.19
4.8
70
4.8
80
387
0.19
4.8
3/8
9.5
9-7726
109
60
37
0.94
0.19
4.8
70
4.8
80
387
0.19
4.8
1/2
3/4
12.7
19.1
9-7726
9-7726
115
117
60
60
17
9
0.43
0.23
0.19
0.19
4.8
4.8
70
70
4.8
4.8
80
80
387
387
0
NR
0.19
0.19
4.8
4.8
Manual 0-2818
A-7
APPENDIX
APPENDIX 5: CUTMASTER 80XL SYSTEM DATA

Thicknesses

CutMaster 80XL Power Supply

Cutting Range
Material
Most Metals
Up to
7/8 inch (22.2 mm)
Speed
10 ipm (0.25 mpm)
Pierce Rating
Material
Thickness
Transfer Distance
Carbon Steel
3/8 inch (9.5 mm)
3/8 inch (9.5 mm)
Gouging
Width
3/16 inch (4.76 mm)
Depth
1/8 inch (3.18 mm)
Number Passes
Speed
Single
20 ipm (0.5 mpm)
Material Thickness
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent

surface.
Good - Slight bevel (0 - 10), slightly wider kerf (2-1/2 x tip
orifice diameter), some dross (easily removed), medium-smooth cut surface, slight top edge rounding.

Degrees

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
3/4 inch
Aluminum
0 to 45
1/2 inch (13 mm)
Gas Requirement
Type Gas
Air
Operating Pressure
60 psi (4.1 bar)
Max Input Pressure

Cutting & Gouging
Total Flow
125 psi (8.6 bar)

310 scfh (146 lpm)
Consumable Matrix For CutMaster 80XL

Application
Electrode
Gas Distributor
Tip
Shield Cup
Drag Cutting
9-8402
8-7501
8-7503
8-7500
9-8402
8-7501
9-7726
8-7500
9-8402
8-7501
9-7726
8-7507
Gouging
9-8402
8-7508
8-7506
8-7500
APPENDIX
A-8
Manual 0-2818

Air Plasma Cutting Speed Data Chart For CutMaster 80XL
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/16
1.6
9-7726
100
60
375
9.53
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
1/8
3.2
9-7726
100
60
225
5.72
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
60
90
2.29
0.188
4.8
60
4.1
50
275
0.15
0.25
6.4
60
30
0.76
0.188
4.8
60
4.1
50
275
NA
NA
NA
1/4
6.4
9-7726
100
1/2
12.7
9-7726
100

Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/16
1.6
9-7726
100
60
300
7.62
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
60
145
3.68
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
1/8
3.2
9-7726
95
1/4
6.4
9-7726
105
60
65
1.65
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
3/8
9.5
9-7726
105
60
45
1.14
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
60
22
0.56
0.188
4.8
60
4.1
50
275
0.50
0.25
6.4
1/2
12.7
9-7726
105
3/4
19.1
9-7726
115
60
10
0.25
0.188
4.8
60
4.1
50
275
NA
NA
NA
25.4
9-7726
115
60
0.13
0.188
4.8
60
4.1
50
275
NA
NA
NA

Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7726
95
60
130
3.30
0.188
4.8
60
4.1
50
275
0.25
0.20
5.1
1/4
6.4
9-7726
100
60
45
1.14
0.188
4.8
60
4.1
50
275
0.50
0.20
5.1
3/8
9.5
9-7726
100
60
25
0.64
0.188
4.8
60
4.1
50
275
0.50
0.20
5.1
1/2
12.7
9-7726
105
60
16
0.41
0.188
4.8
60
4.1
50
275
NA
NA
NA
5/8
15.9
9-7726
115
60
12
0.30
0.188
4.8
60
4.1
50
275
NA
NA
NA
3/4
19.1
9-7726
115
60
0.20
0.188
4.8
60
4.1
50
275
NA
NA
NA
Manual 0-2818
A-9
APPENDIX
APPENDIX 6: CUTMASTER 100 SYSTEM DATA

CutMaster 100 Power Supply

Thicknesses
Cutting Range
Material
Most Metals
Up to
1 inch (25.4 mm)
Speed
10 ipm (0.25 mpm)
Pierce Rating
Material
Thickness
Transfer Distance
Carbon Steel
3/8 inch (9.5 mm)
3/8 inch (9.5 mm)
Gouging
Width
1/4 inch (6.3 mm)
Depth
3/16 inch (4.8 mm)
Number Passes
Speed
Single
20 ipm (0.5 mpm)

Degrees
Material Thickness
0 to 45

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
one inch
Aluminum
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent

surface.
1/2 inch (12.7 mm)
Gas Requirement
Type Gas
Air
Operating Pressure
70 psi (4.8 bar)
Max Input Pressure
125 psi (8.6 bar)
Cutting & Gouging

Total Flow
400 scfh (190 lpm)
Consumable Matrix For CutMaster 100

Application
Drag Cutting
Gouging
APPENDIX
Electrode
9-8407
9-8407
9-8407
9-8407
Gas Distributor
Tip
8-7501
8-7503
8-7501
8-7503 (40A) or 9-7728 (80A)
8-7501
9-7728
8-7508
8-7506
A-10
Shield Cup
8-7500
8-7500
8-7500
8-7500
Manual 0-2818

Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
0.05
1.3
9-7728
100
80
373
9.47
0.19
4.83
70
4.8
47
387
0.19
4.83
0.102
2.6
9-7728
103
80
253
6.43
0.19
4.83
70
4.8
47
387
0.19
4.83
1/4
6.4
9-7728
106
80
135
3.43
0.19
4.83
70
4.8
47
387
0.19
4.83
3/8
9.5
9-7728
111
80
66
1.68
0.19
4.83
70
4.8
47
387
0.19
4.83
1/2
3/4
1
12.7
19.1
25.4
9-7728
9-7728
9-7728
112
117
120
80
80
80
45
21
13
1.14
0.53
0.33
0.19
0.19
0.19
4.83
4.83
4.83
70
70
70
4.8
4.8
4.8
47
47
47
387
387
387
0
NR
NR
0.19
0.19
0.19
4.83
4.83
4.83

Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
0.05
1.3
9-7728
100
80
350
8.89
0.19
4.83
70
4.8
47
387
0.19
4.83
0.134
3.4
9-7728
103
80
230
5.84
0.19
4.83
70
4.8
47
387
0.19
4.83
1/4
6.4
9-7728
106
80
112
2.84
0.19
4.83
70
4.8
47
387
0.19
4.83
3/8
9.5
9-7728
111
80
55
1.40
0.19
4.83
70
4.8
47
387
0.19
4.83
1/2
3/4
1
12.7
19.1
25.4
9-7728
9-7728
9-7728
112
117
120
80
80
80
38
18
10
0.97
0.46
0.19
0.19
4.83
4.83
4.8
4.8
47
47
4.83
4.8
47
0
NR
NR
4.83
4.83
0.19
387
387
387
0.19
0.19
0.25
70
70
70
0.19
4.83

Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
0.05
1.3
9-7728
100
80
350
8.89
0.19
4.83
70
4.8
47
387
0.19
4.83
0.134
3.4
9-7728
103
80
230
5.84
0.19
4.83
70
4.8
47
387
0.19
4.83
1/4
6.4
9-7728
106
80
110
2.79
0.19
4.83
70
4.8
47
387
0.19
4.83
3/8
9.5
9-7728
111
80
48
1.22
0.19
4.83
70
4.8
47
387
0.19
4.83
1/2
3/4
1
12.7
19.1
25.4
9-7728
9-7728
9-7728
112
117
120
80
80
80
30
14
10
0.76
0.36
0.25
0.19
0.19
0.19
4.83
4.83
4.83
70
70
70
4.8
4.8
4.8
47
47
47
387
387
387
0
NR
NR
0.19
0.19
0.19
4.83
4.83
4.83
Manual 0-2818
A-11
APPENDIX
APPENDIX 7: PAK MASTER 75XL PLUS SYSTEM DATA

Pak Master 75XL Plus Power Supply
Cutting Range
Material
Cut Quality on Various Materials and Thicknesses

Most Metals
Up to
3/4 inch (19 mm)
Speed
10 ipm (0.25 mpm)
Pierce Rating
Material
Thickness
Carbon Steel
3/8 inch (9.5 mm)
3/8 inch (9.5 mm)
Transfer Distance
Gouging

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
3/4 inch
Aluminum
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent

Width
1/8 inch (3.2 mm)
Depth
1/8 inch (3.2 mm)
Number Passes
Speed
Single
20 ipm (0.5 mpm)

Degrees
Material Thickness
0 to 45

surface.
1/4 inch (6.3 mm)
Gas Requirement
Type Gas
Air
Operating Pressure
60 psi (4.1 bar)
Max Input Pressure
125 psi (8.6 bar)
Cutting & Gouging

Total Flow
300 scfh (142 lpm)
NOTE
For CE Applications refer to Appendix 9.
Consumable Matrix For Pak Master 75XL Plus

Application
Drag Cutting
Gouging
APPENDIX
Electrode
9-8407
9-8407
9-8407
9-8407
Gas Distributor
8-7501
8-7501
8-7501
8-7508
A-12
Tip
8-7503
9-7726
9-7726
8-7506
Shield Cup
8-7500
8-7500
8-7507
8-7500
Manual 0-2818
Air Plasma Cutting Speed Data Chart For PAK Master 75XL Plus
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/16
1.6
9-7726
100
60
375
9.53
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
1/8
3.2
9-7726
100
60
225
5.72
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
60
90
2.29
0.188
4.8
60
4.1
50
275
0.15
0.25
6.4
60
30
0.76
0.188
4.8
60
4.1
50
275
NA
NA
NA
1/4
6.4
9-7726
100
1/2
12.7
9-7726
100
Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/16
1.6
9-7726
100
60
300
7.62
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
60
145
3.68
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
1/8
3.2
9-7726
95
1/4
6.4
9-7726
105
60
65
1.65
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
3/8
9.5
9-7726
105
60
45
1.14
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
60
22
0.56
0.188
4.8
60
4.1
50
275
0.50
0.25
6.4
1/2
12.7
9-7726
105
3/4
19.1
9-7726
115
60
10
0.25
0.188
4.8
60
4.1
50
275
NA
NA
NA
25.4
9-7726
115
60
0.13
0.188
4.8
60
4.1
50
275
NA
NA
NA
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7726
95
60
130
3.30
0.188
4.8
60
4.1
50
275
0.25
0.20
5.1
1/4
6.4
9-7726
100
60
45
1.14
0.188
4.8
60
4.1
50
275
0.50
0.20
5.1
3/8
9.5
9-7726
100
60
25
0.64
0.188
4.8
60
4.1
50
275
0.50
0.20
5.1
1/2
12.7
9-7726
105
60
16
0.41
0.188
4.8
60
4.1
50
275
NA
NA
NA
5/8
15.9
9-7726
115
60
12
0.30
0.188
4.8
60
4.1
50
275
NA
NA
NA
3/4
19.1
9-7726
115
60
0.20
0.188
4.8
60
4.1
50
275
NA
NA
NA
Manual 0-2818
A-13
APPENDIX
APPENDIX 8: PAK MASTER 100XL PLUS SYSTEM DATA

CE Pak Master 100XL Plus Power Supply
Cutting Range
Material
1 inch (25.4 mm)
Speed
6 ipm (0.15 mpm)
Pierce Rating
Material
Carbon Steel
Distance
3/8 inch (9.5 mm)

3/8 inch (9.5 mm)
Gouging
Width
1/4 inch (6.3 mm)
Depth
3/16 inch (4.76 mm)
Number Passes
Speed
Single
20 ipm (0.5 mpm)

Degrees
Material Thickness

Most Metals
Up to
Transfer Distance
Cut Quality on Various Materials and Thicknesses

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
one inch
Aluminum
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent

surface.
0 to 45
1/2 inch (13 mm)
Gas Requirement
Type Gas
Air
Operating Pressure
70 psi (4.8 bar)
Max Input Pressure
125 psi (8.6 bar)
Cutting & Gouging

Total Flow
400 scfh (190 lpm)
NOTE
For CE Applications refer to Appendix 10.
Consumable Matrix For Pak Master 100XL Plus

Application
Drag Cutting
Gouging
APPENDIX
Electrode
9-8407
9-8407
9-8407
9-8407
Gas Distributor
Tip
8-7501
8-7503
8-7501
9-7726 (60A) or 9-7728 (80A)
8-7501
9-7726 (60A) or 9-7728 (80A)
8-7508
8-7506
A-14
Shield Cup
8-7500
8-7500
8-7507
8-7500
Manual 0-2818

Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7728
105
80
225
5.72
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
1/4
6.4
9-7728
105
80
115
2.29
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
3/8
9.5
9-7728
110
80
60
0.76
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
1/2
12.7
9-7728
120
80
30
0.76
0.188
4.8
70
4.8
85
365
NA
NA
NA
3/4
19.1
9-7728
125
80
10
0.25
0.188
4.8
70
4.8
85
365
NA
NA
NA
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
1/16
1.6
9-7728
100
80
400
10.16
0.188
4.8
70
4.8
85
365
0.0
0.20
mm
5.1
1/8
3.2
9-7728
105
80
180
4.57
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
1/4
6.4
9-7728
105
80
90
2.29
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
5.1
3/8
9.5
9-7728
105
80
50
1.27
0.188
4.8
70
4.8
85
365
0.1
0.20
1/2
12.7
9-7728
110
80
30
0.76
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
19.1
9-7728
120
80
12
0.30
0.188
4.8
70
4.8
85
365
NA
NA
NA
25.4
9-7728
120
80
0.15
0.188
4.8
70
4.8
85
365
NA
NA
NA
3/4
1
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7728
105
80
150
3.81
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
1/4
6.4
9-7728
105
80
75
1.91
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
3/8
9.5
9-7728
105
80
40
1.02
0.188
4.8
70
4.8
85
365
0.2
0.20
5.1
1/2
12.7
9-7728
110
80
18
0.46
0.188
4.8
70
4.8
85
365
NA
NA
NA
3/4
19.1
9-7728
125
80
10
0.25
0.188
4.8
70
4.8
85
365
NA
NA
NA
Manual 0-2818
A-15
APPENDIX
APPENDIX 9: CE PAK MASTER 75XL PLUS SYSTEM DATA


Thicknesses
Cutting Range
Material

Most Metals
Up to
3/4 inch (19 mm)
Speed
10 ipm (0.25 mpm)
Pierce Rating
Material
Carbon Steel
Distance
3/8 inch (9.5 mm)
Transfer Distance
3/8 inch (9.5 mm)
Gouging
Width
1/8 inch (3.2 mm)
Depth
1/8 inch (3.2 mm)
Number Passes
Speed
Single
20 ipm (0.5 mpm)

Degrees
Material Thickness
0 to 45
1/4 inch (6.3 mm)

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
3/4 inch
Aluminum
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent

surface.
Gas Requirement
Type Gas
Air
Operating Pressure
60 psi (4.1 bar)
Max Input Pressure
125 psi (8.6 bar)
Cutting & Gouging

Total Flow
300 scfh (142 lpm)
NOTE
For Non- CE Applications refer to Appendix 7.
Consumable Matrix For CE Pak Master 75XL Plus

Application
Drag Cutting
Gouging
APPENDIX
Electrode
9-8402
9-8402
9-8402
Gas Distributor
8-7501
8-7501
8-7501
Tip
8-7503
9-7726
9-7726
Shield Cup
8-7500
8-7500
8-7507
9-8402
8-7508
8-7506
8-7500
A-16
Manual 0-2818

Air Plasma Cutting Speed Data Chart For CE PAK Master 75XL Plus
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/16
1.6
9-7726
100
60
375
9.53
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
1/8
3.2
9-7726
100
60
225
5.72
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
60
90
2.29
0.188
4.8
60
4.1
50
275
0.15
0.25
6.4
60
30
0.76
0.188
4.8
60
4.1
50
275
NA
NA
NA
1/4
6.4
9-7726
100
1/2
12.7
9-7726
100
Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/16
1.6
9-7726
100
60
300
7.62
0.188
4.8
60
4.1
50
275
0.10
0.25
6.4
60
145
3.68
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
1/8
3.2
9-7726
95
1/4
6.4
9-7726
105
60
65
1.65
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
3/8
9.5
9-7726
105
60
45
1.14
0.188
4.8
60
4.1
50
275
0.25
0.25
6.4
9-7726
105
60
22
0.56
0.188
4.8
60
4.1
50
275
0.50
0.25
6.4
19.1
9-7726
115
60
10
0.25
0.188
4.8
60
4.1
50
275
NA
NA
NA
25.4
9-7726
115
60
0.13
0.188
4.8
60
4.1
50
275
NA
NA
NA
1/2
3/4
1
12.7
Type Torch: PCM-102
Thickness

Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7726
95
60
130
3.30
0.188
4.8
60
4.1
50
275
0.25
0.20
5.1
1/4
6.4
9-7726
100
60
45
1.14
0.188
4.8
60
4.1
50
275
0.50
0.20
5.1
3/8
9.5
9-7726
100
60
25
0.64
0.188
4.8
60
4.1
50
275
0.50
0.20
5.1
1/2
12.7
9-7726
105
60
16
0.41
0.188
4.8
60
4.1
50
275
NA
NA
NA
5/8
15.9
9-7726
115
60
12
0.30
0.188
4.8
60
4.1
50
275
NA
NA
NA
3/4
19.1
9-7726
115
60
0.20
0.188
4.8
60
4.1
50
275
NA
NA
NA
Manual 0-2818
A-17
APPENDIX
APPENDIX 10: CE PAK MASTER 100XL PLUS SYSTEM

DATA
Thicknesses

Cutting Range
Material

Most Metals
Up to
1 inch (25.4 mm)
Speed
6 ipm (0.15 mpm)

Material
Type of
Thickness
Material
Carbon Steel
Gage
to
Stainless
one inch
Aluminum
Pierce Rating
Material
Carbon Steel
Distance
3/8 inch (9.5 mm)
Transfer Distance
3/8 inch (9.5 mm)
Type of
Gas
Air
Air
Air
Cut
Characteristics
Good - Excellent
Good - Excellent
Good - Excellent
Gouging
Width
1/4 inch (6.3 mm)
Depth
3/16 inch (4.76 mm)
Number Passes
Speed
Single

surface.
20 ipm (0.5 mpm)

Degrees
Material Thickness
0 to 45

1/2 inch (13 mm)
Gas Requirement
Type Gas
Air
Operating Pressure
70 psi (4.8 bar)
Max Input Pressure
125 psi (8.6 bar)
Cutting & Gouging

Total Flow
400 scfh (190 lpm)
NOTE
For Non- CE Applications refer to Appendix 8.
Consumable Matrix For CE Pak Master 100XL Plus

Application
Electrode
Drag Cutting
9-8402
9-8402
9-8402
Gouging
9-8402
APPENDIX
Gas Distributor
8-7501
8-7501
8-7501
8-7508
A-18
Tip
8-7503
9-7726 (60A) or 9-7728 (80A)
9-7726 (60A) or 9-7728 (80A)
8-7506
Shield Cup
8-7500
8-7500
8-7507
8-7500
Manual 0-2818

Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7728
105
80
225
5.72
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
6.4
9-7728
105
80
115
2.29
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
3/8
9.5
9-7728
110
80
60
0.76
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
1/2
12.7
9-7728
120
80
30
0.76
0.188
4.8
70
4.8
85
365
NA
NA
NA
9-7728
125
80
10
0.25
0.188
4.8
70
4.8
85
365
NA
NA
NA
1/4
3/4
19.1
Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
1/16
1.6
9-7728
100
80
400
10.16
0.188
4.8
70
4.8
85
365
0.0
0.20
5.1
1/8
3.2
9-7728
105
80
180
4.57
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
1/4
6.4
9-7728
105
80
90
2.29
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
3/8
9.5
9-7728
105
80
50
1.27
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
1/2
12.7
9-7728
110
80
30
0.76
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
3/4
19.1
9-7728
120
80
12
0.30
0.188
4.8
70
4.8
85
365
NA
NA
NA
25.4
9-7728
120
80
0.15
0.188
4.8
70
4.8
85
365
NA
NA
NA
mm
Type Torch: PCM-102

Thickness
Tip
Standoff
Plasma Gas Press
Flow (SCFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
(VDC)
(Amps)
Inches
Meters
Inches
mm
psi
bar
Plasma
Total
Delay (Sec)
Inches
mm
1/8
3.2
9-7728
105
80
150
3.81
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
9-7728
105
80
75
1.91
0.188
4.8
70
4.8
85
365
0.1
0.20
5.1
1/4
6.4
3/8
9.5
9-7728
105
80
40
1.02
0.188
4.8
70
4.8
85
365
0.2
0.20
5.1
1/2
12.7
9-7728
110
80
18
0.46
0.188
4.8
70
4.8
85
365
NA
NA
NA
9-7728
125
80
10
0.25
0.188
4.8
70
4.8
85
365
NA
NA
NA
3/4
19.1
Manual 0-2818
A-19
APPENDIX
APPENDIX 11: TORCH CONNECTION DIAGRAMS

Hand Torch Connection:
Hand Torch and Leads

Torch Head
Power Supply
Adapter
Torch Leads
PIP
Contacts
Black
Orange
Torch
Switch
Power Supply
Bulkhead
Green
White
Negative / Plasma
Pilot
Pilot
Art # A-03863
MachiineTorch Connection:
To Torch
Control Device
Torch Control
Cable
Control Connector
Plug with Connectors
Torch Control
Connectors
To Power Supply
Control Connector
Control Shield
Connector
Torch Lead
Assembly
APPENDIX
Lead Shield
Connector
A-20
Connectors only on
Shielded Leads
Art # A-02801
Manual 0-2818

2818 PCH&amp;M-102 SureLok Torch (I)

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2818 PCH&amp;M-102 SureLok Torch (I)

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Copyright:

Formatos disponibles

PLASMA

Manual No. 0-2818

Plasma Cutting Torch

Where Purchased: _______________________________________

Notes, Cautions and Warnings .....................................................................

Scope of Manual ...........................................................................................

TABLE OF CONTENTS (continued)

Introduction ................................................................................................... 5-1

Introduction ................................................................................................... 6-1

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

GASES AND FUMES

Throughout this manual, notes, cautions, and warnings

Use an air-supplied respirator if ventilation is not

The kinds of fumes and gases from the plasma arc

A procedure which, if not properly followed, may

Always read the Material Safety Data Sheets

For information on how to test for fumes and gases

1.02 Important Safety Precautions

Use special equipment, such as water or down draft

OPERATION AND MAINTENANCE OF

Date: January 27, 2004

This product, when used for welding or cutting,

Wear dry gloves and clothing. Insulate yourself

PLASMA ARC RAYS

Disconnect power source before performing any

Read and follow all the instructions in the Operating Manual.

Keep helmet and safety glasses in good condition.

FIRE AND EXPLOSION

Protect others in the work area from the arc rays.

Fire and explosion can be caused by hot slag, sparks, or

Use the shade of lens as suggested in the following

* These values apply where the actual arc is clearly

Provide a fire watch when working in an area where

Do not cut or weld on containers that may have

Ventilate all flammable or explosive vapors from

Less Than 300*

Date: January 27, 2004

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

Toute procdure pouvant provoquer des blessures

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

1.05 Precautions De Securite

Coupant larc au jet de plasma produit de lnergie

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

1.04 Note, Attention et

Lisez toujours les fiches de donnes sur la scurit

Ne touchez jamais une pice sous tension ou vive;

Utilisez un quipement spcial tel que des tables de

Nutilisez pas le chalumeau au jet de plasma dans une

Procurez une bonne aration de toutes les fumes

Le phosgne, un gaz toxique, est gnr par la fume

Ne coupez pas et ne soudez pas les conteneurs ayant

RAYONS DARC DE PLASMA

Date: January 27, 2004

ultra-violets trs forts. Ces rayons darc nuiront vos

* Ces valeurs sappliquent ou larc actuel est observ

Date: January 27, 2004

1.06 Documents De Reference

Date: January 27, 2004

1.07 Declaration of Conformity

Date: January 27, 2004

1.08 Statement of Warranty

Main Power Magnetics

2818 PCH&M-102 SureLok Torch (I)

2818 PCH&M-102 SureLok Torch (I)