Therma Pak Master 50

R
Air Plasma Cutting System
Operating Manual
The System Includes:
Pak Master 50 Power Supply

PCH/M-35 Smart Torch with Leads
Optional Input Power Cable
Work Cable with Clamp
Manual No. 0-2344

July 1995 Third Edition
THERMADYNE
Thermal Dynamics
WARNING
Read and understand this entire instruction manual and your

employers safety practices before installing, operating, or
servicing the equipment.
WARNING
While the information contained in this instruction manual

represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Pak Master 50 Air Plasma Cutting System
Instruction Manual Number 0-2344
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1992 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 the Pak Master 50 Air Plasma Cutting System
Instruction Manual, whether such error results from negligence,
accident, or any other cause.
Printed in the United States of America
Third Edition Revised
July, 1995
RECORD SERIAL NUMBERS FOR WARRANTY PURPOSES
Purchase Date
Power Supply
Torch
TABLE OF CONTENTS
Introduction
Notes, Cautions, and Warnings ........................................................ ii

Important Safety Precautions ........................................................... iii
Statement of Warranty ........................................................................ x
General Information
1.1 System Description ...................................................................... 1

1.2 Specifications................................................................................ 2
1.3 Options and Accessories............................................................. 4
Installation
Operation
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Unpacking .................................................................................... 5
Choosing a Location .................................................................... 6
Setting Up the Torch ................................................................... 7
Installing the Torch ..................................................................... 9
Remote Control Harness Installation ...................................... 10
Electrical Connections ............................................................... 12
Work Cable and Ground Connections ................................... 15
Gas Connections ........................................................................ 16
3.1 Operating Controls .................................................................... 19

3.2 Getting Started ........................................................................... 21
3.3 Sequence of Operation .............................................................. 22
3.4 Torch Parts Selection ................................................................. 23
3.5 Cut Quality ................................................................................. 24
3.6 Operating the System ................................................................ 26
3.7 Operating with a Hand Torch .................................................. 28
3.8 Operating with a Machine Torch ............................................ 29
3.9 Recommended Cutting Speeds ............................................... 32
3.10 Gouging ...................................................................................... 33
Service
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Power Supply Maintenance ..................................................... 35

Replacing Consumable Torch Parts ........................................ 36
Torch Maintenance .................................................................... 37
Servicing Torch Head Components ........................................ 39
Servicing Torch Leads Components ....................................... 45
Torch and Leads Troubleshooting .......................................... 48
Power Supply Troubleshooting Guide ................................... 50
Parts List
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Ordering Information ............................................................... 53

System Components and Accessories .................................... 54
Replacement Torches and Leads ............................................. 55
Torch Head Components ......................................................... 56
Consumable Torch Parts .......................................................... 57
Torch Options and Accessories ............................................... 58
Torch Spare Parts Kits ............................................................... 60
INTRODUCTION
NOTES, CAUTIONS, AND WARNINGS
Throughout this manual, notes, cautions, and warnings are used

to highlight important information. These highlights are categorized as follows:
NOTE
CAUTION
WARNING
INTRODUCTION
An operation, procedure, or background information which

requires additional emphasis or is helpful in efficient operation of
the system.
A procedure which, if not properly followed, may cause damage
to the equipment.
A procedure which, if not properly followed, may cause injury
to the operator or others in the operating area.
ii
IMPORTANT SAFETY PRECAUTIONS
WARNING
Gases and Fumes
Operation and maintenance of plasma arc equipment involves

potential hazards. All operators and personnel should be alerted
to possible hazards and precautions should be taken to prevent
possible injury.
GASES AND FUMES produced during the plasma cutting
process can be dangerous and hazardous to your health.
Ventilation must be adequate to remove gases and fumes
during operation. Threshold limit values and how to measure
the amounts to assure adequate ventilation are found in publication (A), page v.
Vapors of chlorinated solvents can form the toxic gas phosgene
when exposed to ultraviolet radiation from an electric arc.
Solvents, degreasers, and potential sources of these vapors
must be removed from the cutting area.
Keep all fumes and gases from the breathing area.
Use a downdraft cutting table or water table to capture fumes
and gases.
Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.
Arc Rays
ARC RAYS can injure eyes and burn skin.

Use a welding shield with proper filter. A #4 filter or darker is
recommended for drag cutting. A #10 filter or darker is recommended when cutting with a standoff.
Wear proper protective clothing.
Make sure others in the operating area are protected from arc
rays.
iii
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Electric Shock
ELECTRIC SHOCK can kill.

Install and maintain equipment according to USA Standard C1,
National Electric Code.
Proper grounding procedures must be adhered to when using
plasma arc cutting equipment. The workpiece must be
grounded to a solid electrical ground.
Do not contact electrically live parts. Do not touch torch parts
when input power is present in the power supply.
Insulate yourself and others from the workpiece and ground.
Replace any cracked or damaged insulating parts including
torches, hoses, and leads.
Disconnect power source before disassembling the torch. Turn
off primary power before working on torch parts, including
changing cups and tips.
The shield cup must be installed prior to operating the torch.
When operating plasma arc cutting equipment in a damp or
wet area, extra care should be taken.
Use this equipment for plasma cutting and gouging only. It is
not designed for any other cutting or welding process.
Use only the torches specified in this instruction manual.
Fire
FIRE can be caused by hot slag and sparks.

Remove combustibles from working area or provide a fire
watch.
Do not cut containers that have held combustibles. Remove all
flammable and combustible materials in the operating area that
may be ignited by sparks.
Do not mount this equipment over combustible surfaces.
Noise
NOISE can cause permanent hearing loss.

Wear proper protective ear muffs or plugs.
Make sure others in the operating area are protected from noise.
Compressed Gas
Cylinders
INTRODUCTION
Compressed gas cylinders are potentially dangerous.

Refer to suppliers for proper handling procedures.
iv
IMPORTANT SAFETY PRECAUTIONS (continued)
Publications
The following publications provide additional information on

safety precautions:
(A) Bulletin No. C5.2-83 Recommended Safe Practices for
Plasma Arc Cutting
(B) American National Standard ANSI Z49.1-1983 Safety in
Welding and Cutting
Both publications are available from:
American Welding Society Inc.
2501 Northwest 7th Street
Miami, Florida 33125
Telephone (305) 443-9353
(C) OSHA Safety and Health Standards, 29CFR1910 available
from:
The U.S. Department of Labor
Washington, D.C. 20210
D) CSA Standard W117.2 Safety in Welding, Cutting, and
Allied Processes obtainable from:
The Canadian Standards Association
178 Rexdale Blvd.
Toronto, Ontario M9W1R3, Canada
E) AS1674, AS2745, WITA Technical note 7 obtainable from:
Standards Australia's Quality Assurance Services
80 Arthur Street
North Sydney, N.5.W. 2060
WARNING
Read and understand this instruction manual and your

employers safety practices.
INTRODUCTION
PRCAUTIONS
AVERTISSEMENT
Les gaz et les fumees
La mise en oeuvre et l'entretien de tout quipement plasma

implique des dangers potentiels. Le personnel doit etre mis en
garde contre les risques suivants et toutes les prcautions doivent
etre prises pour eviter de prendre des risques pour la sant.
LES GAZ ET LES FUMEES peuvent etre dangereux et constituer
un risque pour votre sante.
La ventilation doit tre suffisante pour vacuer les fumes lors
de la coupe. (Dans la publication (A), page viii, vous trouverez
la faon de mesurer les quantits permettant d'affirmer que la
ventilation est adquate, ainsi que les valeurs limites ne pas
dpasser.)
Les vapeurs de solvants chlors peuvent former un gaz toxique,
le Phosgne, lorsqu'elles sont exposes aux radiations ultraviolettes mises par l'arc lectrique. Tous les solvants,
dgraissants et sources potentielles de ces vapeurs doivent tre
enlevs de l'aire de coupe.
Evacuer toutes les fumes et les gaz de l'aire de respiration.
Utiliser un tabli de coupe tirage vers le bas pour attirer les
fumes et les gaz.
Utiliser un masque aves arrive d'air si la ventilation n'est pas
suffisante pour liminer tous les gaz et fumes.
INTRODUCTION
vi
PRCAUTIONS (continuer)
Les rayons de l'arc
LES RAYONS DE L'ARC peuvent abimer les yeux et bruler la

peau.
Utiliser un cran de soudage muni d'un filtre numro 4 ou plus
sombre en coupant "au contact" ou numro 10 ou plus sombre
en coupant distance.
Porter des vtements protecteurs adquats.
Assurez vous que les autres personnes ne soient pas atteintes
par les rayons.
Decharge electrique
Une DECHARGE ELECTRIQUE peut tuer.

Faire l'installation et l'entretien de l'appariel selon les normes
du Code Electrique des Etats-Unis (Norme NEC-USA Standard
C1), ou celles en vigueur dans votre pays.
Il faut appliquer les procdures de mise la terre spcifiques
l'utilisation de dispositifs de coupe au plasma. La pice ou le
mtal sur lequel une personne coupe doit tre relie une
bonne prise de terre.
Ne pas toucher des pices sous tension.
Isolez-vous du courant de coupe et de la terre.
Remplacer toute pice isolante fendue ou endommage, y
compris le corps de torche et les cbles.
Couper l'alimentation avant la depose du chalumeau. Couper
l'alimentation avant d'intervenir sur la torche, y compris pour
changer la buse ou l'lectrode.
Avant d'utilisere le chalumeau s'assurer que l'ecran de protection est en place.
Soyez particulirement vigilant lorsque vous coupez avec un
appariel de coupe au plasma dans un endroit humide.
Un encendie
Les etincelles et les scories peuvent provoquer UN ENCENDIE.

Oter tout combustible de l'aire de coupe ou installer un
dtecteur de flammes.
Ne pas couper de rcipient ayant contenu des combustibles.
Tout matriel inflammable ou combustible pouvant tre allum
par une tincelle doit tre enlev de l'aire de coupe.
vii
INTRODUCTION
PRCAUTIONS (continuer)
Le bruit
LE BRUIT peut causer la surdit.

Prot des protecteurs auditifs.
Assur que tous les autres sont protg du bruit.
Bouteilles de gaz
comprimes
LES RSERVOIRS DE GAZ SONT DANGEREUX.
Les publications
LES PUBLICATIONS suivantes contiennent des renseignements supplmentaires sur les prcautions prendre pour
garantir la scurit.
Se rfrer aux directives du constructeur pour une bonne

utilisation.
(A) Bulletin No. C5.2-83 Recommended Safe Practices for

Plasma Arc Cutting
(B) American National Standard ANSI Z49.1-1983 Safety in
Welding and Cutting
Vous pouvez vous les procurer toutes les deux auprs de:
American Welding Society Inc.
2501 Northwest 7th Street
Miami, Florida 33125 U.S.A.
Tlphone (305) 443-9353
(C) OSHA Safety and Health Standards 29CFR 1910,
disponible auprs du:
U.S. Department of Labor
Washington DC 20210, USA
(D) Norme de l'ACNOR W117-2, Safety in Welding, Cutting,
and Allied Processes que l'on peut obtenir auprs de:
L'Association Canadienne Des Normes
178 Rexdale Blvd
Toronto, Ontario, Canada, M9W 1R3
(E) AS1674, AS2745, WITA Technical note 7 obtainable from:
Standards Australia's Quality Assurance Services
80 Arthur Street
North Sydney, N.5.W. 2060
AVERTISSEMENT
INTRODUCTION
Lire et comprendre ce manuel d'instructions, ainsi que les

pratiques sur la securite emises par votre employeur.
viii
DECLARATION OF CONFORMITY
Manufacturer: Thermal Dynamics Corporation

Address:
Industrial Park #2
West Lebanon, New Hampshire 03784
USA
Description of equipment:
Plasma Cutting Equipment: Namely, Pak2XT, Pak Master 25, Pak Master 50,
Pak Master 100, Stak Pak, Signature 625XR, Signature 1250XR, PAK 15XC,
Pak44, Pak 45, TA 500, TA 1000 and associated accessories.
Plasma Welding Equipment: Namely, WC100B, HE150, Weld Sequencer,
PS3000 and associated accessories.
* Serial numbers are unique with each individual piece of equipment and
details description, parts used to manufacture a unit and date of manufacture.
*The equipment conforms to all applicable aspects and regulations of the Low Voltage Directive
(Directive 73/23/EU, as recently changed in Directive93/63EU) and to the National legislation for the
enforcement of this Directive.
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-M1990 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* IEC 974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment anassociated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine
design and manufacturing process, to ensure the product is safe 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 that perform in a safe manner for more than 30 years
and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative:
David Ashworth
Vice President & Managing Director
Thermadyne Europe
Chorley England.
ix
INTRODUCTION
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, recommen dations 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: 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 following further limitations on such two (2) year period:
PAK UNITS, POWER SUPPLIES
PARTS
LABOR
MAIN POWER MAGNETICS ....................................................... 2 YEARS ..................... 1 YEAR

ORIGINAL MAIN POWER RECTIFIER ..................................... 2 YEARS ..................... 1 YEAR
CONTROL PC BOARD .................................................................. 2 YEARS ..................... 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ......................... 1 YEAR ...................... 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT ........................... 1 YEAR ...................... 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ..................................................................... 180 DAYS .................. 180 DAYS
REPAIR/REPLACEMENT PARTS ................................................. 90 DAYS .................... 90 DAYS
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized
Thermal Arc repair facility within thirty (30) days of the repair. Authorized Thermal Arc repair facilities are authorized distributors and authorized Thermal Arc Service Centers. No transportation costs of
any kind will be paid under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer's risk and expense. This warranty supersedes all previous Thermal warranties.
Thermal Arc is a Registered Trademark of Thermal Dynamics.
Effective January 18, 1991
INTRODUCTION
1.1 SYSTEM DESCRIPTION
The Pak Master 50

Air Plasma Cutting
System Includes:
Pak Master 50 - The power supply provides 35 amp maximum

output and includes all control circuitry, electrical and gas
inputs and outputs, pilot circuitry, and a quick disconnect torch
leads receptacle. The power supply is shipped with a work
cable and clamp attached. A 230V single-phase primary input
power cable with molded 50 amp plug is optional. Machine
torch systems also include a remote hand control and remote
control wire harness.
PCH/M-35 Torch with Leads (Packaged Separately) - The torch
provides a maximum 1/2 inch (12 mm) cut capacity. Hand
torches are available in 70 and 90 configurations which
include a handle and multi-position switch assembly. Machine
torches include a rack and pinion mounting assembly. A
phenolic (plastic) pinch block mounting assembly is optional.
Torch leads are available in 12.5, 25, or 50 ft (3.8, 7.6, or 15.2 m)
lengths with a quick disconnect torch leads fitting for simple
installation. The PCH/M-35 includes a spare parts kit which
provides an assortment of replacement consumable torch parts.
See page 4 for a list of other system options and accessories.
Pak Master 50
Power Supply
PCH-35 Torch
with Leads
Work Cable
with Clamp
Figure 1-A System Components
GENERAL INFORMATION
1.2 SPECIFICATIONS
Controls
Panel Indicators
Input Power
ON/OFF Switch
RUN/SET Switch
Output Current Control
Corner Slowdown Control
Pressure Regulator Control
LED Indicators:
AC Power, TEMP, PIP (Parts-In-Place), GAS, DC Power, PILOT
Pressure Gauge
200 to 460 VAC (10%), 50 or 60 Hz, Single or Three-Phase
575V Requires Additional Transformer (Catalog No. 9-6211)
Output Power
Continuously variable from 15 to 35 Amps maximum

70% Duty Cycle
Cut Capacity
1/2 in (12.7 mm) at 10 ipm
Pilot Circuitry
High Frequency (HF), Constant DC
CNC Capability
Weight
Dimensions
Remote Start/Stop, OK-to-Move, and Corner Slowdown (CSD)

69.8 lbs (31.7 kg)
18.5" High x 11.1" Wide x 21.7" Long
(470 x 282 x 551 mm)
Table 1-A Power Supply Specifications
Configurations
70 or 90 Hand Torch, 180 Machine Torch
Current Rating
35 amps Maximum, DC Straight Polarity
Duty Cycle
100% @ 35 amps
Cutting Range
Most materials up to 1/2 in (12.7 mm)
Pierce Rating
1/4 in (6.3 mm)
Transfer Distance
3/8 in (9.5 mm)
Consumable Parts
Gas Distributor, Electrode, Tip, Shield Cup
Gases
Pressure Requirements
Flow Requirements
Available Leads Lengths
Compressed Air, Nitrogen (N2)

70 psi (4.8 BAR)
Cutting - 200 scfh (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
12.5 ft (3.8 m), 25 ft (7.2 m), or 50 ft (15.2 m)
Extendable to 150 ft (45.6 m)
Table 1-B Torch Specifications
GENERAL INFORMATION
1.2 SPECIFICATIONS (continued)
2.99 in
(76 mm)
1.06 in (27 mm)

9.54 in (242 mm)
PCH-35 70 Hand Torch
3.12 in
(79 mm)
1.06 in (27 mm)
8.95 in (227 mm)

PCH-35 90 Hand Torch
6.44 in (164 mm) Min.

15.20 in (386 mm) Max.
1.38 in
(9.7 mm)
0.20 in (5 mm)
1.06 in
(27 mm)
PCM-35 Machine Torch with Rack and Pinion Mounting Assembly
Figure 1-B PCH/M-35 Torch Dimensions
GENERAL INFORMATION
1.3 OPTIONS AND ACCESSORIES
Pak Master 50
System Options and
Accessories
Remote Control (RC) Wire Harness ...................... Cat. No. 9-6210

For converting a hand cutting system to mechanized use with a
remote hand pendant control or computer control (CNC) cable.
Remote Hand Pendant Control ............................. Cat. No. 7-3114
Hand-held remote ON/OFF control device for systems with
remote wire harness installed. Includes a 25 ft (7.6 m) cable.
Computer (CNC) Interface Cable - 25 ft (7.6 m) .. Cat. No. 8-5557
Computer (CNC) Interface Cable - 50 ft (15.2 m) Cat. No. 8-5558
For interfacing the power supply with a computer or auxiliary
control device. Provides ON/OFF, OK-to-move, and corner
slowdown signals. (Remote wire harness must be installed.)
High Pressure Regulator - Air ............................... Cat. No. 9-3022
High Pressure Regulator - Nitrogen (N2) ............. Cat. No. 9-2722
Running Gear ........................................................... Cat. No. 7-3201
For transporting the system with torch and leads storage.
Air Line Filter - Single Stage .................................. Cat. No. 7-3265
Air Line Filter - Two Stage ..................................... Cat. No. 7-3340
Remove damaging moisture and contaminants from the air
stream when using compressed air.
575V Transformer Unit ........................................... Cat. No. 9-6211
For operating standard systems with 575V three-phase input.
Torch Options
and Accessories
Spare Parts Kit - Standard Cutting ...................... Cat. No. 5-6001S

Spare Parts Kit - Gouging ....................................... Cat. No. 5-6015
Spare Parts Kit - Long Life ..................................... Cat. No. 5-6001
Kits contain replacement front-end torch parts (see detailed
description of spare parts kit contents on page 72).
Leads Extension Kit - PCH-35, 25 ft (7.6 m) ......... Cat. No. 4-6007
Leads Extension Kit - PCH-35, 50 ft (15.2 m) ....... Cat. No. 4-6008
Leads Extension Kit - PCM-35, 25 ft (7.6 m) ......... Cat. No. 4-6009
Leads Extension Kit - PCM-35, 50 ft (15.2 m) ....... Cat. No. 4-6010
For extending torch leads up to 150 ft (45.7 m).
Phenolic Mounting Tube ........................................ Cat. No. 7-3251
Phenolic Pinch Block Mounting Assembly .......... Cat. No. 7-3252
For machine mounted torch applications where a non-metal
mounting assembly is desired.
Switch Lever Kit ...................................................... Cat. No. 8-5170
Provides a lever for activating the hand torch control switch.
NOTE
See System Components and Accessories (page 62) or Torch

Options and Accessories (page 72) for more information.
GENERAL INFORMATION
2.1 UNPACKING
Each component of the system is packaged separately and protected with a carton and packing material to prevent damage
during shipping.
What's Included with

the Power Supply
Included with each power supply is:

(1) Work Cable with Clamp (Attached)
(1) 230V Single-Phase Input Power Cable with Plug (Optional)
(1) Air Q/D Coupling - 1/4 NPT to #6 Barb .......... Cat. No. 9-6258
(1) Fuse - 2 Amp, 600V .............................................. Cat. No. 9-3861
(1) Spare Parts Container (without Parts) ............... Cat. No. 8-3213
(1) Pak Master 50 Instruction Manual ..................... Cat. No. 0-2344
Included with each machine torch system is:
(1) Remote Control Hand Pendant .......................... Cat. No. 7-3114
(1) Remote Control Interface Wire Harness ........... Cat. No. 9-6210
What's Included
with the Torch
Torches are packaged separately. Included with each torch is:

(1) PCH/M-35 Torch (with Shield Cup, Tip, Electrode, and Gas
Distributor Installed)
(1) Torch Leads with Quick Disconnect (Attached)
(1) Torch Handle Assembly (For Hand Torches), or
(1) Machine Torch Mounting Assembly (For Machine Torches)
(1) Standard Long Life Cutting Spare Parts Kit (5-6001):
(1) Standard Shield Cup ..................................... Cat. No. 9-6003
(5) Tips (Standoff Cutting) ................................. Cat. No. 9-6500
(3) Tips (Drag Cutting) ....................................... Cat. No. 9-6501
(5) Electrodes ....................................................... Cat. No. 9-6506
(1) Gas Distributor .............................................. Cat. No. 9-6507
Other accessories are packaged separately.
Unpacking Procedure
1. Unpack each item and remove all packing material.

2. Locate the packing list(s) 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.
INSTALLATION
2.2 CHOOSING A LOCATION
Choosing a Location
Select a clean, dry location with good ventilation and adequate

working space around all components.
The power supply is cooled by air flow through the rear panel.
Air flow must not be obstructed. Provide at least 2 feet (0.61 m) of
clearance in the rear. Provide at least 6 inches (0.15 m) clearance
on each side. Provide sufficient clearance in front of the unit to
allow access to front panel controls (minimum 6 in or 0.15 m).
CAUTION
Operation without proper air flow will inhibit proper cooling and
reduce duty cycle.
NOTE
Review Important Safety Precautions (page iii) to be sure that the

selected location meets all safety requirements.
INSTALLATION
2.3 SETTING UP THE TORCH (continued)
WARNING
Hand Torch Set-Up
Disconnect primary power at the source before disassembling

the power supply, torch, or torch leads.
The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, standoff cutting, or gouging). Refer to Torch Parts Selection (page 23).
The torch is factory assembled with the control switch in the top
front position (see Figure 2-A below). To position the control
switch on the bottom (underside) of the handle, pull the handle
back approximately 2 inches (51 mm) and rotate the handle
assembly 180 (do not rotate beyond 180). To position the
control switch in the rear position:
1. Locate the tab on the back of the switch track closure. Gently
press in on the tab and carefully pry the closure upward.
2. Remove the switch track insert and the torch control switch.
3. Reinstall the switch track insert, then the switch, then the
switch track closure.
The optional switch lever kit (Cat No. 8-5170) provides a lever for
activating the torch control switch. Refer to Torch Options and
Accessories (page 72) for ordering information.
Reverse view of
closure - press
tab to remove
Switch Track Closure

Switch Track Insert
Switch Assembly
Switch Track
Switch Lever
with Mounting
Brackets
(Optional)
Bottom mounted
torch switch (shown
with optional switch lever)
Figure 2-A Hand Torch Switch Options
INSTALLATION
2.3 SETTING UP THE TORCH (continued)
WARNING
Machine Torch Set-Up

must correspond with the type of operation (drag cutting, standoff cutting, or gouging). Refer to Torch Parts Selection (page 23).
Metal mounting tubes with rack and pinion assemblies are
standard for machine torches. Phenolic (plastic) mounting tubes
with pinch blocks are optional (see Torch Options and Accessories, page 72).
1. Mount the torch assembly on the cutting table.
Refer to Figure 2-B and:
2. To obtain a clean vertical cut, use a square to align the torch
perpendicular to the surface of the workpiece.
Use a square to align

the torch assembly
perpendicular to the surface
of the workpiece
PCM-35 torch
with phenolic pinch
block mounting
assembly
PCM-35 torch
with rack and
pinion mounting
assembly
Figure 2-B Machine Torch Set-Up
INSTALLATION
2.4 INSTALLING THE TORCH
WARNING
CAUTION
Installing the Torch

This system is designed for use with the PCH/M-35 torch only.
Do not connect any other torch to this power supply.
1. Check the torch for proper assembly (refer to Torch Parts
Selection, page 23).
2. Connect the torch leads fitting onto the receptacle marked
TORCH on the front panel of the power supply.
Connect torch
leads to quick
disconnect fitting
Figure 2-C Torch Connections
INSTALLATION
2.5 REMOTE CONTROL HARNESS INSTALLATION
RC Wire Harness
WARNING
Installation of the remote control (RC) wire harness (Cat No. 96210) is required to convert hand to machine torch systems.
Installation requires four #6-32 screws with locknuts.
Disconnect primary power at the source before assembling or
disassembling the power supply, torch parts, or torch and leads
assemblies.
Refer to Figure 2-D and:
Remove the Hole Plug
1. Remove the hole plug from the hole marked REMOTE

CONTROL on the upper left rear panel of the power supply.
Open the Enclosure
2. Locate the eight screws which hold together the two halves of
the power supply enclosure. Lay the power supply on its side
with the screw heads facing UP. Remove all eight mounting
screws and carefully lift the upper half of the enclosure from
the unit. Lift the unit from the lower half of the enclosure and
set the unit in upright position on a secure working surface.
(continued on next page)
Remote Control
Wire Harness
J7 Connector
Remove hole
plug from
hole marked
REMOTE
CONTROL
Connect the remote

control wire harness
to the J7 connector
on the top panel
of the power supply
Connect the ground

wire to the ground
stud on the inside
of the rear panel
Pak Master
Rear Panel
Figure 2-D Installing the RC Wire Harness
INSTALLATION
10
2.5 REMOTE CONTROL HARNESS INSTALLATION (continued)
Install the Wire Harness
3. Inside the power supply, locate the white 6-pin connector J7

on the top panel, close to the REMOTE CONTROL hole
location.
4. Connect the 6-pin plug on the remote control wire harness to
the 6-pin connector J7.
5. Locate the ground stud on the RIGHT side of the rear panel,
inside the panel, at approximate center height. Connect the
ground wire of the remote control wire harness to the ground
stud.
CAUTION
Do not ground the remote control wire harness to the system

ground stud, which is visible on the top panel of the power
supply.
6. Using the four #6-32 screws with locknuts, install the remote
control receptacle (J24) in the rear panel (position the receptacle in the hole from INSIDE the unit).
CAUTION
Reassemble the
Enclosure
Before reassembling the power supply enclosure, check that all

wire harnesses and ribbon cables are properly located in the
notches of the top and middle panels.
7. Position the unit in an upright position. Tip the unit and slide
one of the case halves onto the chassis. Then lift the unit and
set it down on its side with the case half down.
8. Before installing the other case half, make sure the edges of
the bottom, middle, and top chassis panels are fully inserted
into the slots in the case. Look for gaps between the front and
rear panels and the edge of the case. Look into the case to see
that the notches in the top corners of the front and rear panels
are flush against the plastic stops of the case. Some lifting and
re-settling of the chassis may be required to get all components aligned correctly.
9. Gently lower the other half of the enclosure onto the other
side of the chassis by tipping it slightly so that the top is
slightly lower than the bottom. Then push and gently tap
down until the two case halves are within l/16 inch. (If you
have trouble getting the case halves close enough, remove the
top half and check to see that the bottom half is fully engaged
and that there are no wires out of place on the top and middle
panels.
10. Install the eight screws, lockwashers and nuts to complete the
assembly.
11
INSTALLATION
2.6 ELECTRICAL CONNECTIONS
Primary Input Voltages
The unit can accept any input voltage from 200V to 460V ( 10%),
single or three phase, 50 or 60 Hz. 575V input requires an additional step-down transformer (Catalog No. 9-6211).
Input voltage settings must be verified before applying power to
the unit. Refer to Figure 2-E, below.
CAUTION

WARNING
Input Voltage
Changeover
1. Remove the voltage selection access panel.

2. Connect the 9-circuit plug on the rear panel to the receptacle
which corresponds with the actual primary input voltage
(HIGH for 380/415/460V or LOW for 200/220V).
3. Connect the single-circuit plug on the rear panel to the
receptacle which corresponds to the actual primary input
voltage (460V, 380/415V, or 200/220V).
4. Replace the voltage selection access panel.
460V
LOW
HIGH
380/415V
TE
MO L
RE TRO
N
CO
200/220V
380/415/460
VAC
SE
FU 00V
,6
2A
200/220
VAC
Detail of Voltage Connection Panel

W
LO
Connect 9-circuit plug to

corresponding receptacle
(HIGH for 380/415/460V,
or LOW for 200/220V)
0-
38
HIG
0-
20
40
0-2
20 AC
V
6
0-4
38 AC
V
Connect single-circuit plug

to corresponding receptacle
(460V, 380/415V, or 200/220V)
Remove Access Panel
Figure 2-E Input Voltage Selection
INSTALLATION
12
2.6 ELECTRICAL CONNECTIONS (continued)
CAUTION
Input Power Cable

Connections
WARNING
Both input voltage settings on the power supply must correspond

to the actual primary input voltage.
Systems ordered for 230V operation come supplied with a 230V
single-phase input power cable attached. For any other input
voltage, the 230V input power cable must be removed and
replaced with an appropriate power cable.
Refer to Figure 2-F (page 14) and:
1. Remove the access panel on the rear panel of the unit and
disconnect the factory-installed 230V input power cable.
Loosen the strain relief and remove the cable.
NOTE
CAUTION
Input power connections can be made directly to a properly

fused disconnect or by using a plug which conforms to the
recommended ratings.
The primary power source, power cable, and plug all must
conform to local electric code and the recommended circuit
protection and wiring requirements (see Table 2-A, page 14).
2. Before connecting the replacement input power cable, strip
back the outer covering approximately 3 inches (76 mm) to
expose the individual wires. Then cut back the insulation on
the individual wires approximately 1/8 - 3/16 inch (3-5 mm).
3. Install a #10 ring terminal on the ground (GND) wire of the
input power cable.
WARNING
Make sure the ground wire is designated as GND on the other

end of the cable. Electric shock and damage to the unit could
occur if power is applied to the GND terminal.
4. Connect the input power cable according to Figure 2-F.
Terminal L3 is not used for single-phase connections.
13
INSTALLATION
2.6 ELECTRICAL CONNECTIONS (continued)
Attach ground wire to

terminal marked GND
Input Power Cable Connections
Terminal L1
Single-Phase (1)
GND
L1
Terminal L2
Three-Phase (3)
GND
L1
L2
L2
L3
L3
Terminal L3
(Three-Phase Only)
TE
MO L
RE TRO
N
CO
SE
FU 00V
,6
A
2
Figure 2-F Input Power Cable Connections

Input
Voltage
(Volts)
Power
1-Ph
3-Ph
(kVA)
(kVA)
Input Current
1-Ph
3-Ph
(Amps) (Amps)
Freq.
(Hz)
Fuse
1-Ph
(Amps)
3-Ph
Recommended Sizes
Wire (AWG) Wire (Canada)
1-Ph
3-Ph
1-Ph
3-Ph
180
37
17
50/60
45
20
10
14
10
200
33
15
50/60
40
20
10
16
12
220
30
14
50/60
35
20
10
16
12
240
28
13
50/60
35
15
12
12
12
380
18
50/60
25
10
14
18
10
12
460
14
50/60
20
10
16
18
10
12
506
13
50/60
15
16
18
12
12
Table 2-A Line Voltages with Recommended Circuit Protection and Wire Sizes
(Based on Table 310-16, 1987 National Electric Code) and Table 4, Canadian
Electrical Code.
INSTALLATION
14
2.7 WORK CABLE AND GROUND CONNECTIONS
Electromagnetic
Interference (EMI)
High frequency pilot arc initiation generates electromagnetic

interference (EMI), commonly called RF noise. EMI may interfere
with nearby electronic equipment such as CNC controllers, etc.
Torch leads are shielded to help prevent this problem. To further
minimize RF interference, follow these grounding procedures
when installing mechanized systems:
Creating an Earth
Ground
1. Install a ground wire (not included) between the internal

ground stud in the power supply and a solid earth ground (or
star ground). To create a solid earth ground, drive a 1/2 in
(12 mm) copper rod approximately 6-8 ft (1.8-2.4 m) into the
earth so that the rod contacts moist soil over most of its
length. The depth required will vary depending on location.
Locate the rod as close as possible to the power supply. The
work table should be connected to the same earth ground.
2. Connect the control device (CNC) to a separate earth ground.
The ground cable should be at least 12 gauge wire.
3. To minimize RF interference, position torch leads as far as
possible (at least 1 ft or 0.3 m) from any CNC components,
control cables, or primary power lines.
4. Keep torch leads clean. Dirt and metal particles bleed off
energy, which causes difficult starting and increased chance
of RF interference.
Work Cable Connection
Refer to Figure 2-G and:

5. Make sure the work cable is properly connected to the
workpiece before operating the system.
S
GA
PIP
RU
MP
TE
ON
AC
T
SE
Make a solid work cable

connection to the workpiece or cutting table
OF
UR
SS
RE
RC
SP
GA
TO
WO
Torch Leads
Figure 2-G Work Cable Connection
15
INSTALLATION
2.8 GAS CONNECTIONS
Gases
Pressure
Flow
Compressed Air or Nitrogen (N 2) Only

70 psi (4.8 BAR)
Cutting - 200 scfh (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
CAUTION
Max input pressure must not exceed 125 psi (8.6 BAR/860kPa)
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.
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!
Filtering
An air line filter (not included) is required when using air from a
compressor to insure that moisture and debris from the supply
hose does not enter the torch. The filter must be capable of
filtering to at least 5 microns, For highly automated applications,
a refrigerated drier may be used.
Gas Connections
Using High Pressure

Gas Cylinders
The rear panel of the power supply is equipped with a 1/4 NPT
gas input fitting. A quick disconnect coupling (1/4 NPT to #6
barb) is supplied with the unit.
Refer to the manufacturer's specifications for installation and
maintenance procedures for high pressure gas regulators. Do not
use an air line filter with high pressure gas cylinders. To use air
or nitrogen from a high pressure gas cylinder:
1. Examine the cylinder valves to be sure they are clean and free
of oil, grease or any foreign material. Momentarily open each
cylinder valve to blow out any dust which may be present.
2. Each cylinder must be equipped with an adjustable highpressure regulator capable of pressures up to 125 psi (8.6
BAR) maximum and flows of up to 700 scfh (328 lpm).
Refer to Figure 2-H (page 17) and:
3. Connect the 1/4 NPT adaptor fitting to the gas input fitting
on the rear panel of the power supply.
4. Connect the 1/4 NPT male side of the quick disconnect
coupling to the adaptor fitting.
5. Connect the supply hose from the high pressure regulator to
the barb side of the quick disconnect coupling.
6. Connect the quick disconnect coupling.
INSTALLATION
16
2.8 GAS CONNECTIONS (continued)
7. Set the high pressure regulator to 100 psi and adjust the unit
regulator for the desired 70 psi.
CAUTION
Always open the high pressure cylinder valve slowly to prevent

damage to the unit gas regulator.
Using Shop Air
An air line filter (ordered separately) is required when using air

from a compressor to insure that moisture and debris from the
supply hose does not enter the torch.
The LeMan two stage air line filter kit is recommended for most
applications. Follow the installation instructions for this kit on
page 18.
Air Line Filter Kit - Two Stage .................................. Cat. No. 7-3340
TE
MO L
RE TRO
N
CO
SE
FU 00V
,6
2A
AC
RE
U
SS
RE AX
TP IM
PU S
IN 25 P
1
Quick Disconnect
Coupling (1/4 NPT
to #6 Hose)
Quick Disconnect
Fitting (1/4 NPT)
Rear Panel Fitting

(1/4 NPT)
Supply Hose from

Source (#6 Hose)
Figure 2-H Gas Connections
17
INSTALLATION
2.8 GAS CONNECTIONS (continued)
Installing
Air Line Filter
Refer to Figure 2-I and:.

1. Press fit the nylon screw receptacles into the rear panel
openings as shown.
2. Secure the air filter with bracket to the power supply with the
1/2 in pan head screws.
3. Connect the 1/4 NPT male coupling of the gas hose assembly
to the power supply first, then connect the female JIC fitting
to the air filter . Tighten both fittings with a 9/16 in wrench.
NOTE
Supply hoses must be at least #6 hose (3/8 in or 9.5 mm I.D.).
Nylon Screw
Receptacles
TE
MO L
RE TRO
N
CO
SE
FU 00V
,6
2A
AC
RE
SU
ES X
PR MA
UT PSI
P
IN 25
1
Female
JIC
Male
1/4 NPT
Rear Panel Fitting
(1/4 NPT)
Figure 2-I Gas Connections Using Optional Air Line Filter
INSTALLATION
18
Air Filter
Assembly
3.1 OPERATING CONTROLS
PIP (Parts-In-Place) Indicator
GAS Indicator
TEMP Indicator
DC Indicator
AC Indicator
PILOT Indicator
RUN/SET Switch
CSD Control
ON/OFF Switch
Current Control
ON
RUN
CSD
SET
AC
TEMP
PIP
GAS
DC
80
20
CURRENT
60
40
TORCH
PILOT
bar
psi
100
OFF
TORCH Receptacle
Gas Pressure Gauge

GAS PRESSURE
WORK Cable
Gas Pressure Control
WORK
Figure 3-A Operating Controls (See Table 3-A, page 20)
19
OPERATION
3.1 OPERATING CONTROLS (continued)
INDICATOR
FUNCTION
1. ON/OFF Switch
ON position supplies AC power to activate all system control circuits. OFF

position deactivates control circuits.
2. RUN/SET Switch
RUN position is used for torch operation. SET position is used for setting gas
pressure and purging lines.
3. AC Indicator
Green LED light indicates AC input power is present in the system when the
ON/OFF switch is in ON position.
4. TEMP Indicator
Green LED light indicates proper operating temperature range. Red light
indicates overheating; unit must be allowed to cool.
5. PIP (Parts-In-Place)
Indicator
Yellow LED light indicates proper torch assembly. Light goes out if the shield
cup is not fully seated against the PIP pins in the torch body.
6. GAS Indicator
Yellow LED light (with RUN/SET switch in SET position) indicates gas pressure
is above the minimum (42 psi or 2.9 BAR) to the torch. Light goes out in RUN
position until torch is activated.
7. DC Indicator
Yellow LED light indicates adequate DC power output for main arc when the
torch is activated.
8. PILOT Indicator
Yellow LED light indicates pilot arc circuit is activated. Light goes out when
main arc is established and comes back on if the main arc is interrupted and
pilot arc restarts.
9. Corner Slowdown
Adjustment
Sets corner slowdown (CSD) output to a percentage of main output. Minimum

output during CSD is 15 amps. Turn fully clockwise for maximum output (100%
of main current) during CSD. See Corner Slowdown Operation, page 29.
10. Current Control
Selects output current.
11. Pressure Gauge
Displays input pressure to the torch.
12. Pressure Control
Adjusts pressure from the regulator. Pull knob out and turn clockwise to
increase pressure to desired level.
Table 3-A Operating Controls
OPERATION
20
3.2 GETTING STARTED
WARNING

Follow this set-up procedure each time the system is operated:
Check Torch Parts
1. Check the torch for proper assembly and appropriate front

end torch parts (see Torch Parts Selection, page 23 and
Replacing Consumable Torch Parts, page 36).
Check Input Power
2. Check primary power source as follows:

a. Check the power source for proper input voltage. Make
sure the power source meets circuit protection and wiring
requirements (see Table 2-A, page 14).
b. Make sure that the power supply is set for the proper
voltage (see Electrical Connections, page 12).
c. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
Connect Work Cable

Check Gas Supply
Purge the System

(Gas Pre-Flow)
Select Output Current

Set Operating Pressure
3. Check for a solid work cable connection to the workpiece.

4. Select desired gas (air or nitrogen). Make sure gas sources
meet pressure and flow requirements (see Gas Connections,
page 16). Check connections and turn gas supply on.
5. Move the ON/OFF switch to ON position. When the unit is
switched on, an automatic 20-second pre-flow gas purge will
remove any moisture that may have accumulated in the torch
and leads while the system was shut down. The torch cannot
be activated during pre-flow. After 20 seconds, if the RUN/
SET switch is in SET position, gases will flow. If the RUN/
SET switch is in RUN position, there will be no gas flow.
6. Select the desired current output level (15 to 35 amps).
7. Move the RUN/SET switch to SET position. Adjust the gas
pressure to 70 psi (4.8 BAR).
8. Set the RUN/SET switch to RUN position.
The system is now ready for operation.
21
OPERATION
3.3 SEQUENCE OF OPERATION
ACTION
ACTION
ACTION
ACTION
Close external
disconnect switch.
ON/OFF switch
to ON.
RUN/SET switch
to SET.
RUN/SET switch
to RUN.
RESULT
RESULT
RESULT
RESULT
Power to system.
AC, TEMP, PIP

indicators on.
Fan on.
Pilot disabled during
20 second pre-flow.
Gas solenoid open,

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

GAS indicator off.
Power circuit ready.
ACTION
ACTION
Protect eyes and

activate torch.
Torch moved away

from work (while
still activated).
RESULT
RESULT
Gas flows.
GAS indicator on.
Main arc stops.

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

DC indicator on.
Power supply enabled.
HF relay closes.
Pilot arc established.
PILOT indicator on.
ACTION
PILOT ARC
Torch moved within

transfer distance of
workpiece.
RESULT
Main arc transfer.
Pilot arc off.
PILOT indicator off.
DC indicator still on.
ACTION
Torch deactivated (by torch switch
release or by remote device).
RESULT
Main arc stops. Pilot stops.
(Power supply enable signal removed.)
DC indicator off.
PILOT indicator off.
ACTION
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.
ON/OFF switch
to OFF.
RESULT
After post-flow:
All indicators off.

Power supply
fan off.
Gas solenoid closes, gas flow stops.

GAS indicator off.
Figure 3-B Sequence of Operation
OPERATION
22
ACTION
Open external
disconnect.
RESULT
No power to system.
3.4 TORCH PARTS SELECTION
Torch Parts Selection
must correspond with the type of operation (drag cutting, standoff cutting, or gouging).
Standard Shield Cup (For Standoff Cutting) .......................... 9-6003
Crown Shield Cup Standoff (For Drag Cutting) .................... 9-6004
Tip - Standoff Cutting ................................................................9-6000
Tip - Drag Cutting ...................................................................... 9-6001
Tip - Drag Cutting (Heavy Duty) ............................................ 9-6120
Tip - Gouging ............................................................................. 9-6002
Electrode ......................................................................................9-6006
Gas Distributor ........................................................................... 9-6007
Long Life Parts
CAUTION
Shield Cup Attachment, Long Life ..........................................9-6503

Tip - Standoff, Long Life ........................................................... 9-6500
Tip - Drag, Long Life .................................................................9-6501
Tip - Gouging, Long Life ........................................................... 9-6502
Electrode, Long Life ................................................................... 9-6506
Gas Distributor, Long Life ........................................................ 9-6507
Do not use long life parts with standard parts. Long life shield
cup attachment (No. 9-6503) and Crown Cup (No. 9-6004) must
be installed over the standard shield cup (No. 9-6003).
LONG LIFE PARTS

Standard Shield Cup
Catalog No. 9-6003
Crown Shield Cup

Catalog No. 9-6004
Standoff Cutting Tip

(.031 in)
Catalog No. 9-6000
Drag Cutting Tip

(.031 in)
Catalog No. 9-6001
Heavy Duty Drag Tip

(.036 in)
Catalog No. 9-6120
Gouging Tip
(.046)
Catalog No. 9-6002
Long Life Standoff

Cutting Tip (.031 in)
Catalog No. 9-6500
Long Life Drag

Catalog No. 9-6501
Electrode
Catalog No. 9-6006
Gas Distributor
Catalog No. 9-6007
Long Life Electrode

Catalog No. 9-6506
Long Life Gas Distributor

Catalog No. 9-6507
Long Life Shield Cup

Catalog No. 9-6503
A-00017
A-00318
Figure 3-C Torch Parts Selection
23
OPERATION
3.5 CUT QUALITY
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 Figure 3-D below:
Cut Surface
The condition (smooth or rough) of the face of the cut.
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.
Top-Edge Rounding
Dross Build-up
and Top Spatter
Kerf Width
Nitride Build-up
Rounding on the top edge of a cut due to wearing from the

initial contact of the plasma arc on the workpiece.
Dross is molten material which is not blown out of the cut area
and re-solidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece. Excessive dross
may require secondary clean-up operations after cutting.
The width of material removed during the cut.
Nitride deposits which may remain on the surface of the cut
when nitrogen is present in the plasma gas stream. Nitride
buildups may create difficulties if the material is welded after
the cutting process.
Direction of Cut
Kerf Width
Bevel Angle
Top Spatter
Top Edge
Rounding
Cut Surface
Dross Build-Up
Figure 3-D Cut Quality Characteristics
OPERATION
24
3.5 CUT QUALITY (continued)
GAS
MATERIAL
THICKNESS
Air
Nitrogen
Gage to 1/2 in.
TYPE OF MATERIAL
Carbon Steel
Stainless Steel
Aluminum
Good - Excellent
Good - Excellent
Good - Excellent
Good
Good
Good
Table 3-B Cut Quality on Various Materials and Material Thicknesses
Description of Cut
Characteristics
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.
Fair - Excessive bevel (over 10), wide kerf (over 2-1/2 x tip
orifice diameter), medium to heavy dross, rough cut surface, top
edge rounding.
NOTE
Cut quality depends heavily on set-up and parameters such as

torch standoff, alignment with the workpiece, cutting speed, gas
pressures, and operator ability.
25
OPERATION
3.6 OPERATING THE SYSTEM
WARNING

WARNING
Frequently review the Important Safety Precautions (page iii). 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.
CAUTION
Sparks from the cutting process can cause damage to coated,

painted, and other surfaces such as glass, plastic and metal.
NOTE
Handle torch leads with care and protect them from damage.
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.
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 generally results in a more square cut. A specially
designed shield cup attachment is available for drag cutting
(crown cup), which allows the operator to keep the torch in
contact with the workpiece during operation. Drag cutting also
requires special cutting tips.
Edge Starting
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. 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.
Direction of Cut
In the PCH/M-35 torch, the plasma gas stream swirls as it leaves

the torch. The purpose of the swirl is to maintain a smooth
column of gas. The 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.
Dross
If 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.
OPERATION
26
3.6 OPERATING THE SYSTEM (continued)
Dross
(continued)
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.
Common Cutting Faults

Problem
Possible Cause
Insufficient
Penetration
1.
2.
3.
4.
5.
Cutting speed too fast

Torch tilted too much
Metal too thick
Worn torch parts
Cutting current too low
Main Arc
Extinguishes
1.
2.
3.
4.
5.
Cutting speed too slow

Torch standoff too high from workpiece
AC line too low - reduce output current
Work cable disconnected
Worn torch parts
1.
2.
3.
4.
5.
Cutting speed too slow (bottom dross) Easily removed

Cutting speed too fast (bottom dross) Tight bead, Difficult to remove
Torch standoff too high from workpiece (top dross) Easily removed
Worn torch parts
Improper cutting current
1.
2.
3.
4.
5.
Oil or moisture in air source

Exceeding system capability (material too thick)
Excessive pilot arc time
Air flow too low (incorrect pressure)
Improperly assembled torch
Excessive
Dross Formation
Short Torch
Parts Life
Table 3-C Common Causes of Operating Problems
27
OPERATION
3.7 OPERATING WITH A HAND TORCH
Cutting with a
Hand Torch
1. The torch can be comfortably held in one hand or steadied

with two hands. Choose the technique that feels most comfortable and allows good control and movement. Position the
index finger or thumb to press the control switch on the torch
handle.
2. 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. For piercing, angle the torch
slightly to direct sparks away from the torch until the pierce
is complete.
3. For drag cutting, keep the torch in contact with the
workpiece. Drag cutting requires special torch parts. Drag
cutting is not recommended on materials over 3/16 in (5 mm)
thick. For standoff cutting, hold the torch 1/8-3/8 in (3-9 mm)
from the work.
4. With the torch in starting position, press and hold the control
switch. After an initial two-second gas purge, the pilot arc
will come on and remain on until the cutting arc starts.
5. Once on, the main arc remains on as long as the control
switch 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.
6. To shut off the torch simply release the control switch. When
the switch is released a ten second post-flow will occur. If the
torch switch is closed during the post-flow, the cutting arc
will restart immediately when the torch is brought within
range of the workpiece.
Piercing with a
Hand Torch
1. When piercing with a hand torch, tip the torch slightly so that
blowback particles blow away from the torch tip (and operator) rather than directly back into it.
2. Start and complete the pierce close to the cutting line and
then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.
3. Clean spatter and scale from the shield cup and the tip as
soon as possible. The shield cup may be removed and a light
coating of anti-spatter compound applied to the outside to
minimize the amount of scale which adheres to it. Be careful
not to get anti-spatter compound on the torch tip or other
parts.
OPERATION
28
3.8 OPERATING WITH A MACHINE TORCH
WARNING
NOTE
Using Corner Slowdown

for Mechanized Cutting

Frequently review the Important Safety Precautions beginning on

page iii of this manual.
The corner slowdown (CSD) function provides a reduction in
output current which corresponds with the reduced travel speed
of a mechanized torch as it changes direction at a sharp corner.
When activated (by CNC or other control device) corner slowdown eliminates excessive metal removal in corners.
Normally open (NO) contacts (supplied by the control device)
close when the torch travel speed decreases through a corner.
When the contacts close, power supply output drops to a preset
current level.
Tools Required
Setting CSD Output
Small Standard (Slotted Head) Screwdriver

The corner slowdown adjustment is located on the upper front
panel (see Figure 3-A, page 19). CSD output is a percentage of the
main output setting. Minimum output is 15 amps during CSD.
Turn the control clockwise to increase CSD output. Maximum
CSD output is 100% of the main output level. Typically, CSD
output should not be set lower than 70% of the main current level
to insure full arc penetration during corner slowdown. When
adjusting output current level, corner slowdown output should
be adjusted accordingly.
29
OPERATION
3.8 OPERATING WITH A MACHINE TORCH (continued)
The machine torch can be activated by remote control pendant or

by a remote interface device such as CNC.
Cutting with a
Machine Torch
Refer to Figure 3-E below and:

1. Use a square to align the torch perpendicular to the workpiece to obtain a clean, vertical cut (see Setting Up the Torch,
page 8).
2. To start a cut at the plate edge, position the center of the torch
along the edge of the plate
Shown with
rack and pinion
mounting assembly
Dir
ect
ion
of T
orc
hT
Standoff is the
distance between the
torch tip and the surface
of the workpiece
rav
el
A straight arc is
perpendicular
to the surface of
the workpiece
A trailing arc is directed in the

opposite direction of torch travel
A leading arc is directed in the

same direction as torch travel
Figure 3-E Machine Torch Set-up and Operation
OPERATION
30
3.8 OPERATING WITH A MACHINE TORCH (continued)
Standoff Distance
Travel Speed
Proper tip-to-work (standoff) distance is critical to ensure accuracy, optimum cut quality, and maximum consumable parts life
in mechanical systems. The recommended standoff distance for
mechanized systems is 3/16 in (5 mm).
Proper travel speed is indicated by the trail of the arc which is
seen below the plate (see Figure 3-E, page 30). A straight arc is
generally recommended for the best cut using air plasma on
stainless or aluminum. For air plasma on mild steel, a five degree
leading arc is recommended.
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 supply has a corner slowdown
feature which reduces output for this purpose (see Corner Slowdown Operation, page 29).
Piercing with a
Machine Torch
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.
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 - 3/8 inch (3 - 9 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.
31
OPERATION
3.9 RECOMMENDED CUTTING SPEEDS
Recommended
Cutting Speeds
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:
Torch parts wear
Air quality
Line voltage fluctuations
Torch standoff height
Proper work cable connection
NOTE
This information represents realistic expectations using recommended practices and well-maintained systems. Actual speeds
may vary up to 50% from those shown.
Thickness
(Inches)
Tip
(Cat. No.)
Gas(es)
Voltage
(Volts)
Amperage
(Amps)
Speed (Per Minute)

(Inches)
(Meters)
Standoff
(Inches)
1/16
9-6500
Air
97
35
260
6.6
1/8
1/8
9-6500
Air
102
35
75
1.9
1/8
1/4
9-6500
Air
108
35
45
1.1
1/8
3/8
9-6500
Air
115
35
22
0.6
1/8
1/2
9-6500
Air
120
35
12
0.3
1/8
Table 3-D PCM-35 Cutting Speeds - Air Plasma on Mild Steel

Thickness
(Inches)
Tip
(Cat. No.)
Gas(es)
Voltage
(Volts)
Amperage
(Amps)
Speed (Per Minute)

(Inches)
(Meters)
Standoff
(Inches)
1/16
9-6500
Air
100
35
250
6.6
1/8
1/8
9-6500
Air
118
35
100
1.9
1/8
1/4
9-6500
Air
124
35
25
1.1
1/8
3/8
9-6500
Air
130
35
15
0.6
1/8
1/2
9-6500
Air
136
35
0.3
1/8
Table 3-E PCM-35 Cutting Speeds - Air Plasma on Aluminum

Thickness
(Inches)
Tip
(Cat. No.)
Gas(es)
Voltage
(Volts)
Amperage
(Amps)
Speed (Per Minute)

(Inches)
(Meters)
Standoff
(Inches)
1/16
9-6500
Air
110
35
250
6.6
1/8
1/8
9-6500
Air
112
35
75
1.9
1/8
1/4
9-6500
Air
114
35
20
1.1
1/8
3/8
9-6500
Air
117
35
10
0.6
1/8
1/2
9-6500
Air
124
35
0.3
1/8
Table 3-F PCM-35 Cutting Speeds - Air Plasma on Stainless Steel

NOTE: Speed performance shown for the 9-6500 Tip is the same as the 9-6000 Tip
OPERATION
32
3.10 GOUGING
WARNING
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 (page iii) have been followed. Make sure no part of
the operators body comes in contact with the workpiece when
the torch is activated.
CAUTION
Sparks from plasma gouging can cause damage to coated,

painted or other surfaces such as glass, plastic, and metal.
CAUTION
Check torch parts. The torch parts (shield cup, tip, electrode, and
gas distributor) must correspond with the type of operation (drag
cutting, standoff cutting, or gouging). Refer to Torch Parts Selection (page 23).
WARNING
Disconnect primary power to the system before disassembling

the torch, leads, or power supply.
Gouging Parameters
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 Travel Speed
Optimum torch travel speed for gouging is between 20 and 120

inches per minute (0.5 and 3.0 meters per minute). Travel speed is
dependent on current setting, lead angle, and mode of operation
(hand or machine torch).
Current Setting
Current settings depend on torch travel speed, mode of operation

(hand or machine torch), and the amount of material to be removed.
Lead Angle
The angle between the torch and workpiece depends on the

current setting and torch travel speed. At 35 amps, the recommended lead angle is 35. An angle greater than 45 may result in
inconsistent metal removal. 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.
33
OPERATION
3.10 GOUGING (continued)
Standoff Distance
Slag Build-up
OPERATION
The tip to work distance affects gouge quality and depth. A

standoff of 1/8 - 1/4 in (3 - 6 mm) allows smooth, consistent
metal removal. A smaller standoff may result in a severance cut
rather than a gouge. A standoff greater than 1/4 in (6 mm) may
result in minimal metal removal or loss of transferred main arc.
Slag generated by gouging on materials such as carbon and
stainlesss 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 buildup 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.
34
4.1 GENERAL POWER SUPPLY MAINTENANCE
Routine Maintenance
WARNING
CAUTION
The only routine maintenance required for the power supply is a

thorough cleaning and inspection, with the frequency depending
on the usage and the operating environment.
Do not blow air into the power supply during cleaning. Blowing
air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.
To clean the unit, open the enclosure by removing the eight
mounting screws with nuts which secure the enclosure. Lay the
power supply on its side with the mounting screw heads facing
up. Remove the mounting screws and carefully lift the upper
enclosure half from the chassis.
Use a vacuum cleaner to remove any accumulated dirt and dust.
The unit should also be wiped clean. If necessary, solvents that
are recommended for cleaning electrical apparatus may be used.
35
SERVICE
4.2 REPLACING CONSUMABLE TORCH PARTS
WARNING

WARNING
DO NOT TOUCH internal torch parts while the AC indicator on

the front panel of the power supply is lit.
NOTE
The tip, gas distributor, and electrode 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.
Refer to Figure 4-A and:
1. Unscrew and remove the shield cup from the torch. Inspect
the cup for damage. Wipe it clean or replace if damaged.
2. Remove the tip. Check for excessive wear (indicated by an
elongated or oversized orifice). Clean and replace the tip if
necessary.
3. Remove the gas distributor and check for excessive wear,
plugged gas holes, or discoloration. Replace if necessary.
Torch Head Assembly
(70 Hand Torch Shown)
Electrode
Tip
Optional
Crown (Castle)
Shield Cup Extension
Gas
Distributor
Standard
Shield Cup
Figure 4-A PCH/M-35 Consumable Parts
SERVICE
36
4.2 REPLACING CONSUMABLE TORCH PARTS (continued)
4. Remove the electrode. The face of the electrode should not be

recessed more than 0.10 inch (2.5 mm). If it is worn beyond
this point it must be replaced.
5. Reinstall the parts and shield cup on the torch as shown.
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 with installation.
4.3 GENERAL TORCH MAINTENANCE
Cleaning the 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.
WARNING

WARNING
DO NOT touch any internal torch parts while the AC indicator

light on the front panel of the power supply is lit.
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 (see Servicing the Torch,
page 39) and cleaned more thoroughly by pouring electrical
contact cleaner into the torch and blowing it through with compressed air.
CAUTION
Dry the torch thoroughly before reinstalling.
37
SERVICE
4.3 GENERAL TORCH MAINTENANCE (continued)
Checking the
Center Insulator
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.
WARNING

WARNING

Refer to Figure 4-A (page 36) and:
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.
2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch quick disconnect
fittings. Infinite resistance (no continuity) should be found. If
continuity is found, refer to Torch and Leads Troubleshooting
(page 48).
SERVICE
38
4.4 SERVICING TORCH HEAD COMPONENTS
WARNING

WARNING
NEVER touch any internal torch parts while the AC indicator

light on the front panel of the control module is lit.
Tools Required
Removing a Machine
Torch Head
(1) No. 1 Phillips Head Screwdriver

(2) 1/4 in Open End Wrenches
Refer to Figure 4-B and:
1. Unscrew the retaining nut from the mounting tube and slide
the mounting assembly up over the leads.
2. Pull the mounting adaptor from the torch head assembly.
Slide the mounting assembly back over the leads to expose
the negative/plasma lead connection, pilot lead connection,
and two PIP (parts-in-place circuit) connectors.
3. Disconnect the negative/plasma and pilot leads and the PIP
connectors to allow removal of the torch head.
Pinion Assembly
Bushing
Positioning Tube
Machine Torch Head
Mounting Adaptor
Retaining Nut
Negative/Plasma Lead Connection

PIP Connectors
Pilot Lead Connection
Figure 4-B Torch Mounting Assembly (PCM-35 Machine Torch)
39
SERVICE
4.4 SERVICING TORCH HEAD COMPONENTS (continued)
WARNING
Tools Required
Removing a Hand Torch

Control Switch

(1)
(1)
(2)
(1)
No. 1 Phillips Head Screwdriver

No. 1 Slotted Head Screwdriver
1/4 inch Open End Wrench
Pin Removal Tool (Catalog No. 9-5847)
Refer to Figure 4-C and:

1. Pull the protective boot from the end of the torch handle and
slide it back over the leads to expose the two torch switch
connectors. Disconnect both torch switch connectors. It is not
necessary to disconnect the PIP connectors.
2. Remove the switch closure from the torch handle by carefully
pressing in on the switch closure tab and gently prying the
closure upward. Remove the switch insert. Slide the switch
out of the track on the torch handle.
3. Push the torch switch connectors through the end of the torch
handle to allow removal of the torch switch.
NOTE
Slide protective
boot back
It may be necessary to remove the connectors from the switch

leads before removing or reinstalling the switch assembly.
Press tab
to remove
closure
Reverse view
of closure
PIP
Connectors
Remove switch
closure from
torch handle
Switch
Insert
Torch
Switch
Disconnect
torch switch
connectors
Torch Handle
Figure 4-C Removing the Torch Control Switch (PCH-35 Hand Torch)
SERVICE
40
WARNING
Removing a Hand
Torch Head

Refer to Figure 4-D and:
1. Slide the torch handle back over the leads to expose the
negative/plasma lead connection, the pilot lead connection,
and the two PIP (parts-in-place circuit) connectors.
2. Disconnect the negative/plasma and pilot leads and the PIP
connectors to allow removal of the torch head.
Disassembling a
Torch Head Assembly
Refer to Figure 4-E (page 42) and:

1. Remove the two O-rings from the back of the torch head
assembly.
2. Remove the shield cup, tip, gas distributor and electrode if
necessary (see Figure 4-A, page 36).
3. Remove the two assembly screws which secure the split
holder and separate the two halves of the holder to allow
removal of the torch head and PIP assemblies.
Negative/Plasma
Lead Connection
Slide torch
handle back
over leads
Torch Handle
O-Rings
PIP Connectors
Pilot Lead Connection
Figure 4-D Removing the Torch Head (PCH-35 Hand Torch)
41
SERVICE
Handle O-Rings
Mounting Screws
Position PIP wires

in notches in back
of split holder
Align notch on
pilot lead with
notch in split holder
PIP Pin Assemblies
Figure 4-E Disassembling the Split Holder
WARNING
Replacing the
PIP Assembly

Refer to Figure 4-F (page 43) and:
1. Carefully remove the PIP wires from the strain relief bosses
inside the split holder.
2. Slide the PIP pin receptacles forward out of the retention
slots.
CAUTION
Do not lift the PIP pin receptacles out of the split holder to avoid
damage to holder and/or PIP pin receptacles may occur.
3. Install replacement PIP pin assemblies by positioning the
square solder post of the PIP pin receptacle in the retention
slot in the split holder and sliding the assembly up into place.
Position the flange on the PIP pin receptacle flush with the
front face of the split holder.
4. Route the PIP wires around the strain relief bosses as shown.
Push the teflon insulation covering both PIP wires up to the
strain relief boss closest to the back of the split holder for
voltage insulation from the brass pilot lead connector.
SERVICE
42
Replacing the
PIP Assembly
(continued)
5. Position both PIP leads through the notch where the negative/plasma lead exits the holder.
6. Position the torch head inside the holder. Align the notch on
the pilot lead with the corresponding tab on the split holder.
Make sure the negative/plasma fitting is securely inserted in
the groove in the holder. Make sure the crescent on the torch
head is inserted into the mating groove in the holder.
7. Place the second half of the holder over the torch head.
Confirm that the PIP pin assemblies, PIP leads, and the
negative/plasma and pilot leads are properly positioned.
CAUTION
Reassembling
the Torch Head
Do not force the holder together. Damage to the insulation on the

leads will cause torch head failure. The PIP leads must be positioned correctly to allow reassembly of the torch head.
Refer to Figure 4-E (page 42) and:
1. Install the two assembly screws to secure the split holder and
reinstall the O-rings on the back of the torch head assembly.
Refer to Figure 4-A (page 36) and:
2. Install the front end torch parts.
To keep teflon tubing positioned correctly,

apply shrink-on tubing up against
with closest PIP connector as shown.
End of teflon tubing must cover

up to first strain relief as shown.
Install both PIP wires over
strain relief bosses as shown
Flange on
PIP receptacle
must be flush with
face of split holder.
Remove and install PIP assemblies

from the front. Position assemblies
in slots in split holder.
Figure 4-F Installing a Replacement PIP Assembly
43
SERVICE
WARNING
Reassembling the
Hand Torch Handle and
Switch Assembly

Refer to Figure 4-D (page 41) and:
1. Connect the two PIP lead connectors and the negative/
plasma and pilot leads. Use electrical tape to secure the PIP
leads to the torch leads covering.
2. Slide the torch handle securely onto the torch head.
Refer to Figure 4-C (page 40) and:
3. Install the torch switch by pushing the torch switch connectors through the end of the handle and inserting the switch
into the track on the torch handle.
NOTE
It may be necessary to remove the connectors from the switch

leads before removing or reinstalling the switch assembly.
4. Install the switch insert and switch closure.
5. Reattach the torch switch leads connectors if necessary and
connect the torch switch leads. Slide the protective boot
forward to cover the end of the handle.
Reassembling the
Machine Torch
Mounting Assembly
NOTE
Refer to Figure 4-B (page 39) and:

1. Connect the two PIP lead connectors and the negative/
plasma and pilot leads.
On a machine torch, the control leads are not used. The two
connectors are taped to the leads covering. Do not confuse the
control leads (green/white) with the PIP leads (black/red).
2. Slide the mounting adaptor and retaining nut down and push
the adaptor securely onto the back of the torch head.
3. Slide the positioning tube and pinion assembly down and
thread the retaining nut onto the positioning tube.
SERVICE
44
4.5 SERVICING TORCH LEADS COMPONENTS
WARNING
Tools Required

(1)
(1)
(1)
(1)
(1)
3/32 inch Allen Wrench

15/16 inch (or Adjustable) Open End Wrench
11/16 inch (or Adjustable) Open End Wrench
No. 1 Slotted Head Screwdriver
Sharp Probe or O-Ring Tool
Refer to Figure 4-G (page 46) and:

1. Disconnect the torch leads from the power supply.
Loosening the Set

Screws
2. Turn the outer retaining nut until one of the three set screws
in the inner retaining ring is visible through one of the slots in
the nut.
3. Partially loosen each of the set screws which secure the inner
retaining ring and boot onto the quick disconnect body. If the
set screws are turned too far out, the outer retaining nut will
not turn properly.
Disassembling the
Quick Disconnect Fitting
4. Pull the protective boot and inner retaining ring from the
quick disconnect body and slide them back over the torch
leads to expose the leads connections.
5. Slide the outer retaining nut back over the leads.
6. Remove the locking tabs from the signal connector plug.
7. Gently push the tabs in (toward the center) on the front of the
signal connector plug. Carefully push the connector out
through the back of the quick disconnect body.
Disconnecting the Leads

from the Fitting
8. Disconnect the negative/plasma and pilot lead fittings.
Reassembling the
Quick Disconnect Fitting
1. Slide the inner retaining ring and outer retaining nut onto the
torch leads. Attach the inner retaining ring to the boot.
9. Remove the inner retaining ring from the boot. Remove both
the outer retaining nut and inner retaining ring from the
leads. The boot cannot fit over the signal connector plug.
2. Connect the negative/plasma and pilot fittings to the quick

disconnect body.
3. Insert the signal connector plug in the quick disconnect body
and install locking tabs on both sides. Install the locking tabs
with the beveled edge toward the signal connector.
4. Slide the outer retaining nut, boot, and inner retaining ring
down onto the quick disconnect body.
5. Tighten the three set screws to secure the inner retaining ring
onto the quick disconnect body.
45
SERVICE
4.5 SERVICING TORCH LEADS COMPONENTS (continued)
NOTE - PCH/M-35 Quick Disconnect Replacement Kit

(Catalog No. 9-5836) includes all quick disconnect items.
Outer Retaining
Ring
Rotate retaining ring

to access all three
set screws
Set Screw
Gently press tabs inward

and remove connector
Locking Tabs
(Reverse View)
Slide boot and retaining

ring back over leads to
expose leads connections
Pilot Lead
Connection
Negative/Plasma
Lead Connection
Figure 4-G Disassembling the Quick Disconnect Fitting
SERVICE
46
4.5 SERVICING TORCH LEADS COMPONENTS (continued)
10 11 12 13 14
6 7 8 9
1
Pins
Description
3, 4
Torch Switch
1, 6
Parts-In-Place (PIP)
13, 14
Shield (GND)
Pilot Return - Positive
Negative - Gas
Figure 4-H Torch Quick Disconnect Fitting - Front End View
47
SERVICE
4.6 TORCH AND LEADS TROUBLESHOOTING
WARNING

WARNING

Checking the
Center Insulator
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.
2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch quick disconnect
fittings. Infinite resistance (no continuity) should be found. If
possible, test with a Hypot tester set to 2,500 vdc.
Checking the Torch

Head Connections
3. If there is continuity between the two torch quick disconnect

fittings, remove the torch head from the leads (see Servicing
Torch Head Components, page 39). Visually check that the
PIP wires, torch switch wires, pilot lead connection, and
negative/plasma lead connections are properly connected
and in good condition (no shorts or arcing). If problems are
evident, repair or replace as required.
Checking the
Torch Head
4. With the torch head disconnected from the leads, measure the
resistance between negative cathode body of the torch head
(where the electrode seats) and the positive anode body of the
torch head (the outer threads where the shield cup seats).
Infinite resistance (no continuity) should be measured between negative and positive sections of the torch head. If any
current can flow through the center insulator, the torch head
is faulty and must be replaced. If the torch head is okay, the
problem is in the leads or quick disconnect assembly.
Checking the Torch

Quick Disconnect
Assembly
5. Slide the quick disconnect body, boot, and retaining ring back
(see Servicing Torch Leads Components, page 45). Visually
inspect the quick disconnect components to verify that there
is no contact between the positive and negative sections. If
contact is evident, repair or replace as required. If no problems are evident, remove the quick disconnect assembly from
the torch leads and check for continuity between the positive
and negative torch quick disconnect fittings. If there is no
continuity, the quick disconnect assembly is okay. If continuity is found, replace the torch quick disconnect assembly.
SERVICE
48
4.6 TORCH AND LEADS TROUBLESHOOTING (continued)
Checking the
Torch Leads
6. If the torch quick disconnect assembly is okay, check the

torch leads by measuring the resistance between the positive
pilot lead connector and the negative/plasma lead fitting. If
continuity is found, replace the torch leads. If no continuity is
found, test with a Hypot tester set to 2,500 vdc.
Reassembling the
Torch and Leads
7. Recheck the torch head, leads, and quick disconnect assembly

to confirm proper measurements. If each component is found
to be okay, there is an assembly problem. Carefully reassemble the torch, leads, and quick disconnect and return to
step 2.
49
SERVICE
4.7 POWER SUPPLY TROUBLESHOOTING
Troubleshooting and repairing the Pak Master 50 power supply

is a process which should be undertaken only by those familiar
with high voltage high power electronic equipment.
WARNING
Basic and Advanced

Troubleshooting
There are extremely dangerous voltage and power levels present

inside this unit. Do not attempt to diagnose or repair unless you
have had training in power electronics measurement and
troubleshooting techniques.
Basic troubleshooting is covered in this guide. This first (basic)
level of troubleshooting are those which can be performed
without special equipment or knowledge, and without removing
the plastic enclosure from the unit.
Advanced troubleshooting can be found in the PakMaster 50
Service Manual No. 0-2444, which also provides procedures for
replacing power components and subassemblies.
NOTE
SERVICE
If major complex subassemblies are faulty, the unit must be

returned to an authorized service center for repair.
50
4.7 POWER SUPPLY TROUBLESHOOTING (continued)
SYMPTOM
A. AC indicator not lit.
B. AC indicator lit. TEMP

indicator red
POSSIBLE CAUSE
REMEDY
1. Input power not properly

connected to input panel
1. Check that input power is

present and properly
connected (see Electrical
Connections, page 12)
2. Input power selection does

not correspond to actual
input voltage
2. Check actual line voltage

vs. voltage selection on
rear panel (see Electrical
Connections, page 12)
3. Input fuse blown
3. Check fuse on rear panel.

If blown, doublecheck
voltage selection and
replace fuse. If fuse blows
again, return unit to an
authorized service station
1. Unit is overheated
1. Make sure the unit has not

been operated beyond 70%
duty cycle limit
2. Fan not running (or

airflow obstructed)
2. Check for obstructed air

flow (see Service Procedures, page 59)
1. Check that quick disconnect is properly attached
C. AC indicator lit, TEMP

indicator green, PIP
indicator not lit
1. Torch not properly connected to power supply

2. Shield cup not properly
installed on torch
3. Faulty PIP assembly in
torch holder
4. Faulty pins inside torch
quick disconnect
D. AC indicator lit, TEMP

indicator green, PIP
indicator lit, GAS indicator
not lit
1. Gas not connected or

pressure too low
51
2. Check that shield cup is

fully seated against torch
head (do not overtighten)
3. Check PIP assembly (see
Servicing Torch Head
Components, page 36)
4. Check for continuity
between pins 1 and 6.
Check that pins in either
half of quick disconnect
are not pushed back. See
Figure 4-H (page 47)
1. Check source for at least
70 psi (4.8 BAR). In SET
position, adjust gas pressure to 70 psi
SERVICE
4.7 POWER SUPPLY TROUBLESHOOTING (continued)
SYMPTOM
POSSIBLE CAUSE
E. When power is applied to

unit, GAS indicator
remains lit for more than
20 seconds
1. RUN/SET switch in SET

position
1. Set switch to RUN position
F. Torch will not pilot when

torch switch is activated
1. Switch activated during 20

second pre-flow
1. Release switch and wait at

least 20 seconds before
activating switch again
2. Faulty torch parts
2. Inspect torch parts and

replace if necessary (see
Replacing Consumable
Torch Parts, page 36)
3. Gas pressure too high
3. Set pressure to 70 psi (4.8

BAR)
G. DC indicator not lit when

torch switch is activated
1. Switch activated during 20

second pre-flow
1. Release switch and wait at

least 20 seconds before
activating switch again
H. Torch pilots but does not

cut
1. Torch too far from

workpiece
1. Hold torch 1/8-3/8 inch

(3-9 mm) from workpiece
2. Work lead not connected
2. Make sure work lead is

connected securely (check
continuity if necessary)
1. Current set too low
1. Increase current setting
2. Torch is being moved too

fast across workpiece
2. Reduce cutting speed (see

Cutting Speeds, page 32)
3. Excessive oil or moisture

in torch
3. Hold torch 1/8 inch (3

mm) from clean surface
while purging and observe
oil or moisture buildup
(do not activate torch)
I. Torch cuts but not adequately
SERVICE
52
REMEDY
5.1 ORDERING INFORMATION
Ordering Information
Parts listed without item numbers are not shown, but may be
ordered by the catalog number shown.
Order replacement parts by catalog number and complete description of the part or assembly, as listed in the description
column of the Parts List. Also include the model and serial
number of the torch. Address all inquiries to your authorized
Thermal Dynamics distributor.
If a Thermal Dynamics product must be returned for service,
contact your Thermal Arc distributor. Materials returned to
Thermal Dynamics without proper authorization will not be
accepted.
53
PARTS LIST
5.2 SYSTEM COMPONENTS AND ACCESSORIES
Item Qty. Catalog

No.
Number
Description
Complete systems include power supply with 230V primary power cable, work lead, PCH/M-35
torch with leads, and torch spare parts kit. Machine torch systems include metal mounting tube
and pinion assembly and remote pendant control with ON/OFF switch:
-
1
1
1
1-6249
1-6250
1-6251
Pak Master 50 with PCH-35 70 Torch and 12.5 ft (3.8 m) Leads

Pak Master 50 with PCH-35 70 Torch and 25 ft (7.6 m) Leads
1
1
1
1-6252
1-6253
1-6254
Pak Master 50 with PCH-35 90 Torch and 12.5 ft (3.8 m) Leads

1
1
1
1-6255
1-6256
1-6257
Pak Master 50 with PCM-35 Machine Torch and 12.5 ft (3.8 m) Leads
Pak Master 50 with PCM-35 Machine Torch and 25 ft (7.6 m) Leads
Pak Master 50 with PCM-35 Machine Torch and 50 ft (15.2 m) Leads
Complete 575V Systems Only:

Complete 575V systems include power supply with work lead, 575 VAC transformer assembly,
PCH/M-35 torch with leads, and torch spare parts kit. Machine torch systems include metal
mounting tube and pinion assembly and remote pendant control with ON/OFF switch:
-
1
1
1
1-6260
1-6261
1-6262
Pak Master 50(575V) with PCH-35 70 Torch and 12.5 ft Leads

Pak Master 50(575V) with PCH-35 70 Torch and 25 ft Leads
1
1
1
1-6263
1-6264
1-6265
Pak Master 50(575V) with PCH-35 90 Torch and 12.5 ft Leads

1
1
1
1-6266
1-6267
1-6268
Pak Master 50(575V) with PCM-35 Machine Torch and 12.5 ft Leads
Pak Master 50(575V) with PCM-35 Machine Torch and 25 ft Leads
Pak Master 50(575V) with PCM-35 Machine Torch and 50 ft Leads
PARTS LIST
54
5.3 REPLACEMENT TORCHES AND LEADS
Item Qty. Catalog

No.
Number
Description
Replacement Hand Torches with Leads and Spare Parts Kit:

-
1
1
1
2-6001
2-6002
2-6003
PCH-35 70 Hand Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit

PCH-35 70 Hand Torch, 25 ft (7.6 m) Leads, Spare Parts Kit
1
1
1
2-6004
2-6005
2-6006
PCH-35 90 Hand Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit

Replacement Machine Torches with Leads, Mounting Assembly, and Spare Parts Kit
-
1
1
1
2-6083
2-6084
2-6085
PCM-35 Machine Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit

PCM-35 Machine Torch, 25 ft (7.6 m) Leads, Spare Parts Kit
Replacement Machine Torches with Leads, Phenolic Mtg Tube w/Pinch Block, Spare Parts Kit:
-
1
1
1
2-6007
2-6008
2-6009
PCM-35 Machine Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit

Replacement Torches with Leads Only:

-
1
1
1
2-6052
2-6053
2-6054
PCH-35 70 Hand Torch, 12.5 ft (3.8 m) Leads

PCH-35 70 Hand Torch, 25 ft (7.6 m) Leads
1
1
1
2-6055
2-6056
2-6057
PCH-35 90 Hand Torch, 12.5 ft (3.8 m) Leads

1
1
1
2-6100
2-6101
2-6102
PCM-35 Machine Torch, Metal Mtg. Assy, 12.5 ft (3.8 m) Leads

PCM-35 Machine Torch, Metal Mtg. Assy, 25 ft (7.6 m) Leads
PCM-35 Machine Torch, Metal Mtg. Assy, 50 ft (15.2 m) Leads
1
1
1
2-6058
2-6059
2-6060
PCM-35 Machine Torch, Pinch Block Assy, 12.5 ft (3.8 m) Leads

PCM-35 Machine Torch, Pinch Block Assy, 25 ft (7.6 m) Leads
PCM-35 Machine Torch, Pinch Block Assy, 50 ft (15.2 m) Leads
Replacement Torch Leads with Quick Disconnect Assembly:

-
1
1
1
4-6023
4-6024
4-6025
Replacement Leads - 12.5 ft (3.8 m)

Replacement Leads - 25 ft (7.6 m)
Replacement Torch Leads without Quick Disconnect Assembly:

-
1
1
1
4-6033
4-6034
4-6035
Replacement Leads - 12.5 ft (3.8 m)

55
PARTS LIST
5.4 TORCH HEADS AND SPLIT HOLDERS
Item
No.
Qty.
Catalog
Number
Description
1
2
3
1
1
1
9-5807
9-5808
9-5809
Basic Internal Head - PCH-35 70 Hand Torch

Basic Internal Head - PCH-35 90 Hand Torch
Basic Internal Head - PCM-35 Machine Torch
4
5
6
1
1
1
9-6259
9-6260
9-6261
Split Holder (Two Parts) - PCH-35 70 Hand Torch

Split Holder (Two Parts) - PCH-35 90 Hand Torch
Split Holder (Two Parts) - PCM-35 Machine Torch
7
8
1
2
9-6103
8-0533
PIP Pin Wire Assembly

O-Ring
8
1
Figure 5-F Torch Heads and Split Holders
PARTS LIST
56
5.5 CONSUMABLE TORCH PARTS
Item
No.
Qty.
Catalog
Number
Description
1
1
1
1
1
1
1
1
9-6003
9-6004
9-6000
9-6001
9-6120
9-6002
9-6006
9-6007
Standard Shield Cup (For Standoff Cutting)

Shield Cup Standoff Attachment (for Drag Cutting)
Tip - Standoff Cutting
Tip - Drag Cutting
Tip - Drag Cutting (Heavy Duty)
Tip - Gouging
Electrode
Gas Distributor
LONG LIFE PARTS
1
1
1
1
1
1
9-6503
9-6500
9-6501
9-6502
9-6506
9-6507
Long Life Shield Cup Attachment (Install Over Standard Cup)

Long Life Standoff Cutting Tip
Long Life Drag Cutting Tip
Long Life Gouging Tip
Long Life Electrode
CAUTION
Do not use long life parts (Tips, Gas Distributor or Electrode) with standard parts. Shield
cup attachment (No. 9-6503) must be installed
over the standard shield cup (No. 9-6003).
Standard Shield Cup
Catalog No. 9-6003
Crown Shield Cup

Catalog No. 9-6004
Standoff Cutting Tip

(.031 in)
Catalog No. 9-6000
Drag Cutting Tip

(.031 in)
Catalog No. 9-6001
Heavy Duty Drag Tip

(.036 in)
Catalog No. 9-6120
Gouging Tip
(.046)
Catalog No. 9-6002
Long Life Standoff

Catalog No. 9-6500
Long Life Drag

Catalog No. 9-6501
Electrode
Catalog No. 9-6006
Gas Distributor
Catalog No. 9-6007
Long Life Electrode

Catalog No. 9-6506

Catalog No. 9-6507
Long Life Shield Cup

Catalog No. 9-6503
A-00017
A-00318
Figure 5-G PCH/M-35 Consumable Torch Parts
57
PARTS LIST
5.6 TORCH OPTIONS AND ACCESSORIES
Item
No.
Qty.
Catalog
Number
7-3291
PCH-35 Cutting Guide Kit
1
1
1
1
4-6007
4-6008
4-6009
4-6010
Leads Extension Kit - PCH-35 Hand Torch - 25 ft (7.6 m)

Leads Extension Kit - PCH-35 Hand Torch - 50 ft (15.2 m)
Leads Extension Kit - PCM-35 Machine Torch - 25 ft (7.6 m)
Leads Extension Kit - PCM-35 Machine Torch - 50 ft (15.2 m)
1
2
1
1
8-4305
8-4304
Torch Handle
Torch Handle Boot
3
4
5
1
1
1
1
1
2
8-4303
8-4302
8-4301
8-5170
8-4340
8-4341
Switch Track Closure

Switch Track Insert
Switch Assembly
Switch Lever Kit - Includes 8-4340 and 8-4341
Switch Lever
Switch Lever Mounting Bracket
8-5172
PCH-35 Handle Extension Kit
8
9
10
11
12
1
1
1
1
1
1
7-3253
8-4306
7-3207
8-4204
8-4018
7-2827
Machine Torch Mounting Tube Kit (Metal) - Includes:

Adaptor Tube
Metal Mounting Tube (includes Item 10)
End Cap (Bushing)
Retaining Nut
Pinion Assembly
13
7-3291
Circle Cutting Attachment
6
7
PARTS LIST
Description
58
5.6 TORCH OPTIONS AND ACCESSORIES (continued)
6
4
5
7
2
10
1
12
8
11
13
Figure 5-H Torch Mounting Components
59
PARTS LIST
5.7 TORCH SPARE PARTS KITS
Item
No.
Qty.
Catalog
Number
1
5
3
5
1
5-6001S
9-6003
9-6000
9-6001
9-6006
9-6007
Spare Parts Kit - PCH/M-35 Standard Cutting - Includes:

Shield Cup - Standard
Tip - Drag Cutting
Electrode
Gas Distributor
2
6
5
2
5-6015
9-6003
9-6002
9-6006
9-6007
Spare Parts Kit - PCH/M-35 Gouging - Includes:

Shield Cup - Standard
Tip - Gouging
Electrode
Gas Distributor
1
10
10
10
10
2
5-6021
9-6004
9-6000
9-6001
9-6120
9-6006
9-6007
Spare Parts Kit - PCH/M-35 Drag Cutting - Includes:

Crown Cup Attachment
Tip - Drag Cutting
Tip - Drag Cutting (Heavy Duty)
Electrode
Gas Distributor
1
5
3
5
1
5-6001
9-6503
9-6500
9-6501
9-6506
9-6507
Spare Parts Kit - PCH/M-35 Long Life - Includes:

Long Life Shield Cup Attachment (Install Over Standard Cup)
Long Life Standoff Cutting Tip
Long Life Drag Cutting Tip
Long Life Electrode
PARTS LIST
Description
60

Therma Pak Master 50

Uploaded by

Copyright:

Available Formats

Therma Pak Master 50

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Therma Pak Master 50

Uploaded by

Copyright:

Available Formats

R

Air Plasma Cutting System

Pak Master 50 Power Supply

Manual No. 0-2344

Read and understand this entire instruction manual and your

While the information contained in this instruction manual

RECORD SERIAL NUMBERS FOR WARRANTY PURPOSES

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

1.1 System Description ...................................................................... 1

3.1 Operating Controls .................................................................... 19

Power Supply Maintenance ..................................................... 35

Ordering Information ............................................................... 53

NOTES, CAUTIONS, AND WARNINGS

Throughout this manual, notes, cautions, and warnings are used

An operation, procedure, or background information which

IMPORTANT SAFETY PRECAUTIONS

Gases and Fumes

Operation and maintenance of plasma arc equipment involves

ARC RAYS can injure eyes and burn skin.

IMPORTANT SAFETY PRECAUTIONS (continued)

ELECTRIC SHOCK can kill.

FIRE can be caused by hot slag and sparks.

NOISE can cause permanent hearing loss.

Compressed gas cylinders are potentially dangerous.

IMPORTANT SAFETY PRECAUTIONS (continued)

The following publications provide additional information on

Read and understand this instruction manual and your

Les gaz et les fumees

La mise en oeuvre et l'entretien de tout quipement plasma

Les rayons de l'arc

LES RAYONS DE L'ARC peuvent abimer les yeux et bruler la

Une DECHARGE ELECTRIQUE peut tuer.

Les etincelles et les scories peuvent provoquer UN ENCENDIE.

LE BRUIT peut causer la surdit.

LES RSERVOIRS DE GAZ SONT DANGEREUX.

Se rfrer aux directives du constructeur pour une bonne

(A) Bulletin No. C5.2-83 Recommended Safe Practices for

Lire et comprendre ce manuel d'instructions, ainsi que les

Manufacturer: Thermal Dynamics Corporation

MAIN POWER MAGNETICS ....................................................... 2 YEARS ..................... 1 YEAR

1.1 SYSTEM DESCRIPTION

The Pak Master 50

Pak Master 50 - The power supply provides 35 amp maximum

Figure 1-A System Components

Continuously variable from 15 to 35 Amps maximum

1/2 in (12.7 mm) at 10 ipm

High Frequency (HF), Constant DC

Remote Start/Stop, OK-to-Move, and Corner Slowdown (CSD)

Table 1-A Power Supply Specifications

70 or 90 Hand Torch, 180 Machine Torch

35 amps Maximum, DC Straight Polarity

Most materials up to 1/2 in (12.7 mm)

1/4 in (6.3 mm)

3/8 in (9.5 mm)

Gas Distributor, Electrode, Tip, Shield Cup

Compressed Air, Nitrogen (N2)

Table 1-B Torch Specifications

1.2 SPECIFICATIONS (continued)

1.06 in (27 mm)

1.06 in (27 mm)