1996 Thermal Dynamics PAK 5XR Plasma Cutting System

Model: PAK 5XR | S/N L62418AT8321A | 55 Amp Industrial Duty

Overview

The Thermal Dynamics PAK 5XR is an industrial-grade, transformer-based plasma cutter designed for high-uptime fabrication and maintenance environments. Unlike modern, lightweight inverter units that rely on delicate circuit boards, the 5XR is built around a heavy copper-wound transformer. This "old school" construction makes it significantly more resistant to the dust, humidity, and voltage fluctuations common in a busy welding shop.

With a 55-amp output, this machine is a powerhouse for manual cutting, capable of piercing and cutting through most conductive metals—including mild steel, stainless, and aluminum—with ease.

Factory Specifications & Technical Data

• Year of Manufacture: 1996
• Cutting Capacity: 1/2" (12.7mm) Clean Cut / 5/8" Severance
• Output Current: 55 Amps (at 100V Secondary)
• Selectable Output Ranges: * Range I: 20 Amps (Thin gauge/Precision)
• Range II: 35 Amps (Medium plate)
• Range III: 55 Amps (Heavy-duty 1/2" plate)
• Duty Cycle: Industrial rated for high-volume use.
• Gas Requirement: Standard Compressed Air (requires 50–75 PSI).
• Pilot Arc: High-Frequency (HF) Start for reliable arc initiation, even on painted or rusted surfaces.
• Input Power: [Check data plate: Typically 220V Single-Phase or 460V 3-Phase].
• Weight: Approx. 200 lbs (Unit only) / 240 lbs with cart and leads.

Key Features & Dealer Benefits

• Transformer-Based Reliability: Built in 1996 during the "Golden Era" of Thermal Dynamics, this unit is engineered to last decades. It is far more serviceable than modern "disposable" plasma cutters.
• Versatile 3-Range Control: The physical range switch allows the operator to dial in the exact amperage needed, preventing dross buildup on thin materials while maintaining the "punch" needed for 1/2" plate.
• Thermal Overload Protection: Built-in safeguards prevent the machine from overheating during long production runs, protecting the internal windings.
• Readily Available Consumables: Uses standard Thermal Dynamics torches (like the PCH/M-51 or updated SL60/SL100), meaning tips, electrodes, and shields are available at almost any local welding supply store.
• Clean Cutting Performance: Known for leaving a minimal Heat Affected Zone (HAZ), resulting in parts that require less grinding and are virtually weld-ready.