The size of the surrounding area to be Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety, nor connected to earth ing place.
Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty.
Étiquette de sécurité ...............................1a-6 Section 2 SPECIFICATIONS Introduction ................................2-2 Model 500 Torch ..............................2-3 Control Console ...............................2-3 Operator’s Panel ..............................2-3 Model H401 Power Supply..........................2-4 Model H601 Power Supply..........................2-4 Argon-Hydrogen Manifold ..........................2-4 Water Supply (single torch)..........................2-4 Water Supply (two torch)..........................2-4 PAC500 Instruction Manual...
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Section 5 MAINTENANCE Routine Maintenance ..............................5-2 Protecting Copper Surfaces ..........................5-2 Nozzle ................................5-2 Electrode ................................5-3 Swirl Ring .................................5-3 Torch ................................5-3 Water Tube ..............................5-4 Spark Gap ................................5-5 Control Circuit Description ............................5-5 Test Mode ................................5-5 Run Mode.................................5-6 Two Torch Operation ............................5-6 PAC500 Instruction Manual...
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Remote Stop/Start ..............................6-8 Argon-Hydrogen Manifold ............................6-10 Operator’s Panel (1-Torch) .............................6-12 Operator’s Panel (2-Torch) .............................6-14 Gas and Water Flowmeter ............................6-16 Electrical Compartment PAC500 Console ......................6-18 Plumbing Compartment PAC500 Console ......................6-20 Water Supply System .............................6-24 Appendix A PROPYLENE GLYCOL SAFETY DATA ..................a-2 BENZOTRIAZOLE SAFETY DATA ....................a-7...
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Grounding Safety ............................1-4 Compressed Gas Equipment Safety.......................1-5 Gas Cylinders Can Explode If Damaged ......................1-5 Noise Can Damage Hearing ...........................1-5 Pacemaker and Hearing Aid Operation......................1-5 A Plasma Arc Can Damage Frozen Pipes ......................1-5 Additional Safety Information ..........................1-5 Warning Label ..............................1-6 Hypertherm Plasma Systems...
• Install an aeration manifold on the floor of the water closed container. table to eliminate the possibility of hydrogen • Do not cut containers that have held combustible detonation. Refer to the Appendix section of this materials. manual for aeration manifold details. Hypertherm Plasma Systems 11-98...
• Provide a disconnect switch close to the power grounding conductor first. supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not an emergency situation.
Work Table Connect the work table to an earth power cord ground. Fasten the retaining nut tightly. ground, in accordance with appropriate national or • Tighten all electrical connections to avoid excessive local electrical codes. heating. Hypertherm Plasma Systems 4-99...
Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or cutting. Do not remove or paint over (cover) warning labels. Hypertherm Plasma Systems 8-99...
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages............1a-5 Le bruit peut provoquer des problèmes auditifs ....................1a-5 Pacemakers et prothèses auditives ......................1a-5 Un arc plasma peut endommager les tuyaux gelés ..................1a-5 Étiquette de sécurité .............................1a-6 Hypertherm Systèmes plasma 1a-1 2/12/01...
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 Hypertherm Systèmes plasma 2/12/01...
• Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée. proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm cas d’urgence.
Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 2/12/01...
LES TUYAUX GELÉS • Se tenir le plus loin possible de la source de courant. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01...
6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 Hypertherm Systèmes plasma 2/12/01...
Section 2 SPECIFICATIONS In this section: Introduction ................................2-2 Model 500 Torch...............................2-3 Control Console ...............................2-3 Operator’s Panel ..............................2-3 Model H401 Power Supply..........................2-4 Model H601 Power Supply..........................2-4 Argon-Hydrogen Manifold ..........................2-4 Water Supply (single torch) ..........................2-4 Water Supply (two torch)..........................2-4 PAC500 Instruction Manual...
Consequently, double arcing from the nozzle touching the workpiece is virtually eliminated. The PAC500 can also be operated in the conventional mode for cutting plate in the 3-in. to 6-in. thickness range. In this mode of operation, the injection water is used for nozzle cooling only; arc constriction is achieved purely by the nozzle.
Dimensions Width..............13 in. Height...............16 in. Depth ...............15 in. Weight..............75 lbs. Operator’s Panel Dimensions Width..............6.5 in. Add 6 in. in width for each additional torch Height...............14 in. Depth ...............6 in. Weight..............12 lbs. (single torch) PAC500 Instruction Manual...
Length ..............26 in. Weight..............90 lbs. Water Supply (two torch) Input Voltage ............230/460 volts, 3 phase Input Current ............9.2/4.6 amperes Rated Pump Output .........5.0 gpm at 175 psi Dimensions Width..............10 in. Height...............24 in. Length ..............26 in. Weight..............115 lbs. PAC500 Instruction Manual...
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Input Power ..............................3-2 Leads and Hoses Track ...........................3-3 Equipment Supplied and Accessories ........................3-3 Installation Instructions .............................3-3 Control Console ...............................3-3 Power Supply ..............................3-3 Water Supply System............................3-4 Torch ................................3-5 Gas System..............................3-5 Operator’s Panel ..............................3-5 Argon-Hydrogen Manifold ..........................3-6 System Check-Out..............................3-6 PAC500 Instruction Manual...
The following requirements must be fulfilled before installing the PAC500 Plasma Cutting System. Water Supply The PAC500 system needs a clean water supply to cool the torch and constrict and accelerate the arc. The maximum water temperature recommended for the torch is 70° F (21° C). The total flow rate required is approximately 2.5 gallons/min.
Equipment Supplied and Accessories Table II (pages 5-10 and 5-11) breaks down what is included in the PAC500 single and two torch systems. A listing of the required and optional accessories is also included. Although standard lead and hose lengths are specified, other lengths are available to suit individual requirements.
Do not omit the 2PL-C connection as improper grounding of the pilot arc circuit will result causing starting difficulties and possible damage to the control. In Hypertherm power supplies there is a specific terminal for this connection as noted in the power supply instruction manual. In other power supplies the connection should be made directly to the positive (+) terminal if no other appropriate terminal is available.
The corresponding fitting is also color coded. The gas hoses are green and color coded with tape: a green band is gas to the operator's panel; a red band is gas from the operator's panel. PAC500 Instruction Manual...
Make sure a good clean connection is made. Run the ground cable to a high quality earth ground. If the PAC500 is installed on an N/C cutting machine, the ground leads from the console, cutting machine, power supply and cutting table should be connected to a common, high quality “star”...
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Note the reading on the ammeter and adjust the power up or down to obtain the proper current as specified in the Cut Charts. Press the STOP button to terminate the cut. 14. The system is now operational. PAC500 Instruction Manual...
Thickness Range: 3 in. to 6 in..........................4-4 General Comments ............................4-5 Cut Charts.................................4-6 Operating Data for Mild Steel...........................4-6 Operating Data for Stainless Steel........................4-7 Operating Data for Aluminum...........................4-8 Operating Data for Other Materials ........................4-9 Operating Data for High Current Cutting......................4-10 PAC500 Instruction Manual...
The arc is switched off at the end of the cut by means of the STOP switch or by letting the torch run off the workpiece. If the PAC500 is operated in the conventional mode rather than the Water-injection mode, a special premixed gas, 65% argon-35% hydrogen, must be used. DO NOT connect this gas mixture to the control console because this enclosure is not properly vented for hydrogen bearing gases (Refer to Section 1 Safety).
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Brass, Tapered Retaining Cap ....Part No. 020034 The flared retaining cap is designed to provide optimum performance of the Water-Muffler. The flared front end produces a thicker, more stable water curtain thereby improving sound attenuation. This retaining cap also PAC500 Instruction Manual...
Thickness Range: 3 in. to 6 in. The PAC500 is operated in the conventional mode in this thickness range. The water spray from the .250 nozzle is used for cooling purposes only and does not constrict the arc. A mixture of 65% Argon-35% Hydrogen is used instead of nitrogen because it produces a deeper penetrating arc.
(Refer to Section 1 Safety.) When cutting material over 2 inches in thickness, in the Water-Injection mode, it is sometimes beneficial to shut off the water muffler and lower the water level an inch or two to improve arc penetration. PAC500 Instruction Manual...
If deviations from these conditions are necessary, they should be limited to changes in arc current, arc voltage, and travel speed. These parameters have a significant effect on cut quality. Do not deviate from specified gas and water flows. PAC500 Instruction Manual...
3 inches (75 mm) below the lower surface of the workpiece. Also de-energize the Water Muffler pump to improve arc penetration. For cutting thicker plate refer to the chart Operating Data for High Current Cutting on page 4-10. PAC500 Instruction Manual...
75 Maximum current for this nozzle is 750 amp. Use the brass tapered retaining cap part no. 020034 above 400 amperes. For cutting thicker plate refer to the chart Operating Data for High Current Cutting on page 4-10. PAC500 Instruction Manual...
Warning: The plasma console is not vented for combustible gases. The optional ARGON/HYDROGEN MANIFOLD part number 028057 is required when using Argon/Hydrogen gas mixtures. Caution: Never operate Water-Injection nozzles with Argon/Hydrogen gas mixtures. 4-10 PAC500 Instruction Manual...
Spark Gap ................................5-5 Control Circuit Description ............................5-5 Test Mode.................................5-5 Run Mode.................................5-6 Two Torch Operation ............................5-6 Equipment Troubleshooting ............................5-7 Process Troubleshooting ............................5-9 Table II – Equipment Supplied and Accessories.....................5-10 PAC500 Single Torch System ........................5-10 PAC500 Two Torch System ..........................5-11 PAC500 Instruction Manual...
O-ring which will impair cut quality. However, tighten the retaining cap by hand only. Pitting will never occur if proper care is taken as outlined above. See Torch on next page. PAC500 Instruction Manual...
4. Insert the swirl ring placing the smaller diameter end up toward the rear of the torch as in figure on page 5-4. Torch When changing or inspecting any consumable parts, clean the current ring of the torch with a clean paper towel or Q-tip to remove any dirt, grease, etc. PAC500 Instruction Manual...
11/32" (8.5 mm). Check for tightness. 3. Remove and replace the water tube (120035) by using the water tube wrench (027347) supplied by Hypertherm. When installing water tube, do not overtighten! Snug down by hand only. WARNING...
The relay therefore operates in reverse logic manner which may be confusing to those unfamiliar with the circuit. The normally closed contacts of the relay are open when the arc is PAC500 Instruction Manual...
The control relay (5CR) mounted in the Operator's Panel is energized on 1TR, line 22, figure 9. When both consoles are ON, the first preflow delay relay (1TR) to time in will energize 5CR, which actuates both high frequency starting circuits simultaneously. Three and four torch systems are a simple iteration of this circuit. PAC500 Instruction Manual...
Place a jumper between terminals 1TB-18 and 1TB-19. d. Place TEST/RUN Switch in TEST. e. Turn control power ON. f. Turn water flowmeter OFF. g. Depress start button. h. Set gas flowmeter at 70%. i. Verify gas pressure input to console is 150 psig. PAC500 Instruction Manual...
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Place the CONTROL switch to MAN position,the ARC switch to AUTO position, and the Plasma TEST/RUN switch to the RUN position. d. Depress the START switch and note the Voltage Divider output. e. Press the STOP switch to de-energize the main contactor after you have taken the Divider measurement. PAC500 Instruction Manual...
3. Nozzle size too small. If steps 1 and 2 do not eliminate the dross, go to the next nozzle size and set the current 100 amperes below the maximum current rating of the nozzle; adjust the cutting speed accordingly. PAC500 Instruction Manual...
MAINTENANCE Table II Equipment Supplied and Accessories PAC500 Single Torch System Description Part No. Quantity Items Included Model 500 Torch 028031 Torch Leads Pkg. 1 Set Console 028121 Operator’s Panel 028122 Operator’s Panel Leads 1 Set Amphenol Plug, 4 conductor...
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GAS (Green hose, coded green) FLOWMETER (GREEN) WATER (Black hose, coded green) WATER WATER (Black hose, coded red) FLOWMETER (RED) GAS (Green hose, coded red) Connections within square are for Operator’s Panel only. Figure 2 Service Connections PAC500 Instruction Manual 5-13...
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MAINTENANCE FEEDTHROUGHS FOR WATER-COOLED TORCH POWER CABLES AND PILOT ARC WIRE Attach braided metal sheath to feedthrough GAS (Green hose) GAS OUT NOZZLE WATER (Red hose-LH fitting) WATER OUT Figure 3 Torch Connections 5-14 PAC500 Instruction Manual...
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MAINTENANCE Figure 4 Direction of Cut Figure 5 Cut Angle PAC500 Instruction Manual 5-15...
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PILOT ARC RELAY 4CR ARC DETECION CIRCUIT TERMINAL STRIP 2TB COUPLING CAPACITORS TANK CAPACITOR C1 (2) C2, C3 SPARK GAP ASSEMBLY TANK COIL .020 inch (.5 mm) gap HIGH VOLTAGE TRANSFORMER HVT Figure 6 High Frequency Generator 5-16 PAC500 Instruction Manual...
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H.F. SUPPRESSION CAPACITOR C4 CATHODE BLOCK FLOWSWITCH 1FLS (rear) (Electrode cooling -1.2 gpm) FLOWSWITCH 2FLS (front) (Nozzle cooling- .25gpm) IHS GAS SOLENOID 3SOL ARC GAS SOLENOID 2SOL NOZZLE WATER SOLENOID 1SOL (rear) GAS PRESSURE SWITCH 1PS WATER COOLED RESISTOR R2 (3OHMS) Figure 7 Plumbing Compartment...
PARTS LIST Model 500 Torch PAC500 Instruction Manual...
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Swirl Ring (CCW, .166 and .187 Nozzle) 020048 Swirl Ring (.250 Nozzle) 020043* Nozzle Retaining Cap (Flared) 020034** Nozzle Retaining Cap (Tapered) * Components that come with 028031 torch ** See page 5-4 for illustration of water tube and tapered retaining cap PAC500 Instruction Manual...
Torch Leads, 25 ft. – Part No. 028140 040080 Shield Collar & Ring 023013 Water Cooled Cable 023037 High Frequency Lead 024028 Gas Hose, Green, RH 024034 Water Hose, Red, LH 046033 HV Vinyl Hose Sheath 25 ft. 046114 RF Braided Shield 25 ft. PAC500 Instruction Manual...
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Torch Leads, 40 ft. – Part No. 028143 004080 Shield Collar & Ring 023016 Water Cooled Cable 023040 High Frequency Lead 024031 Gas Hose, Green, RH 024037 Water Hose, Red, LH 046033 HV Vinyl Hose Sheath 40 ft. 046114 RF Braided Shield 40 ft. PAC500 Instruction Manual...
Each package consists of four hoses and one multiconductor cable of specified length with fittings and plug attached. Length Part No. 5 ft. 028144 10 ft. 028145 15 ft. 028146 20 ft. 028147 2S ft. 028148 30 ft. 028149 PAC500 Instruction Manual...
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PARTS LIST 4/ 5 Remote Stop/Start PAC500 Instruction Manual...
Item Part No. Description Qty. 005021 Enclosure 005022 Pushbutton, Green “Start” 005023 Pushbutton, Red “Stop” 008043 3/4 NPT X 18/3 Strain Relief 008643 Lock washer: Used on 008043 047005 Cord: 6-4 SO UL / CSA 20 ft. PAC500 Instruction Manual...
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PARTS LIST Argon-Hydrogen Manifold 6-10 PAC500 Instruction Manual...
Section IV Fire and Explosion Hazard Data....................a-8 Section V Health Hazard Data ........................a-8 Section VI Reactivity Data..........................a-9 Section VII Spill or Leak Procedures.......................a-9 Section VIII Special Protective Information .....................a-9 Section IX Special Precautions ........................a-10 Section X Regulatory Status .........................a-10 PAC500 Instruction Manual...
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