Thermal Dynamics PAK 200 Operating Manual
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Thermal Dynamics PAK 200 Operating Manual

Plasma cutting system
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200
Operating Manual
PAK
®
PLASMA CUTTING SYSTEM
Rev. AB
Operating Features:
Date: October 8, 2008
Manual # 0-5057
460V /
208-
230

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Summary of Contents for Thermal Dynamics PAK 200

  • Page 1 ® PLASMA CUTTING SYSTEM Operating Manual Rev. AB Date: October 8, 2008 Manual # 0-5057 Operating Features: 460V / 208-...
  • Page 2 1888, or visit us on the web at www.thermal-dynamics.com. This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply, PAK 200 Operating Manual No. 0-5057 PCH/M 200 Torch Published by:...
  • Page 4 This page intentionally blank...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION .................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ..............1-1 1.03 Publications....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................1-5 1.07 Declaration of Conformity ................1-6 1.08 Statement of Warranty ................1-7 SECTION 2: SPECIFICATIONS .....................2-1...
  • Page 6 TABLE OF CONTENTS SECTION 4: OPERATION ......................4-1 4.01 Power Supply Indicators ................4-1 4.02 Control Console Features ................4-2 4.03 Operating Set-up ..................4-3 4.04 Cut Quality ....................4-4 4.05 System Operation ..................4-5 4.06 Operational Suggestions ................4-6 4.07 Recommended Cutting Speeds ..............4-10 SECTION 5: MAINTENANCE ....................5-1 5.01 Coolant Filter Cleaning Procedure ..............5-1 5.02...
  • Page 7 TABLE OF CONTENTS SECTION 7: TORCH MAINTENANCE ...................7-1 7.01 Introduction ....................7-1 7.02 General Torch Maintenance ................7-1 7.03 Common Operating Faults ................7-2 7.05 Troubleshooting Guide ................7-4 7.06 Servicing Hand Torch Components ............7-5 7.07 Servicing Machine Torch Components ............7-7 7.08 Torch And Leads Troubleshooting ...............7-8 APPENDIX 1: Control Cable Pinouts ...................
  • Page 8 TABLE OF CONTENTS...

  • Page 9: Section 1: General Information

    PAK 200 SECTION 1: • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the GENERAL INFORMATION different processes. You must be very careful when cutting...

  • Page 10: Publications

    PAK 200 1.03 Publications • Do not cut or weld on containers that may have held combus- tibles. Refer to the following standards or their latest revisions for more • Provide a fire watch when working in an area where fire hazards information: may exist.

  • Page 11: Note, Attention Et Avertissement

    PAK 200 1.04 Note, Attention et Avertissement • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont sur le métal et des différents procédés.
  • Page 12 PAK 200 produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables. BRUIT • Soyez certain qu’aucune matière combustible ou inflammable ne Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés se trouve sur le lieu de travail.

  • Page 13: Documents De Reference

    PAK 200 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM- MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À Consultez les normes suivantes ou les révisions les plus récentes ayant LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT été...

  • Page 14: Declaration Of Conformity

    Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 15: Statement Of Warranty

    90 Days Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.
  • Page 16 PAK 200 This Page Intentionally Blank GENERAL INFORMATION Manual 0-5057...

  • Page 17: Section 2: Specifications

    PAK 200 SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical PAK200 plasma cutting system includes: ® • One Power Supply • Arc Starter / Gas Control Module (Mounted on Power Supply) • General Purpose Plasma Cutting Torch with Connecting Leads •...

  • Page 18: Power Supply Specifications & Electrical Requirements

    PAK 200 2.06 Power Supply Specifications & Electrical Requirements PAK 200 Power Supply Specifications Max OCV (U 380 vdc Max Output Current 200 Amps Output Voltage 160 vdc Duty Cycle Rating 100% @ 200A @ 160V (32 kW) Operating range 14°F to 122°F (-10°C to + 50°C)

  • Page 19: Power Supply Dimensions

    PAK 200 2.07 Power Supply Dimensions 27 inch 680 mm 41.25 inch 1050 mm 48.75 inch 1238 mm 33 inch 840 mm 27.5 inch 700 mm 37.75 inch 397 lb / 180 kg 960 mm Art # A-04822 Manual 0-5057...

  • Page 20: Power Supply Rear Panel Features

    PAK 200 2.08 Power Supply Rear Panel Features Gas Control Connector Torch Leads Port Arc Starter Input Power Connector Pilot (Pos) Terminals Terminal Torch (Neg) Terminal AC Power Lamp Gas Entry Ports Circuit Breaker Panel Ground Terminals Gas Control Connector...

  • Page 21: Gas Requirements

    PAK 200 2.09 Gas Requirements The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be equipped with stainless-steel diaphragms and installed as close as possible to the Gas Console. Specify Dual Stage Stainless diaphragm regulators for hi-pressure cylinders (> 400 inlet psi) (example: Victor VTS-450- D-500, Single stage Station-stainless diaphragm regulator for low pressure (<...

  • Page 22: Pch/M 200 Torch Specifications

    PAK 200 2.11 PCH/M 200 Torch Specifications A. Torch Dimensions (35.6mm) 1.4 in. 70° 3.3 in. (83.8mm) 1.5 in. 13.3 in. (38.1mm) (337mm) 13.5 in. (342.9mm) 3.5 in. (88.9mm) 1.4 in. (35.6mm) 90° 1.5 in. (38.1mm) 17.4 in. (44.2mm) 4.3 in.
  • Page 23 PAK 200 C. Torch Parts (Generic Parts Shown) Torch Head Shield Cup Electrode Water Tube Extension Distributor (Gouging Only) A-02188 D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place.
  • Page 24 PAK 200 This page is blank intentionally. SPECIFICATIONS Manual 0-5057...

  • Page 25: Section 3: Installation

    Cooling System Requirements Coolant must be added to the system on installation. The amount required varies with torch leads length. Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures). Coolant Capabiities Cat. Number and Mixture...

  • Page 26: Cables And Leads Identification

    PAK 200 3.02 Cables and Leads Identification Refer to section 3.05 for ground connections and ground cables. Arc Starter / Maximum Length 100’ / 30.5 m Gas Control Module (GCM-200) Torch Lead Set Ground Pilot Return Cable - Coolant Supply w/ Negative...

  • Page 27: Cables And Leads Identification

    PAK 200 3.03 Cables and Leads Identification #8 AWG Cable Pilot Return, Power Supply to Arc Starter #1 AWG Cable Negative Lead, Power Supply to Arc Starter Green Green Coolant Leads, Power Supply to Arc Starter Control Cable, Power Supply...

  • Page 28: Position The Power Supply

    PAK 200 3.04 Position the Power Supply WARNING Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use all four lifting eyes when using lifting straps to lift the power supply.

  • Page 29: Primary Power Connections

    PAK 200 3.05 Primary Power Connections The primary power cable must be supplied by the end user and connected to the power supply. Refer to local and national electrical codes for suggested cable and fuse sizes. Connection Panel Connections Cover...
  • Page 30 PAK 200 Check / Adjust Input Voltage Configuration (208/230V 460V Only) 1. The power supply includes 2 inverters each having a voltage configuration board which must be positioned to match the primary input voltage. Failure to correctly position both boards results in a fault that blinks code 2-2 on the Status Led (front panel).
  • Page 31 PAK 200 Connect Input Power and System Ground Cables 1. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through the connections cover support panel on the rear panel of the power supply.

  • Page 32: Connect Work Cable

    PAK 200 3.06 Connect Work Cable 1. Pass the end of the work cable upward through the leads bracket at the bottom of the power supply rear panel, then up through the opening in the connections cover support panel. 2. Refer to the illustration. Connect the lead as shown. Tighten securely. Do not overtighten.

  • Page 33: Connect Gas Supply Lines

    PAK 200 3.07 Connect Gas Supply Lines 1. Connect the gas supply lines to the appropriate input ports as shown. Plasma Gas - In Shield Gas - In RETURN SUPPLY RETURN SUPPLY Art # A-08463 Manual 0-5057 INSTALLATION...

  • Page 34: Connect Torch Control Cable

    PAK 200 3.08 Connect Torch Control Cable 1. Connect the Torch Control cable to the power supply receptacle marked ‘J15’. To Torch RETURN SUPPLY RETURN SUPPLY Art # A-08492 INSTALLATION 3-10 Manual 0-5057...

  • Page 35: Set Switches For Command-Control Module

    PAK 200 3.09 Set Switches for Command-Control Module Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in you body or surroundings before touching the printed circuit boards.
  • Page 36 PAK 200 CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. SW11 No external connection cover SW12 SW13 SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.)

  • Page 37: Connect Torch Leads To The Gas Control Module / Arc Starter

    PAK 200 3.10 Connect Torch Leads to the Gas Control Module / Arc Starter 1. Remove the top cover from the Gas Control Module / Arc Starter. 2. Pass the torch leads and coolant leads through the torch leads port on the back of the module. Ensure that the leads outer jacket slides into the port.
  • Page 38 PAK 200 Coolant Return Coolant Supply Connection (Tagged Red) Connection (Tagged Green) Plasma Gas Connection Shield Gas Connection Torch Leads Art # A-04832 4. Re-install the module top cover. Art # A-08383 INSTALLATION 3-14 Manual 0-5057...

  • Page 39: Torch Parts Selection

    PAK 200 3.11 Torch Parts Selection Depending on the type of operation to be done (standoff cutting, drag cutting or gouging) determines the torch parts to be used. Torch parts: Shield Cup, Cutting Tip, Electrode, Gas Distributor, and Cooling Tube (Cooling Tube for Gouging Only).
  • Page 40 PAK 200 To change the torch parts for a different operation use the following procedure: NOTE A multi-purpose wrench is supplied for changing the tip, electrode and gas distributor in the torch head. When installing gouging parts, the gouging electrode requires the use of a water extension tube.

  • Page 41: Complete The Installation

    PAK 200 3.12 Complete the Installation 1. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length. 2. Replace the cap on the tank.
  • Page 42 PAK 200 NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. b. After about 30 seconds the system may shut down if the leads are not full of coolant.

  • Page 43: Section 4: Operation

    PAK 200 SECTION 4: OPERATION 4.01 Power Supply Indicators Gas Indicator Status Indicator AC Indicator Temp Indicator DC Indicator Art # A-04813 AC Power Indicator Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. When switch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage is confirmed.

  • Page 44: Control Console Features

    PAK 200 4.02 Control Console Features Art # A-08384 CU T OU T Shield Gas Plasma Gas Pressure Gauge Pressure Gauge Run / Set Selector SHIELD PLASMA Amperage Selector Shield Gas Pressure Plasma Gas Pressure Control Knob Control Knob Use SET position to adjust plasma and shield pressures and flows. Once these are Run / Set Selector: set, switch to RUN position for operation.

  • Page 45: Operating Set-Up

    Disconnect primary power at the source pilot arc is generated. The default pre-flow time before assembling or disassembling power for the PAK 200 is 2 seconds. supply, torch parts, torch and leads assem- Post-Flow: blies or adding coolant.

  • Page 46: Cut Quality

    PAK 200 4.04 Cut Quality Bevel Angle The angle between the surface of the cut edge and a plane Cut quality requirements differ depending on applica- perpendicular to the surface of the plate. A perfectly tion. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after perpendicular cut would result in a 0°...

  • Page 47: System Operation

    PAK 200 4.05 System Operation Left Side Cut Angle Right Side This section contains operating information which is Cut Angle specific to the power supply. WARNING F r e q u e n t l y r e v i e w...

  • Page 48: Operational Suggestions

    PAK 200 3. Check the AC lamp. If lamp is ON, AC input power Error Code section provides explanations of status is present in the power supply. Within 4 seconds codes. of the AC lamp illuminating there will be a series of 4.
  • Page 49 PAK 200 Status Code Key for PAK 200 Status Message Cause/Remedy Code System not Enabled or Missing AC External E-Stop Activated or CCM TB1-1&2 jumper missing; Input Phase Missing AC Phase; GCM200 control cable not connected. Pilot did not start within 15 seconds.
  • Page 50 GCM 200 Control cable not connected or Basic ID signal open; Gas Control Communication fault, Cannot establish Commu- CCM not PAK 200 (SW13-1 should be off) or nication with gas control. CCM defective, replace. Gas Control Communication Does not apply to PAK200, if displayed CCM defective.
  • Page 51 PAK 200 Status Code Key (cond) Status Message Cause/Remedy Code CANBUS Failure to Acknowledge Does not apply to PAK200, if displayed CCM defective. fault. CANBUS Off due to Does not apply to PAK200, if displayed CCM defective. excessive data errors;...

  • Page 52: Recommended Cutting Speeds

    PAK 200 4.07 Recommended Cutting Speeds Type Torch: PCH-200 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Air Amper- Speed Plasma Sec Gas Pierce Thickness Output (Per Minute) Standoff Gas Press Press Total Flow (SCFH) Height Inches mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm bar Plasma Secondary Inches mm 0.032...
  • Page 53 PAK 200 Type Torch: PCH-200 Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Air Output Amper- Speed Plasma Gas Sec Gas Thickness Volts (Per Minute) Standoff Press Press Total Flow (SCFH) Pierce Height Inches mm (Cat. No.) (VDC) (Amps) Inches Meters Inches mm...
  • Page 54 PAK 200 Type Torch: PCH-200 Type Material: Aluminum Type Plasma Gas: Ar-35H2 Type Secondary Gas: Nitrogen Output Amper- Speed (Per Plasma Gas Thickness Volts Minute) Standoff Press Sec Gas Press Total Flow (SCFH) Pierce Height Inches mm (Cat. No.) (VDC)
  • Page 55 PAK 200 This Page Intentionally Blank Manual 0-5057 4-13...
  • Page 56 PAK 200 This Page Intentionally Blank OPERATION 4-14 Manual...

  • Page 57: Section 5: Maintenance

    PAK 200 SECTION 5: MAINTENANCE Perform the following checks periodically to ensure proper system performance. Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. Check cooling fan; clean as needed. Monthly Check cooling fan and radiator;...

  • Page 58: Coolant Replacement Procedure

    PAK 200 5.02 Coolant Replacement Procedure Replace coolant as follows: 1. Disconnect the system from MAINTENANCE input power. At the bottom of the coolant tank, disconnect the coolant line fitting and collect coolant in a disposable container. 2. Connect the system to MAINTENANCE input power and turn it on to allow the pump to empty the tank,. The pump will run approximately for 20 seconds before the flow switch causes an interlock.

  • Page 59: Arc Starter Service

    PAK 200 5.03 Arc Starter Service Arc Starter Service Chart Symptom Cause Check Remedy Coolant has become con- Use conductivity meter Flush system, replace cool- ductive ant. Pilot return wre not con- Visual inspection Connect wire. nected Spark gap set too close Check with feeler gauge Set to 0.063”...

  • Page 60: Arc Starter Spark Gap Adjustment

    PAK 200 5.04 Arc Starter Spark Gap Adjustment 1. Shut off input power. Remove the top console cover. 2. Adjust the spark gap as shown. Re-install the top cover. 0.063" ± 0.002" 1.6 ± 0.05 mm Art # A-04835 MAINTENANCE...

  • Page 61: Section 6: Replacement Assemblies & Parts

    PAK 200 SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog# Pak 200 Power Supply, 208/230 460V 3-0003 Pak 200 Power Supply, 400V 3-0004 Pak 200 Power Supply, 400V (CE) 3-0005 OPTIONAL EQUIPMENT: Wheel Kit...

  • Page 62: System Componants And Accessories

    PAK 200 6.02 System Componants and Accessories Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Two Stage Air Line Filter Assembly 7-3139 First Stage Filter Element Replacement 9-1021 Second Stage Filter Element Replacement...

  • Page 63: Leads And Cables

    - Control Cable Control Cable Primary power Torch Primary Ground Work Cable Work Art # A-08376_AB Leads Catalog Numbers; PAK 200 Power Supply, PCH/M 200 Torch Leads Length Description 3 ft 10 ft 15 ft 25 ft 35 ft 50 ft...

  • Page 64: Leads And Cables

    PAK 200 6.04 Leads and Cables #8 AWG Cable Pilot Return, Power Supply to Arc Starter #1 AWG Cable Negative Lead, Power Supply to Arc Starter Green Green Coolant Leads, Power Supply to Arc Starter Control Cable, Power Supply to Arc Starter...

  • Page 65: Optional Gas Supply Leads

    PAK 200 6.05 Optional Gas Supply Leads HOSE ASSEMBLIES Lengh (feet) 10’ 15’ 25’ 35’ 50’ 75’ 100’ Length (meters) 3.05 10.6 15.2 22.9 30.4 Inert B (RH) 9-2146 9-5061 9-5073 9-5085 9-5097 9-5109 9-5121 1/4” 02 B (RH) 9-9008...

  • Page 66: Power Supply External - Replacement Parts

    PAK 200 6.06 Power Supply External - Replacement Parts Item # Description Catalog # Power Supply Front Panel 9-9380 Power Supply Rear Panel 9-9381 Power Supply Top Panel 9-9382 Power Supply Right Side 9-9383 Power Supply Left Side 9-9384 Louver Panel...

  • Page 67: Power Supply Replacement Parts - Right Side

    PAK 200 6.07 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Heat Exchange Fan FAN 1 9-9338 Radiator 9-9339 Art # A-04790 Manual 0-5057 PARTS LIST...

  • Page 68: Power Supply Replacement Parts - Right Side

    PAK 200 6.08 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Output Filter PC PCB8 9-9341 Sensor HCT2 9-9368 Magnetic Contactor, pilot 9-9343 Resisto 9-9340 Resisto Capacit Art # A-08309 PARTS LIST Manual 0-5057...

  • Page 69: Power Supply Replacement Parts - Right Side

    PAK 200 6.09 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Chopper Module 9-9389 Sensor HCT1 9-9342 Chopper Module HCT1 Art # A-08311 Manual 0-5057 PARTS LIST...

  • Page 70: Power Supply Replacement Parts - Front Panel

    PAK 200 6.10 Power Supply Replacement Parts - Front Panel Item # Description Ref. Des. Catalog # Main Power Switch (‘Circuit Protector’) 9-9344 for 230-400-460 VAC units Art # A-08312 PARTS LIST 6-10 Manual 0-5057...

  • Page 71: Power Supply Replacement Parts - Left Side/Front Panel

    PAK 200 6.11 Power Supply Replacement Parts - Left Side/Front Panel Item # Description Ref. Des. Catalog # PC Board PCB3 9-9365 PC Board 230/460VAC PCB4 9-9370 Display PC Board PCB6 9-9347 PCB3 PCB4 PCB6 Art # A-08313 Manual 0-5057...

  • Page 72: Power Supply Replacement Parts - Left Side

    PAK 200 6.12 Power Supply Replacement Parts - Left Side Item # Description Ref. Des. Catalog # PCBoard 230-400-460VAC PCB1 9-9362 Magnetic Contactor MC1,MC3 9-9364 Art # A-08314 PARTS LIST 6-12 Manual 0-5057...

  • Page 73: Power Supply Replacement Parts - Rear Panel

    PAK 200 6.13 Power Supply Replacement Parts - Rear Panel Item # Description Breaker Rating Cicuit Rating Ref. Des. Catalog # Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A 9-9348 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 1A 9-9349...

  • Page 74: Power Supply Replacement Parts - Right Side

    PAK 200 6.14 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Resistor 9-9363 Rectifier (Diode) 9-9345 Transformer 9-9355 for 230/460 VAC units Diode 9-9486 Terminal Strip Art # A-08310 PARTS LIST 6-14 Manual 0-5057...

  • Page 75: Power Supply Replacement Parts

    PAK 200 6.15 Power Supply Replacement Parts Item # Description Catalog # Inverter Module 460 and 208/230V 9-9360D Inverter Module 400 9-9482D Art # A-04786_AB Manual 0-5057 6-15 PARTS LIST...
  • Page 76 PAK 200 6.16 P ower Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor (Thermistor) 9-9361 Art # A-04787 PARTS LIST 6-16 Manual 0-5057...

  • Page 77: Power Supply Replacement Parts

    PAK 200 6.17 Power Supply Replacement Parts Item # Description Ref. Des. Catalog # Relay PC Board PCB7 9-9366 Internal Control PC Board PCB5 9-9346 Art # A-08315 Manual 0-5057 6-17 PARTS LIST...

  • Page 78: Power Supply Replacement Parts - Right Side

    PAK 200 6.18 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor (Level Switch) LSW1 9-9354 Motor 9-9381 Pump/Check Valve/Bypass Valve Assembly 9-9380 Bypass Valve (part of assembly) Pump (part of assembly) Sensor (Flow Indicator)
  • Page 79 PAK 200 6.19 Power Supply Replacement Parts - Right Side Item # Description Catalog # Pilot Resistor Mounting Bracket 9-0032 Pilot Resistor 3.6 ohms, 300W 9-0039 Manual 0-5057 6-19 PARTS LIST...

  • Page 80: Arc Starter & Gas Control Module (Gcm-200) Replacement Parts

    PAK 200 6.20 Arc Starter & Gas Control Module (GCM-200) Replacement Parts Item # Description Catalog # GCM-200, Gas Box/Arc Starter 9-4997 Base 9-4979 Front Panel 9-4980 Lid (not shown) 9-4981 Gas Bulkhead 9-4982 Bulkhead 9-4983 Solenoid Mount 9-4984 Lid Bracket...

  • Page 81: Command & Control Module - Replacement Parts

    PAK 200 6.21 Command & Control Module - Replacement Parts Item # Description Catalog # Assembly, CCM (PAK200) 9-9418 Plate, CCM Face 9-9419 Panel, CCM Mount Not Available Harness, CCM I/O Board 9-9421 Art # A-06798 Manual 0-5057 6-21 PARTS LIST...
  • Page 82 PAK 200 This Page Intentionally Blank PARTS LIST 6-22 Manual 0-5057...

  • Page 83: Section 7: Torch Maintenance

    PAK 200 SECTION 7: TORCH MAINTENANCE The inside of the torch should be cleaned with electrical 7.01 Introduction contact cleaner using a cotton swab or soft wet rag. This section describes basic maintenance procedures In severe cases, the torch can be removed from the performable by operating personnel.

  • Page 84: Common Operating Faults

    PAK 200 e. Worn torch parts C. Torch O-ring Lubrication f. Non-Genuine Thermal Dynamics Parts The internal o-rings on the torch head assembly (electrode, gas distributor and tip) require lubrication 3. Excessive Dross Formation on a scheduled basis. This will allow the o-rings to remain pliable and provide a proper seal.
  • Page 85 PAK 200 5. Poor Pilot Starting Shield Cup Torch Head Electrode a. High coolant conductivity (Refer to Power Supply Manual) b. Non-Genuine Thermal Dynamics Parts Water Tube Extension Distributor 7.04 Inspection and Replacement (Gouging Only) Consumable Torch Parts A-02188 WARNING Torch Consumable Parts Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 86: Troubleshooting Guide

    PAK 200 Electrode Wear a. Place RUN/SET switch to RUN position. 2. Torch switch activated during 20 second pre-flow 6. Install the electrode and tighten with multipurpose a. Release torch switch and wait at least 20 sec- wrench. Do not over tighten the electrode. The circular onds before activating switch again.

  • Page 87: Servicing Hand Torch Components

    PAK 200 C. Low cutting output with no control a. Check source for at least 100-125 psi (6.9- 8.6 bar) maximum pressure. 1. Incorrect setting of AMPERAGE control on power supply. 2. Faulty components in torch and leads assembly a. Check and adjust to proper setting.
  • Page 88 PAK 200 11. If the torch switch is defective, remove the switch Sheath from the torch handle. Connectors From Torch Control Torch Switch Switch B. Reassembling Torch Switch and Torch Head Assembly NOTE: Verify that small rubber duck valve is in torch plasma fitting.

  • Page 89: Servicing Machine Torch Components

    PAK 200 head then tighten the threaded locking nut against Pinion Assembly the torch handle. Positioning Tube Machine NOTE Bushing Torch Head There will be a slight gap between the torch head and the lock nut. Torch Adaptor 7.07 Servicing Machine Torch...

  • Page 90: Torch And Leads Troubleshooting

    PAK 200 7.08 Torch And Leads Troubleshooting 2. Slide the rigid insulator between the layers of estermat paper on the replacement Torch Head A. General Information Assembly (see note). Failures in the Torch and Leads can be isolated to the Torch NOTE Head or Torch Lead components.
  • Page 91 PAK 200 3. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative WARNING torch fittings. This procedure should be performed only by a • If there is continuity between the two torch qualified electronic technician.
  • Page 92 This Page Intentionally Blank...

  • Page 93: Appendix 1: Control Cable Pinouts

    APPENDIX 1: Control Cable Pinouts Power Supply J55 to Gas Control Console J56 4 Ground 7 Ground 8 Ground 6 Pot Wiper 5 + 10 vdc 14 E-Stop 15 E-Stop 11 Gas On 10 Gas On 17 24 VAC Ret 16 24VAC 24 VAC Ret 33 Ground 34 120VAC POWER SUPPLY J55 35 120VAC Ret...
  • Page 94 APPENDIX 2: Control Cable Pinouts Power Supply J59 to Arc Starter / Gas Control Console J58 Art # A-04849 2: Ground 1 - Jumpered to 4 7 - 120 VAC 4 - Jumpered to 1 9: 120 VAC RET POWER SUPPLY J59 ARC STARTER / GAS CONTROL MODULE J58 2: Ground 7 - 120 VAC 9: 120 VAC RET...

  • Page 95: Appendix 3: Command-Control Pc Board Layout (A)

    APPENDIX 3: Command-Control PC Board Layout (A) Note: Switch Settings May Vary. POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D CPU/COMMUNICATIONS Switches POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D C 2004 TDC 19X2169 REV +5.0V TEMP SENSE TPAD1...

  • Page 96: Appendix 4: Command-Control Pc Board Layout (B)

    APPENDIX 4: Command-Control PC Board Layout (B) TP11 TP12 SW11 PILOT V R224 TP12 R225 CC POT TP11 DC VOLTS K4-OK ARC V- OK CNC K3-E-STOP CNC CONTACTS K1-PSR K2-START C TDC 2005 19X2174 PILOT DEMAND CNC_E-STOP TP14 TP14 33 34 CNC_START TP13 DEMAND...
  • Page 97 APPENDIX 5: CNC - Control Module Board PCB Connections These points are jumpered together at the factory. TB1-1 E-Stop (Com) Remove the jumper to use existing E-Stop circuits. TB1-2 E-Stop TB1-3 TB1-4 Stop Latched TB1-5 Start / Stop Ret TB1-6 Start / Stop or Start Latched (NO) TB1-7 Divided Arc Voltage (-)
  • Page 98 APPENDIX 6: Arc Starter / Gas Control Module Schematic GCM 200 GAS CONTROL & ARC STARTER POWER SUPPLY JUMPER for Plasma Enable GAS PRESSURE GAS PRESSURE +10VDC POT WIPER (10) (11) CURRENT CONTROL POT CURRENT CONTROL POT JUMPER for BASIC GAS CONTROL ID GAS ON GAS ON (12)
  • Page 99 TORCH LEAD TORCH LEAD INNER SHIELD Water Cooled OUTER SHIELD TORCH Inductor NEG & HF (to Torch) NEG (from PS) NEG (from PS) 0.1 uf 1000VDC 0.1 uf 1000VDC PILOT PILOT PILOT RETURN (from torch) WORK WORK 0.1 uf 1000VDC 0.1 uf 1000VDC SHLD 0.047 uf 1000VDC...

  • Page 100: Appendix 7: Power Supply Schematic,460V / 208 - 230V

    APPENDIX 7: Power Supply Schematic,460V / 208 - 230V 100A INVERTER MODULE # 1 (top) N (-)1 N (-)1 CN1-230V CN1-230V INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+)1 P (+)1 CN4 - PCB12 CN4 - PCB12 CN2-460V CN2-460V MC3-A MC3-A...
  • Page 101 603-298-5711 603-298-5711 603-298-5711 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Thursday, January 10, 2008 Thursday, January 10, 2008 Thursday, January 10, 2008 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 102: Appendix 7: Power Supply Schematic,460V / 208 - 230V Cont

    APPENDIX 7: Power Supply Schematic,460V / 208 - 230V Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN)
  • Page 103 603-298-5711 603-298-5711 603-298-5711 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Thursday, January 10, 2008 Thursday, January 10, 2008 Thursday, January 10, 2008 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 104: Appendix 8: Power Supply Schematic, 400V

    APPENDIX 8: Power Supply Schematic, 400V 100A INVERTER MODULE # 1 (top) N (-)1 N (-)1 CN1- not used CN1- not used INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+)1 P (+)1 CN4 - PCB12 CN4 - PCB12 CN2 400V CN2 400V MC3-A...
  • Page 105 Last Modified: Friday, January 18, 2008 Friday, January 18, 2008 Friday, January 18, 2008 12:56:07 12:56:07 12:56:07 PAK 200 Power Supply 400V non-CE PAK 200 Power Supply 400V non-CE PAK 200 Power Supply 400V non-CE 42X1312 42X1312 42X1312 Manual 0-5057...

  • Page 106: Appendix 8: Power Supply Schematic, 400V Cont

    APPENDIX 8: Power Supply Schematic, 400V Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC FLOW_TURBINE_PULSE...
  • Page 107 Friday, January 18, 2008 Friday, January 18, 2008 Friday, January 18, 2008 12:56:07 12:56:07 12:56:07 PAK 200 Power Supply 400V non CE PAK 200 Power Supply 400V non CE PAK 200 Power Supply 400V non CE 42X1312 42X1312 42X1312 Manual 0-5057...

  • Page 108: Appendix 9: Power Supply Schematic, Csa 600V

    APPENDIX 9: Power Supply Schematic, CSA 600V 100A INVERTER MODULE # 1 (top) N (-)1 N (-)1 CN1- not used CN1- not used INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+)1 P (+)1 CN4 - PCB12 CN4 - PCB12 CN2 600V CN2 600V MC3-A...
  • Page 109 603-298-5711 603-298-5711 603-298-5711 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Thursday, January 10, 2008 Thursday, January 10, 2008 Thursday, January 10, 2008 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 110: Appendix 9: Power Supply Schematic, Csa 600V Cont

    APPENDIX 9: Power Supply Schematic, CSA 600V Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC...
  • Page 111 603-298-5711 603-298-5711 603-298-5711 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Thursday, January 10, 2008 Thursday, January 10, 2008 Thursday, January 10, 2008 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 112: Appendix 10: Publication History

    Oct. 8, 2008 Chapter 3 and 4: Up-date and/or add technical information (flow and pressure requirements). NOTE * Thermal Dynamics uses the date on the manual cover to indicate the most recent revision of the manual. Manual 0-5057 A-20 APPENDIX...

  • Page 113: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Telephone: 603+ 6092 2988 Fax: 800-535-0557 Fax : 603+ 6092 1085 Thermadyne Canada...
  • Page 114 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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