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Summary of Contents for Thermal Dynamics Econo-Pak 50
- Page 1 ECONO-PAK 50 Air Plasma Cutting Power Supply The System Includes: • ECONO-PAK 50 Power Supply • PCH-26 Torch with Leads • Work Cable with Clamp Operating Manual Manual No. 0-2450 September 1, 1998...
- Page 2 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 Econo-Pak 50 Air Plasma Cutting Power Supply Operating Manual, whether such error results from negligence, accident, or any other cause.
- Page 3 RECORD SERIAL NUMBERS FOR WARRANTY PURPOSES Purchase Date Power Supply Torch...
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Page 5: Table Of Contents
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ..................1 1.01 Notes, Cautions and Warnings ..............1 1.02 Important Safety Precautions ................ 1 1.03 Publications ....................2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes ............3 1.06 Documents De Reference ................ - Page 6 TABLE OF CONTENTS (continued)
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Page 7: Section 1: General Information
• Use an air-supplied respirator if ventilation is not SECTION 1: adequate to remove all fumes and gases. GENERAL INFORMATION • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. -
Page 8: Publications
• Protect others in the work area from the arc rays. Use protective booths, screens or shields. FIRE AND EXPLOSION • Use the shade of lens as recommended in Subsec- tion 1.03, item 4. Fire and explosion can be caused by hot slag, sparks, or the plasma arc. -
Page 9: Note, Attention Et Avertissement
12. CSA Standard W117.2, CODE FOR SAFETY IN 1.05 Precautions De Securite WELDING AND CUTTING, obtainable from the Ca- Importantes nadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 13. NWSA booklet, WELDING SAFETY BIBLIOGRA- AVERTISSEMENT PHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 L’OPÉRATION ET LA MAINTENANCE DU 14. - Page 10 • Utilisez un équipement spécial tel que des tables de • Prévoyez une veille d’incendie lors de tout travail coupe à débit d’eau ou à courant descendant pour dans une zone présentant des dangers d’incendie. capter la fumée et les gaz. •...
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Page 11: Documents De Reference
• Pour des renseignements sur la manière de tester le 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- bruit, consultez l’article 1, page 5. TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 1.06 Documents De Reference 02269 10. -
Page 12: Declaration Of Conformity
Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. -
Page 13: Statement Of Warranty
90 Days None 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. - Page 14 GENERAL INFORMATION...
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Page 15: Section 2: Introduction & Description
SECTION 2: INTRODUCTION & DESCRIPTION 2.01 SYSTEM SPECIFICATIONS Econo-pak 50 • Econo-pak 50 - The power supply provides 35 amps maximum Air Plasma Cutting output cutting current from a standard 208-230 volt, 60Hz AC System Includes: input service. All electrical, pilot, and gas control circuitry is included. -
Page 16: Torch Parts
2.02 TORCH PARTS Torch Parts Selection The same torch parts are used for drag cutting and standoff cutting. See Section 5.03, Replacing Consumable Torch Parts. Order replacement parts by catalog number and description. Shield Cup Attachment (Copper) Standard Shield Cup Catalog No. -
Page 17: Section 3: Installation
SECTION 3: INSTALLATION 3.01 UNPACKING AND CHOOSING A LOCATION What's Included with Included with each system is: the Power Supply (1) Work Cable with Clamp (Attached) (1) 230V Single-Phase, Three Wire Input Power Cable (Attached) (1) Operating Manual (1) Spare Parts Kit - Includes: (5) Drag Cutting Tips .......... -
Page 18: Gas Connections
3.03 GAS CONNECTIONS Gases Compressed Air or Nitrogen (N Only Pressure 60 psi (4.2 BAR) Flow 135 scfh (64 lpm) CAUTION Maximum input gas pressure must not exceed 125 psi (8.6 BAR). WARNING This cutting system must not be used with Oxygen (O CAUTION Air supply must be free of oil, moisture, and other contaminants. -
Page 19: Gas Connections (Continued)
3.03 GAS CONNECTIONS (Continued) To use shop air from a compressor, refer to Figure 3-A and: Air supply must be free of oil, moisture, and other contaminants. CAUTION 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. - Page 20 INSTALLATION Manual 0-2450...
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Page 21: Section 4: Operation
SECTION 4: OPERATION 4.01 OPERATING CONTROLS RUN/SET Switch AC Indicator Ready Indicator CURRENT Control POWER Switch PRESSURE Gauge PRESSURE Control A-01746 RUN position is used for torch operation. SET position is used for RUN/SET Switch setting gas pressure and purging lines. Green light indicates AC input power is present in the system when AC Indicator the ON/OFF switch is in ON position. -
Page 22: Getting Started
4.02 GETTING STARTED Disconnect primary power at the source before disassembling WARNING the power supply, torch, or torch leads. 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 Section 5.03, Replacing Consumable Torch Parts). -
Page 23: Operating The System
4.03 OPERATING THE SYSTEM Disconnect primary power at the source before disassembling WARNING the power supply, torch, or torch leads. Frequently review the Important Safety Precautions at the front of this Manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. -
Page 24: Operating The System (Continued)
4.03 OPERATING THE SYSTEM (continued) C o m m o n C u tti n g Pro b l e m s Pr o b le m Po s s i b l e C a u s e 1 . C u tt in g sp e e d to o f a st 2 . -
Page 25: Operating With A Hand Torch
4.04 OPERATING WITH A HAND TORCH Cutting with a 1. The torch can be comfortably held in one hand or steadied Hand Torch with two hands. Choose the technique that feels most com- fortable and allows good control and movement. Position the index finger or thumb to press the control switch on the torch handle. -
Page 26: Recommended Cutting Speeds
4.05 RECOMMENDED CUTTING SPEEDS Cutting speed depends on material, thickness, and the operator’s Recommended ability to accurately follow the desired cut line. The following Cutting Speeds factors may have an impact on system performance: • Torch parts wear • Air quality •... -
Page 27: Section 5: Customer/Operator Service
SECTION 5: CUSTOMER/OPERATOR SERVICE 5.01 TROUBLESHOOTING AND MAINTENANCE Basic troubleshooting of the Econo-pak 50 plasma cutting system General can be performed without special equipment or knowledge, and without opening the enclosure. This basic troubleshooting guide covers input power, gas supply, and torch problems. -
Page 28: Basic Troubleshooting Guide
5.02 BASIC TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE REMEDY A. AC indicator not lit. Fan 1. Circuit Breaker open. 1. Reset Breaker. Use 30 does not turn. amp service. B. AC indicator lit. READY 1. Unit is overheated. 1. Make sure the unit has indicator dark. -
Page 29: Replacing Consumable Torch Parts
5.03 REPLACING CONSUMABLE TORCH PARTS Disconnect primary power to the system before disassembling WARNING the torch, leads, or power supply. DO NOT TOUCH internal torch parts while the AC indicator on WARNING the front panel of the power supply is lit. The tip, gas distributor, and electrode are held in place by the NOTE shield cup. - Page 30 CUSTOMER/OPERATOR SERVICE Manual 0-2450...
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Page 31: Section 6: Parts Lists
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, Returns contact your Thermal Dynamics distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted. -
Page 32: Replacement - Complete Systems
Torch with Leads, Torch Spare Parts Kit, and Operating Manual. Description Catalog # Econo-Pak 50 with PCH-26 70° Torch 208/230 Volt Single Phase with 12.5 ft (3.8 m) Leads 1-3500-2 208/230 Volt Single Phase with 25 ft (7.6 m) Leads 1-3501-2 Econo-Pak 50 with PCH-26 90°... -
Page 33: Replacement Torch And Lead Assemblies
6.03 REPLACEMENT TORCH AND LEAD ASSEMBLIES Description Catalog # Replacement Torch With Leads Only: PCH-26 70° Hand Torch with 12.5 ft (3.8 m) Leads 2-3501 PCH-26 70° Hand Torch with 25 ft (7.6 m) Leads 2-3511 PCH-26 90° Hand Torch with 12.5 ft (3.8 m) Leads 2-3500 PCH-26 90°... -
Page 34: Options And Accessories
6.04 OPTIONS AND ACCESSORIES Description Catalog # Single Stage Air Filter Kit 7-0250 Replacement Air Filter Cartridge 7-0252 Dual Stage Air Filter 7-3500 First Stage Replacement Cartridge 9-1021 Second Stage Replacement Cartridge 9-1022 Smart Cart 7-7777 Circle Cutting Guide 7-3291 Spare Parts Kit 5-3500 Tip, Air, 0.031 inch Orifice, Drag Cutting... -
Page 35: Replacement Hand Torch Parts
6.05 REPLACEMENT HAND TORCH PARTS Item # Description Catalog # Assembly, PIP (Parts-In-Place) Pins and Wire 9-6290 O-Ring 8-0533 Holder, Torch, Split, PCH-26 70° Two Parts w/Screws 9-6259 Holder, Torch, Split, PCH-26 90° Two Parts w/Screws 9-6260 Assembly, Basic Head, PCH-26 70° 9-5807 Assembly, Basic Head, PCH-26 90°... - Page 36 PARTS LISTS Manual 0-2450...
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Page 38: Appendix I: System Schematic
APPENDIX I: SYSTEM SCHEMATIC A-01747 APPENDIX Manual 0-2450... - Page 39 Econo-pak 50 System Schematic A-01747 Manual 0-2450 APPENDIX...
- Page 40 APPENDIX Manual 0-2450...
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