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SAFETY

1-2

Hypertherm

Plasma Systems

11-98

SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to

identify potential hazards. When you see a safety
symbol in this manual or on your machine, understand
the potential for personal injury, and follow the related
instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and
safety labels on your machine.

• Keep the safety labels on your machine in good

condition. Replace missing or damaged labels
immediately.

• Learn how to operate the machine and how to use

the controls properly. Do not let anyone operate it
without instruction.

• Keep your machine in proper working condition.

Unauthorized modifications to the machine may
affect safety and machine service life.

DANGER

WARNING

CAUTION

A signal word DANGER or WARNING is used with a
safety symbol. DANGER identifies the most serious
hazards.

• DANGER and WARNING safety labels are located

on your machine near specific hazards.

• WARNING safety messages precede related

instructions in this manual that may result in injury
or death if not followed correctly.

• CAUTION safety messages precede related

instructions in this manual that may result in
damage to equipment if not followed correctly.

Fire Prevention
• Be sure the area is safe before doing any cutting.

Keep a fire extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the

cutting area.

• Quench hot metal or allow it to cool before handling

or before letting it touch combustible materials.

• Never cut containers with potentially flammable

materials inside – they must be emptied and
properly cleaned first.

• Ventilate potentially flammable atmospheres before

cutting.

• When cutting with oxygen as the plasma gas, an

exhaust ventilation system is required.

Explosion Prevention
• Do not use the plasma system if explosive dust or

vapors may be present.

• Do not cut pressurized cylinders, pipes, or any

closed container.

• Do not cut containers that have held combustible

materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.

WARNING

Hydrogen Detonation with Aluminum Cutting

• When cutting aluminum underwater, or with the

water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.

• Install an aeration manifold on the floor of the water

table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.

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Summary of Contents for PAC500

Page 1: ...Water Injection Plasma Cutting System Instruction Manual 800370 Revision 4 PAC500 ...

Page 2: ... Copyright 2001 Hypertherm Inc All Rights Reserved Hypertherm HyDefinition HT HyLife LongLife MAX PAC and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Hanover NH USA www hypertherm com ...

Page 3: ...ublic of Singapore 65 841 2489 Tel 65 841 2490 Fax 65 841 2489 Technical Service Japan 1952 14 Yata Natsumegi Mishima City Shizuoka Pref 411 0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax Hypertherm UK Ltd 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax France 15 Impasse des Rosiers 95610 Eragny France 0805 050 111 Tel 0805 050 222 Fax Hyp...

Page 4: ...nnection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be au thorized by a person who is competent to assess whether the changes will increase the ris...

Page 5: ...herm PATENT INDEMNITY Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against...

Page 6: ...onsignes de sécurité 1a 2 Suivre les instructions de sécurité 1a 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Les chocs électriques peuvent être fatals 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Mise à la masse et à la terre 1a 4 Les rayons de l arc peuvent brûler les yeux et la peau 1a 4 Sécurité des bout...

Page 7: ...n 4 OPERATION Operating Instructions 4 2 Applications Data 4 2 Thickness Range 035 in to 3 in 4 2 Table I Nozzle Thickness Ranges and Limits 4 3 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 ...

Page 8: ...ection 6 PARTS LIST Model 500 Torch 6 2 Torch Leads Package 6 4 Operator Panel Leads Package 6 7 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 BENZOTRIAZ...

Page 9: ...n Kill 1 3 Cutting Can Produce Toxic Fumes 1 3 A Plasma Arc Can Cause Injury and Burns 1 4 Arc Rays Can Burn Eyes and Skin 1 4 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 ...

Page 10: ... sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres...

Page 11: ... on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge N...

Page 12: ...ant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect o...

Page 13: ...s possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible PACEMAKER AND HEARING AID OPERATION ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and...

Page 14: ...cutting path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use fo...

Page 15: ...vention des chocs électriques 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Torches à allumage instantané 1a 4 Les rayons de l arc peuvent brûler les yeux et la peau 1a 4 Protection des yeux Protection de la peau Zone de coupage 1a 4 Mise à la masse et à la terre 1a 4 Câble de retour Table de travail Alimentation 1a 4 Sécurit...

Page 16: ...e sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais ...

Page 17: ...lors du coupage Laisser la pièce à couper en place ou sur la table de travail le câble de retour connecté lors du coupage Avant de vérifier de nettoyer ou de remplacer les pièces de la torche couper l alimentation ou débrancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de sécurité Avant d enlever le capot du système ou de la source de courant couper l alimentati...

Page 18: ...osées du corps Pantalon sans revers pour éviter que des étincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette Peindre les murs et autres surfaces de couleur sombre pour réduire...

Page 19: ...e jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs Utiliser un casque de protection homologué lors de l utilisation du système plasma Prévenir les pe...

Page 20: ... peut être fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4...

Page 21: ...CIFICATIONS 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 ...

Page 22: ... higher degree of arc constriction than can be achieved by conventional means The net result is an extremely hot high velocity plasma jet capable of producing excellent cut quality at high cutting speeds Nozzle life is longer with the Water injection process because water cools the nozzle at the point of maximum arc constriction The protection afforded by the water also allows the entire lower por...

Page 23: ...pm Electrode Cooling Water Flow 1 6 gpm Dimensions 2 in dia x 17 5 long Weight 3 5 lbs without service lines 15 lbs with 20 ft service lines Control Console Electrical Input 120 VAC 50 60 Hz 5 amperes Cutting Gas Supply nitrogen 260 cfh max at 150 psi 65 argon 35 hydrogen 300 cfh max at 150 psi Water Supply 2 5 gpm at 175 psi includes both electrode and cut water flow Dimensions Width 13 in Height...

Page 24: ...Supply 65 Argon 35 Hydrogen 260 cfh to 300 cfh 150 psi Dimensions Width 5 in Height 10 in Depth 5 in Water Supply single torch Input Voltage 230 460 volts 3 phase Input Current 6 0 3 0 amperes Rated Pump Output 2 5 gpm at 175 psi Dimensions Width 10 in Height 24 in 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 ...

Page 25: ...ly 3 2 Water Quality 3 2 Drain 3 2 Gas Supply 3 2 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 ...

Page 26: ...acceptable level of 0 1 grains Hardness 300 ppm Iron 0 3 ppm Silica 15 0 ppm Total Dissolved Solids 350 ppm PH 6 5 to 8 5 A water softener is not adequate if impurities in the untreated water exceed the above levels a reverse osmosis system or other de ionizing equipment must be used Drain The water pump system circulates 1 6 gallons min 6 liters min to the cathode when the control console is on A...

Page 27: ... such as wiring the power supply to the disconnect box have the job inspected before proceeding An electrical and plumbing interconnection diagram for the PAC500 Plasma Cutting System is shown in figure 1 page 5 12 Control Console 1 Mount the control console on the cutting machine and secure with clamps or screws Power Supply 1 Unpack the power supply and insect for shipping damage 2 Connect a gro...

Page 28: ...h ground 2 Connect each power supply to a suitably fused disconnect box 3 Connect the power supply outputs in parallel positive to positive and negative to negative 4 Connect the auxiliary contactor control relay coils in parallel This may be done on H400 and H600 power supplies by means of the eight foot contactor paralleling cable Part No 023011 H401 and H601 power supplies do not use a stock ca...

Page 29: ...rator s Panel Interface connections are made to terminal strip 4TB located inside the operator s panel Control power 120 VAC is connected to 4TB 1 and 4TB 2 L1 L2 The START STOP pushbutton station supplied as an optional accessory item is connected to the terminal strip 4TB The START normally open contacts are connected to the 4TB 5 and 4TB 6 and the STOP normally closed contacts are connected to ...

Page 30: ... connected in parallel with the existing pressure switch 1PS to provide protection from loss of plasma gas These leads are numbered and are connected to 3TB 10 and 3TB 25 The Argon Hydrogen solenoid 3 SOL is paralleled with the water solenoid 1 Sol These leads are also numbered and are connected to 3TB 2 and 3TB 9 5 Connect the gas supply hose to the fitting located at the rear of the manifold Con...

Page 31: ... will go out automatically after about 2 seconds 13 Make a test cut with the 166 nozzle on 3 8 to 3 4 10 to 20mm thick scrap plate Adjust the power supply to the required setting for the material being cut Refer to Cut Charts for recommended operating parameters Do not exceed the current limit of the nozzle in use Press the start button to initiate the arc When the arc is established start the mac...

Page 32: ...Range 035 in to 3 in 4 2 Table I Nozzle Thickness Ranges and Limits 4 3 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 ...

Page 33: ... automatically by the control or manually by the operator If heavy plate is cut a torch travel delay will be necessary One second torch travel delay per inch of plate thickness is a good rule of thumb 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 inject...

Page 34: ... action causes the right hand side of the kerf to be square and the left hand side to be bevelled hence it is important that the direction of travel be selected so that the bevelled side is on scrap For example the outside diameter of a flange is cut with the torch traveling clockwise while the inside diameter is cut counterclockwise This results in the flange having a high quality edge on both cu...

Page 35: ... used instead of nitrogen because it produces a deeper penetrating arc This mixture is available in commercial high pressure cylinders Some gas distributors may not routinely stock this mixture but since it is readily available they will usually stock it if requested to do so It is possible to mix the gases on site with a gas proportioning device but this is not recommended due to the capital inve...

Page 36: ... cause severe arcing and destroy the torch It may also cause rapid nozzle wear without any obvious arcing Do not operate the Water Muffler when cutting in the conventional mode Remove the Water Muffler from the torch body to prevent damage from reflected heat from the arc Lower the water level in the Water Table to four or more inches below the bottom surface of the workpiece These steps prevent t...

Page 37: ...3 8 10 165 600 60 1525 1 1 4 32 Maximum current for this nozzle is 600 amp 3 8 10 175 600 45 1145 1 1 4 32 1 2 13 185 700 50 1270 1 1 2 38 220 N2 70 100 1 2 13 195 700 40 1005 1 3 4 44 1 2 13 200 725 35 890 2 50 Maximum current for this nozzle is 750 amp 1 2 13 205 725 30 760 Use the brass tapered retaining cap part no 020034 above 400 amperes To obtain optimum cut quality plasma arc cutting nozzl...

Page 38: ...mum current for this nozzle is 400 amp 1 4 6 155 400 100 2540 3 4 19 5 16 8 160 400 50 1270 1 25 3 8 10 165 400 30 760 3 4 19 3 8 10 165 500 75 1905 2 25 187 N2 45 75 3 8 10 165 550 60 1525 1 1 2 38 3 8 10 170 580 30 760 2 50 Maximum current for this nozzle is 600 amp 3 8 10 170 600 20 510 2 50 1 2 13 190 700 25 635 3 75 220 N2 70 100 5 8 16 200 750 12 305 Maximum current for this nozzle is 750 am...

Page 39: ...5 260 180 4570 1 8 3 1 4 6 140 300 240 6095 1 4 6 1 4 6 145 325 180 4570 3 8 10 166 N2 45 75 1 4 6 150 350 150 3810 1 2 13 1 4 6 155 375 120 3050 3 4 19 Maximum current for this nozzle is 400 amp 5 16 8 160 400 60 1525 1 25 3 8 10 165 400 35 915 1 25 3 8 10 165 550 70 1830 1 1 2 38 187 N2 45 75 3 8 10 170 550 35 915 2 50 Maximum current for this nozzle is 600 amp 3 8 10 170 600 25 610 2 50 220 N2 ...

Page 40: ... Type and Flowmeter Setting Injection Water Flow Setting Torch to Work Distance Inches mm Arc Voltage Setting Volts Arc Current Setting Amperes Travel Speed ipm mm min Titanium 1 2 13 90 2285 Brass 1 2 13 166 N2 45 75 1 4 6 155 400 70 1780 Copper 1 2 13 60 1525 Cast Iron 5 8 16 80 2030 Titanium 1 25 50 1270 Copper Nickel 20 1 25 187 N2 45 75 3 8 10 165 550 45 1145 ...

Page 41: ...d nozzle retaining cap part no 020034 High Current Cutting is conventional cutting It does not use the Water Injection principle The water sprayed from the nozzle is for nozzle cooling purposes only It does not constrict the arc Always remove the Water Muffler and lower the water level in the Water Table when operating in the High Current Mode Caution Use of the Inductive IHS at high currents may ...

Page 42: ...ozzle 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 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 ...

Page 43: ...ch on the cutting machine operator s panel to OFF 2 Unscrew the retaining cap and remove the nozzle by hand 3 Before replacing the nozzle apply a light coat of silicone grease to the O ring that is on the O D of the copper portion of the nozzle 4 Insert the nozzle into the torch and push into place 5 When replacing the retaining cap tighten snugly by hand to insure good electrical contact between ...

Page 44: ...electrode as outlined previously 2 Remove the swirl ring from the electrode and inspect for plugged holes or other damage 3 Before replacing the swirl ring apply a light coat of silicone grease to both O rings Do not apply an excessive amount of grease because the grease can plug the swirl ring ports As a general rule of thumb you should be able to feel the grease but not see it 4 Insert the swirl...

Page 45: ...or humming or rattling sound coming from the torch If you suspect a problem with the water tube you may need to replace it 1 Remove all consumables from torch see above 2 Look for any damage or bends in the water tube The water tube should be recessed from the face of the torch head by about 11 32 8 5 mm Check for tightness 3 Remove and replace the water tube 120035 by using the water tube wrench ...

Page 46: ...ode The TEST mode allows the control to be cycled without the DC power coming on When placed in the TEST position the TEST RUN switch line 5 deactivates the TEST RUN relay 1CR line 5 so that NO contacts of 1CR opens both the circuit which controls the power supply contactor CON line 13 and the circuit which initiates machine start line 26 The High Frequency Generator does not operate in the TEST m...

Page 47: ...tch is placed in the RUN Mode The NO contacts line 5 of the TEST RUN switch close energizing 1CR This closes the 1CR NO contacts in the power supply contactor control circuit line 13 and in the machine start circuit line 26 When the START button is actuated CRM is latched and CON is energized through 1CR 1FLS 2FLS flowswitch and 1PS pressure switch A water flow of at least 25 gpm to the nozzle is ...

Page 48: ...lve closed 4 Gas supply not on or pressure too low 150 psig req d 5 Console door interlock switches open 6 Low water pressure a Replace filter at water supply b Adjust water supply bypass valve to obtain 175 psig Refer to page 3 6 System Check Out item no 8 C Contacter Light GREEN ON but arc does not strike 1 No high frequency at torch High Frequency Check a Turn power supply disconnect switches O...

Page 49: ...ot transfer 1 Excessive torch to work distance see Section 4 Applications Data 2 Poor ground connection to workpiece a This problem may be caused by a buildup of heavily oxidized metal on the slats of the cutting table Connect the ground lead directly to the workpiece If this cures the problem clean or replace the support slats 3 Heavy layer of scale or primer on the workpiece E Torch dives into w...

Page 50: ... be virtually nonexistent or if it is present easily removed Positive Cut Angle 1 Wrong direction of travel High quality side is on the right with respect to the forward motion of the torch except where CCW Swirl Ring Part No 020042 is used 2 Excessive torch to work distance 3 Excessive cutting speed 4 Arc current set too low 5 Damaged nozzle Negative Cut Angle 1 Torch to work distance is too low ...

Page 51: ...0 Specify Model H601 Power Supply 036031 replaces 036015 Specify Power Supply Leads Pkg 028009 Specify Water Supply System 028291 1 Cooling Water Leads Pkg 1 torch 028010 1 Spare Parts Kit 028041 1 Optional Accessories Remote Start Stop Station 028005 1 Argon Hydrogen Manifold 028057 1 Water Muffler System 034001 1 AVM 1 Arc Voltage Monitor 051001 1 THC 1 Torch Height Control 050001 1 THC 1 RVC Re...

Page 52: ... 036035 replaces 036010 Specify Model H601 Power Supply 036031 replaces 036015 Specify Power Supply Leads Pkg 028009 Specify Water Supply System 028320 1 Cooling Water Leads Pkg 2 torch 028013 2 Spare Parts Kit 028041 2 Optional Accessories Argon Hydrogen Manifold 028057 2 Water Muffler System 034001 2 AVM 1 Arc Voltage Monitor 051001 2 THC 1 Torch Height Control 050001 2 THC 1 RVC Remote Voltage ...

Page 53: ...5 12 PAC500 Instruction Manual 4 MAINTENANCE Figure 1 PAC500 Schematic Layout ...

Page 54: ...R S PANEL 2 RECP POWER SUPPLY WATER DRAIN GAS SUPPLY GAS Green hose coded green WATER Black hose coded green WATER Black hose coded red GAS Green hose coded red Connections within square are for Operator s Panel only WATER IN PUMP TO FLOWMETER GREEN TO FLOWMETER RED WATER OUT GAS IN GAS WATER Figure 2 Service Connections ...

Page 55: ... Manual 4 MAINTENANCE NOZZLE WATER Red hose LH fitting GAS Green hose Attach braided metal sheath to feedthrough WATER OUT GAS OUT Figure 3 Torch Connections FEEDTHROUGHS FOR WATER COOLED TORCH POWER CABLES AND PILOT ARC WIRE ...

Page 56: ...PAC500 Instruction Manual 5 15 4 MAINTENANCE Figure 4 Direction of Cut Figure 5 Cut Angle ...

Page 57: ...NANCE TERMINAL STRIP 2TB ARC DETECION CIRCUIT PILOT ARC RELAY 4CR TANK CAPACITOR C1 2 SPARK GAP ASSEMBLY 020 inch 5 mm gap FUSE 10 amps COUPLING CAPACITORS C2 C3 TANK COIL HIGH VOLTAGE TRANSFORMER HVT FILTER Figure 6 High Frequency Generator ...

Page 58: ...R SOLENOID 1SOL rear GAS PRESSURE SWITCH 1PS FLOWSWITCH 1FLS rear Electrode cooling 1 2 gpm Refer to pages 6 20 6 21 and 6 22 for mounting details and part numbers of the Kobold flow switches which now replace the flow switches shown FLOWSWITCH 2FLS front Nozzle cooling 25gpm H F SUPPRESSION CAPACITOR C4 CATHODE BLOCK WATER COOLED RESISTOR R2 3OHMS ...

Page 59: ...Y BOARD TERMINAL STRIP 1TB 1 T R P R E F L O W D E L A Y 5 S E C 2 T R H I G H F R E Q U E N C Y T I M E R W S E C C R M M A S T E R C O N T R O L R E L A Y 2 C R M A C H I N E S T A R T R E L A Y 3 C R V O L T A G E S E N S I N G R E L A Y 1 C R T E S T 1 R U N R E L A Y ...

Page 60: ...PAC500 Instruction Manual 5 19 4 MAINTENANCE Figure 9 Plasma Console Electrical Schematic ...

Page 61: ...5 20 PAC500 Instruction Manual 4 MAINTENANCE Figure 10 Operator s Panel Electrical Schematic 2 Torch ...

Page 62: ...eads Package 6 4 Operator Panel Leads Package 6 7 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 ...

Page 63: ...6 2 PAC500 Instruction Manual 4 PARTS LIST Model 500 Torch 1 2 3 4 3 6 7 5 3 ...

Page 64: ...le 166 2 O rings included 1 020036 Nozzle 187 2 O rings included 020037 Nozzle 220 2 O rings included 020047 Nozzle 250 2 O rings included 6 020039 Swirl Ring 166 and 187 Nozzle 1 020040 Swirl Ring 220 Nozzle 020042 Swirl Ring CCW 166 and 187 Nozzle 020048 Swirl Ring 250 Nozzle 7 020043 Nozzle Retaining Cap Flared 1 020034 Nozzle Retaining Cap Tapered Components that come with 028031 torch See pag...

Page 65: ...6 4 PAC500 Instruction Manual 4 PARTS LIST Torch Leads ...

Page 66: ...gh Frequency Lead 1 4 024027 Gas Hose Green RH 1 5 024033 Water Hose Red LH 1 6 046033 HV Vinyl Hose Sheath 15 ft 7 046114 RF Braided Shield 15 ft Torch Leads 20 ft Part No 028139 1 004080 Shield Collar Ring 1 2 023012 Water Cooled Cable 2 3 023036 High Frequency Lead 1 4 024017 Gas Hose Green RH 1 5 024018 Water Hose Red LH 1 6 046033 HV Vinyl Hose Sheath 20 ft 7 046114 RF Braided Shield 20 ft To...

Page 67: ...14 RF Braided Shield 30 ft Torch Leads 35 ft Part No 028142 1 004080 Shield Collar Ring 1 2 023015 Water Cooled Cable 2 3 023039 High Frequency Lead 1 4 024030 Gas Hose Green RH 1 5 024036 Water Hose Red LH 1 6 046033 HV Vinyl Hose Sheath 35 ft 7 046114 RF Braided Shield 35 ft Torch Leads 40 ft Part No 028143 1 004080 Shield Collar Ring 1 2 023016 Water Cooled Cable 2 3 023040 High Frequency Lead ...

Page 68: ...ST Operator Panel Leads Packages 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 ...

Page 69: ...6 8 PAC500 Instruction Manual 4 PARTS LIST Remote Stop Start 6 3 2 1 4 5 ...

Page 70: ...Stop Start Part No 028005 Item Part No Description Qty 1 005021 Enclosure 1 2 005022 Pushbutton Green Start 1 3 005023 Pushbutton Red Stop 1 4 008043 3 4 NPT X 18 3 Strain Relief 1 5 008643 Lock washer Used on 008043 1 6 047005 Cord 6 4 SO UL CSA 20 ft ...

Page 71: ...6 10 PAC500 Instruction Manual 4 PARTS LIST Argon Hydrogen Manifold 14 ...

Page 72: ...owmeter 1 4 015001 Bulkhead Adapter 1 5 015014 Adapter 900 1 2 NPT x 4 2 6 015048 Adapter 1 4 NPT x Oxy A 1 7 015009 Adapter 1 4 NPT x Oxy B 1 8 005046 Pressure Switch Enclosed 1 9 015510 1 4 NPT Close Nipple Brass 3 10 015512 1 4 NPT x 3 1 2 Nipple Brass 1 11 024041 4 J1C Hose Assembly 7 1 12 015541 1 4 NPT Tee 1 13 015551 1 4 NPT Coupling 1 14 008047 Strain Relief 1 ...

Page 73: ...6 12 PAC500 Instruction Manual 4 PARTS LIST 1 Torch Operator s Panel ...

Page 74: ...5018 Switch TEST RUN 1 4 014182 Xfmr IDEC AP6 AC Adptr 2 109009 Plt Lt Wht 6VDC LED 1 5 014182 Xfmr IDEC AP6 AC Adptr 1 109008 Plt Lt Grn 6VDC LED 6 008052 Strain Relief Basket Weave 1 7 008073 4TB Terminal Strip 16 1 8 011005 Flowmeter 2 9 015005 Adapter 1 4NPT X 4 JIC 2 10 015014 Adapter 90 deg 1 4NPT X 4 JIC 2 028212 Flowmeter Fittings Kit 1 Parts not shown in drawing ...

Page 75: ...6 14 PAC500 Instruction Manual 4 PARTS LIST 2 Torch Operator s Panel ...

Page 76: ... Switch ON OFF 2 5 005018 Switch TEST RUN 1 6 014182 Xfmr IDEC AP6 AC Adptr 4 109009 Plt Lt Wht 6VDC LED 2 7 014182 Xfmr IDEC AP6 AC Adptr 2 109008 Plt Lt Grn 6VDC LED 2 8 008052 Strain Relief Basket Weave 2 9 008073 4TB Terminal Strip 16 2 10 011005 Flowmeter 4 11 015005 Adapter 1 4NPT X 4 JIC 4 12 015014 Adapter 90 deg 1 4NPT X 4 JIC 4 028212 Flowmeter Fittings Kit 1 009171 Resistor 120K ohm 1 P...

Page 77: ...6 16 PAC500 Instruction Manual 4 PARTS LIST Gas and Water Flowmeter 9 8 7 5 5 6 3 10 11 12 5 4 2 13 1 ...

Page 78: ...011029 Frame assembly 2 011019 Outlet adapter 3 011014 Float stop 4 011013 Adapter clip 5 025010 O ring Kit Adapter O ring Inlet adapter O ring Spindle O ring 6 011020 Inlet adapter 7 011018 Valve spindle 8 011021 Valve plug 9 011012 Control knob 10 011008 Shield 11 011006 Meter tube 12 011007 Float 13 011009 Wide spacer ss clip ...

Page 79: ...ruction Manual 4 PARTS LIST Electrical Compartment PAC500 Console 1 24 23 9 15 21 12 6 5 10 18 33 28 25 8 30 24 23 31 32 26 4 29 4 29 2 29 2 29 2 29 3 29 20 22 11 7 16 13 Torch Pilot Arc Lead Connection 14 17 19 27 7a ...

Page 80: ...80 Capacitor 002UF 15KV 2 004144 Bar Spark Gap Capacitor Mounting 1 13 009246 Capacitor 5 UF 2 14 009043 High Frequency Coil Tank Coil 1 15 009044 Spark Gap Assembly 1 16 009247 Mtg Bracket for 5 Mfd Caps 4 17 014004 Transformer 5KV 1 029007 Arc Detection Circuit 1 18 004052 Base 1 19 009025 Choke 5 mh 1 20 009026 Diode Zener 2 21 009027 Resistor 10 K ohm 1 22 009061 Tie Point 4 2 029039 Main Wiri...

Page 81: ...6 20 PAC500 Instruction Manual 4 PARTS LIST Plumbing Compartment PAC500 Console ...

Page 82: ...PAC500 Instruction Manual 6 21 4 PARTS LIST Plumbing Compartment with Kobold Flow Switches ...

Page 83: ...9 3 8 2 21 024040 Hose assembly 4 x 12 1 22 024057 Hose assembly 6 x 4 7 8 1 024090 Hose assembly 6 x 20 1 029005 Water manifold subassembly 1 23 004276 Manifold block 1 24 006009 Solenoid valve 1 25 015005 Adapter 1 4 NPT x 4 JIC 1 26 015047 Adapter 1 4 NPT x acc A 1 27 015510 Nipple 1 4 NPT x close 1 015561 Plug 1 4 NPT 2 029009 Gas manifold IHS subassembly 1 28 004276 Manifold block 1 29 005231...

Page 84: ...apter 1 4NPT X 6 JIC 2 45 015014 Adapter 90 deg 1 4NPT X 4 JIC 1 46 015015 Adapter 90 deg 1 4NPT X 6 JIC 1 47 015510 Nipple 1 4NPT X Close 2 015561 Plug 1 4NPT 1 48 Bolt Brass 1 2 13 X 3 4 2 49 Washer Brass 1 2 2 Note Older systems without the manifold block use flowswitch part numbers 005053 25 gpm and 005054 1 4 gpm Plumbing Compartment PAC500 Console continued Item Part No Description Qty ...

Page 85: ...6 24 PAC500 Instruction Manual 4 PARTS LIST Water Supply System 21 23 24 25 20 16 15 14 13 11 12 9 8 1 3 19 18 17 26 6 6 6 7 22 8 5 4 7 2 5 6 8 12 12 10 ...

Page 86: ...ss 1 10 1 211 Hose x 5 1 4 long 1 11 1 1 4 NPT x 1 4 NPT Reducer 1 Bushing Brass 12 3 4 NPT x Close Nipple Brass 3 13 3 4 NPT 900 Elbow Brass 1 14 3 4 NPT x 311 Nipple Brass 1 15 027004 Filter Assembly 1 16 027005 Filter Element 1 17 027006 Filter Cover O ring 1 18 027007 Filter Nut Gasket 1 19 022004 Pressure Gauge 0 300 psi 1 20 015029 Adapter 1 2NPT x 8 JlC 1 21 022007 1 4 NPT Adaptor 1 015580 ...

Page 87: ...tion 9 Physical and Chemical Properties a 4 Section 10 Stability and Reactivity a 4 Section 11 Toxicological Information a 4 Section 12 Ecological Information a 5 Section 13 Disposal Considerations a 5 Section 14 Transport Information a 5 Section 15 Regulatory Information a 5 Section 16 Other Information a 5 Benzotriazole COBRATEC Safety Data Section I a 7 Section II Ingredients a 7 Section III Ph...

Page 88: ...a 2 PAC500 Instruction Manual 4 ...

Page 89: ...PAC500 Instruction Manual a 3 4 ...

Page 90: ...a 4 PAC500 Instruction Manual 4 ...

Page 91: ...PAC500 Instruction Manual a 5 4 ...

Page 92: ...a 6 PAC500 Instruction Manual 4 Figure a 1 Freezing Point of Propylene Glycol Solution of Propylene Glycol Temperature F 70 60 50 40 30 20 10 0 10 20 30 40 0 10 20 30 40 50 60 ...

Page 93: ...PAC500 Instruction Manual a 7 4 ...

Page 94: ...a 8 PAC500 Instruction Manual 4 ...

Page 95: ...PAC500 Instruction Manual a 9 4 ...

Page 96: ...a 10 PAC500 Instruction Manual 4 ...

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