PAC-500
Flow Switch Upgrade
Instructions
801230 - Rev. 0
PAC-500
Flow Switch Upgrade
Kit # 028485
Instructions
IM-123
(P/N 801230)
Revision 0 December 1990
Hypertherm, Inc.
P.O. Box A-10 Etna Road
Hanover, New Hampshire 03755
(603) 643-3441
© Hypertherm, Inc., 1990
All Rights Reserved
Purpose
The PAC-500 flow switch upgrade instructions provide the necessary information to allow the
removal of the existing two flow switches and replacing them with the Kobold flow switch subassembly.
Customer Supplied Tools
Straight blade screwdriver
7/16" (11.11 mm) open-end wrench
9/16" (14.29 mm) open-end wrench
11/16" (17.46 mm) open-end wrench
1/4" (6.35 mm) hex wrench
Flow Switch Assembly Upgrade Kit (# 028485)
Kobold flow switch SA, PAC-500, # 029545
Flow switch, 0.25 GPM 1/4 NPT SPST, # 005139
Flow switch, 1.20 GPM 1/4 NPT SPST, # 005140
Flow switch manifold, # 004457
Plug 1/4, # 015561
Tyrap (5), # 074005
PAC-500 FLOW SWITCHES
Procedure
Remove Existing Flow Switches
To remove the existing flow switches from the PAC-500 Console, refer to the following procedure
and the figures called out in the PAC-500 Water-Injection Plasma Arc Cutting System Instruction
Manual IM-37 (P/N 800370).
1. Prior to proceeding with the upgrade installation, shut the power supply downat the front
2. Open the cover to access the plumbing compartment. Locate flow switches 1FLS and 2FLS
3. Remove the tyraps from around the flow switch leads which are connected to terminal strip
4. Disconnect the four (4) flow switch leads from 3TB. These leads are marked 9, 15 (two
5. Disconnect and discard hose assembly (024057) between flow switch 1FLS (005054) and the
6. Disconnect hose assembly (024040) only at flow switch 2FLS (005053).
panel and turn off power at the disconnect box. Disconnect the gas supply to the power
supply. Disconnect the water supply to the power supply.
Refer to Figure 8.
3TB.
leads), and 25.
cathode block.
7. Remove the two (2) screws, washers, and nuts to remove the flow switch SA.
UPGRADE INSTRUCTIONS
Page 1
PAC-500 FLOW SWITCHES
Install Upgrade Kit
To install the Kobold flow switch manifold subassembly upgrade kit, refer to Figure 1.
1. Position the Kobold flow switch manifold subassembly where the removed flow switch
assembly was mounted. Secure with the two (2) screws, washers, and nuts.
2. Route the flow switch leads to terminal strip 3TB. Connect leads to the terminal strip as
shown.
3. Replace Tyraps to secure flow switch leads.
4. Connect hose assembly (024090), which is part of PAC-500 upgrade kit, between the cath-
ode block and Kobold flow switch1FLS (005140/1.20 GPM).
5. Reconnect hose assembly end (024040) to Kobold flow switch 2FLS (005139/.25 GPM).
UPGRADE INSTRUCTIONS
Page 2
PAC-500 FLOW SWITCHES
Flow Sw 1FLS
(1.40 gpm)
005141
Flow Sw 2FLS
(0.25 gpm)
005139
3TB
Flow Switch
Leads
Hose Assy
024090
Manifold
004457
Cathode
Block
Screws
Hose Assy
024040
Figure 1 PAC-500 Upgrade Kit Installation
UPGRADE INSTRUCTIONS
Page 3
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