Thermal Dynamics PAK 200 Operating Manual

460V /
208­ 230

200

®

PAK

PLASMA CUTTING SYSTEM

Operating Manual

Rev. AB Date: October 8, 2008 Manual # 0-5057
Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800-426­1888, 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. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid po­tential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators

Worldwide.

Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through market­leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically ad­vanced products to achieve a safer working environment within
the welding industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat­ing, or servicing the equipment.

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:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

© Copyright 2008 by
Thermadyne Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission
of the publisher is prohibited.

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 this
Manual, whether such error results from negligence, accident, or any
other cause.

Printed in the United States of America

Original Publication Date: June 9, 2008
Revision AB Date: October 8, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

This page intentionally blank

TABLE OF CONTENTS

SECTION 1: GENERAL INFORMATION ................................................................................. 1-1

1.01 Notes, Cautions and Warnings ...................................................................

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

2.01 General Description Of The System ...........................................................

2.02 Plasma Power Supply ................................................................................. 2-1

2.03 Gas Control Module / Arc Starter................................................................2-1

2.04 Plasma Cutting Torch ..................................................................................

2.05 System Component Layout .........................................................................2-1

2.06 Power Supply Specifications & Electrical Requirements ............................2-2

2.07 Power Supply Dimensions ..........................................................................2-3

2.08 Power Supply Rear Panel Features ............................................................2-4

2.09 Gas Requirements ......................................................................................2-5

2.10 Gas Applications .........................................................................................2-5

2.11 PCH/M 200 Torch Specifications ................................................................2-6

1-1

2-1

2-1

SECTION 3: INSTALLATION ..................................................................................................3-1

3.01 Installation Requirements ...........................................................................3-1

3.02 Cables and Leads Identification .................................................................. 3-2

3.03 Cables and Leads Identification .................................................................. 3-3

3.04 Position the Power Supply ..........................................................................3-4

3.05 Primary Power Connections .......................................................................3-5

3.06 Connect Work Cable ................................................................................... 3-8

3.07 Connect Gas Supply Lines .........................................................................3-9

3.08 Connect Torch Control Cable ....................................................................3-10

3.09 Set Switches for Command-Control Module ............................................. 3-11

3.10 Connect Torch Leads to the Gas Control Module / Arc Starter .................3-13

3.11 Torch Parts Selection ................................................................................3-15

3.12 Complete the Installation ..........................................................................3-17

TABLE OF CONTENTS

SECTION 4: OPERATION ......................................................................................................4-1

4.01 Power Supply Indicators .............................................................................

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 Coolant Replacement Procedure ................................................................ 5-2

5.03 Arc Starter Service .....................................................................................5-3

5.04 Arc Starter Spark Gap Adjustment .............................................................5-4

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................ 6-1

6.01 Replacement Power Supply ........................................................................6-1

6.02 System Componants and Accessories .......................................................6-2

6.03 Leads and Cables .......................................................................................6-3

6.04 Leads and Cables .......................................................................................6-4

6.05 Optional Gas Supply Leads ........................................................................6-5

6.06 Power Supply External - Replacement Parts ............................................. 6-6

6.07 Power Supply Replacement Parts - Right Side.........................................6-7

6.08 Power Supply Replacement Parts - Right Side...........................................6-8

6.09 Power Supply Replacement Parts - Right Side..........................................6-9

6.10 Power Supply Replacement Parts - Front Panel .......................................6-10

6.11 Power Supply Replacement Parts - Left Side/Front Panel ........................ 6-11

6.12 Power Supply Replacement Parts - Left Side ........................................... 6-12

6.13 Power Supply Replacement Parts - Rear Panel .......................................6-13

6.14 Power Supply Replacement Parts - Right Side.........................................6-14

6.15 Power Supply Replacement Parts ............................................................6-15

6.17 Power Supply Replacement Parts ............................................................6-17

6.18 Power Supply Replacement Parts - Right Side.........................................6-18

6.19 Power Supply Replacement Parts - Right Side.........................................6-19

6.20 Arc Starter & Gas Control Module (GCM-200) Replacement Parts .......... 6-20

6.21 Command & Control Module - Replacement Parts .................................. 6-21

4-1

TABLE OF CONTENTS

SECTION 7: TORCH MAINTENANCE ...................................................................................7-1

7.01 Introduction .................................................................................................

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 ........................................................................................... 1

APPENDIX 2: Control Cable Pinouts ........................................................................................... 2

APPENDIX 3: Command-Control PC Board Layout (A) ..............................................................3

APPENDIX 4: Command-Control PC Board Layout (B) ..............................................................4

APPENDIX 5: CNC - Control Module Board PCB Connections .................................................. 5

APPENDIX 6: Arc Starter / Gas Control Module Schematic .......................................................6

APPENDIX 7: Power Supply Schematic,460V / 208 - 230V ....................................................... 8

APPENDIX 7: Power Supply Schematic,460V / 208 - 230V Cont. ............................................10

7-1

APPENDIX 8: Power Supply Schematic, 400V ....................................................................... 12

APPENDIX 8: Power Supply Schematic, 400V Cont. ............................................................... 14

APPENDIX 9: Power Supply Schematic, CSA 600V ................................................................ 16

APPENDIX 9: Power Supply Schematic, CSA 600V Cont. ........................................................ 18

APPENDIX 10: PUBLICATION HISTORY ................................................................................20

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

TABLE OF CONTENTS

PAK 200

!

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized as
follows:

NOTE

An operation, procedure, or background information
which requires additional emphasis or is helpful in ef­ficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause
damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause
injury to the operator or others in the operating area.

1.02 Important Safety Precautions

• 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. You must be very careful when cutting
or welding any metals which may contain one or more of the
following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs
will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
this manual.

• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlo
rinated solvents and cleansers. Remove all sources of these
vapors.

• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)

-

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnet­ic emissions that may interfere with the proper function
of cardiac pacemakers, hearing aids, or other electronic
health equipment. Persons who work near plasma arc
cutting applications should consult their medical health
professional and the manufacturer of the health equip­ment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow
all warnings, safety precautions and instructions before
using the equipment. Call 1-603-298-5711 or your local
distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your
head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work
piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or
damp.

• Install and maintain equipment according to NEC code, refer to
item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or
repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma
arc.

• Be sure there is no combustible or flammable material in the
workplace. Any material that cannot be removed must be
protected.

• Ventilate all flammable or explosive vapors from the work
place.

-

Manual 0-5057 1-1 GENERAL INFORMATION

PAK 200

• Do not cut or weld on containers that may have held combus­tibles.

• Provide a fire watch when working in an area where fire hazards
may exist.

• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more
information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear
plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound)
do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsec
tion 1.03, Publications, in this manual.

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
from American National Standards Institute, 1430 Broadway,
New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards

-

Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2,

FIRE PREVENTION IN THE USE OF CUT-

TING AND WELDING PROCESSES, obtainable from American

National Standards Institute, 1430 Broadway, New York, NY

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma
arc process produces very bright ultra violet and infra red light. These
arc rays will damage your eyes and burn your skin if you are not
properly protected.

• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or
other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective
booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/
ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly seen.
Experience has shown that lighter filters may be used
when the arc is hidden by the workpiece.

10018

7. AWS Standard A6.0,

WELDING AND CUTTING CONTAIN-

ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from

American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126

8. NFPA Standard 51,

OXYGEN-FUEL GAS SYSTEMS FOR WELD­ING, CUTTING AND ALLIED PROCESSES, obtainable from
the National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association, Bat­terymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards As­sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces
chemicals known to the State of California to cause cancer, birth defects
and other reproductive harm. Wash hands after handling. (California

Health & Safety Code § 25249.5 et seq.).

GENERAL INFORMATION 1-2 Manual 0-5057

HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018

-

-

PAK 200

!

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur
lequel il importe d’insister davantage ou qui contribue à
l’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure en
question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans
la zone de travail en cas de non-respect de la procédure
en question.

1.05 Precautions De Securite Importantes

• Les sortes de gaz et de fumée provenant de l’arc de plasma
dépendent du genre de métal utilisé, des revêtements se trouvant
sur le métal et des différents procédés. Vous devez prendre soin
lorsque vous coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:

antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec
le matériel que vous utilisez. Les MSDS contiennent des rensei­gnements quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz
de votre lieu de travail, consultez l’article 1 et les documents cités
à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit
d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant
des solvants et des produits de nettoyage chlorés. Eliminez toute
source de telle fumée.

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé
electronique. Ceux qui travail près d’une application à
l’arc au jet de plasma devrait consulter leur membre pro­fessionel de médication et le manufacturier de matériel de
santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertisse­ments, toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le +
603-298-5711 ou votre distributeur local si vous avez
des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.

• Ce produit, dans le procéder de soudage et de coupe, produit de
la fumée ou des gaz pouvant contenir des éléments reconnu dans
L’état de la Californie, qui peuvent causer des défauts de naissance
et le cancer. (La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au
jet de plasma requiert et produit de l’énergie électrique haute tension.
Cette énergie électrique peut produire des chocs graves, voire mortels,
pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail ou
des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.

• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page

• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

5,

article 9.)

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez
votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.

Manual 0-5057 1-3 GENERAL INFORMATION

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes,
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma

PAK 200

produit du métal, des étincelles, des scories chaudes pouvant mettre
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne
se trouve sur le lieu de travail. Protégez toute telle matière qu’il
est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables
ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer
des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium sous
l’eau ou sur une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera
si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dú4ez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de mal­formations fœtales ou d’autres problèmes de reproduction.

Il faut se lave r les main s a p rès toute mani p ulation .

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants)

• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des écrans
de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommenda
tion qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est caché
par moiceau de travail.

-

GENERAL INFORMATION 1-4 Manual 0-5057

PAK 200

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant
été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (Ameri­can National Standards Institute), 1430 Broadway, New York, NY
10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO
TECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM
MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À
LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT
RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018

-

-

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les
Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION
EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire Protection As­sociation, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUD
AGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202

-

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,
disponible auprès de l’Association Nationale de Fournitures de
Soudage (National Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103

Manual 0-5057 1-5 GENERAL INFORMATION

PAK 200

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive
73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/
EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* For environments with increased hazard of electrical shock, Power Supplies bearing the mark conform to EN50192 when used in conjunction

with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to

ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. 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.

Manufacturers responsible representative: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire ,

England PR6 7BX

GENERAL INFORMATION 1-6 Manual 0-5057

PAK 200

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.

Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon
notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications,
instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such
defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage

or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of
the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as
the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether
arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of
the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE
OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for this product shall be: A maximum of three (3) years from date of sale to an authorized distributor and a maximum of
two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (see chart below).

Parts Labor

©

Pak 200
Power Supplies and Components 2 Years 1Year

,

Torch and Leads
PCH 200 Torch
(Excluding Consumable Parts) 1 Year 1 Year

Repair/Replace Parts 90 Days 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. All returned goods shall be at the customer’s risk and expense. This warranty
supersedes all previous Thermal warranties.

Effective May 1, 2008

Manual 0-5057 1-7 GENERAL INFORMATION

PAK 200

This Page Intentionally Blank

GENERAL INFORMATION 1-8 Manual 0-5057

PAK 200

Primary power

Control

Cable

Ground

Cable

Work

Art # A-08376_AB

Torch

Work Cable

PAK 200

Power Supply

Arc Starter /

Gas Control Module

(GCM-200)

Pilot Return

Negative
Coolant Supply
Coolant Return

Control Cable

Torch Lead Set

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

- Control Cable

Maximum Length 100’ / 30.5 m

Primary Ground

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

• Torch Spare Parts Kit

• Work Cable with Clamp Air Hose (see assembly)

The components are connected at installation.

2.02 Plasma Power Supply

The power supply provides the necessary current for cutting operations, and monitors system performance. The
power supply also cools and circulates the liquid coolant for the torch and leads.

2.03 Gas Control Module / Arc Starter

This module mounts to the top of the power supply. This module enables the operator to select gas, set pressures
and flows and set cutting current.

2.04 Plasma Cutting Torch

The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.

2.05 System Component Layout

Manual 0-5057 2-1 SPECIFICATIONS

PAK 200

2.06 Power Supply Specifications & Electrical Requirements

PAK 200 Power Supply Specifications

Max OCV (U0) 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)
Power Factor 0.70 @ 200 ADC Output
Cooling Forced Air (Class F)

PAK-200 Power Supply

Input Power Input Current Suggested Sizes (See Note)

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 60 47 130 160 #2
230 60 49 125 150 #2
400 50 54 77 100 #4

400 (CE) 50 54 77 100 #4

460 60 59 75 90 #4

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

1

Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW

2

Extra Hard Usage Type G, G-GC, W

2

2

1

1

1

CAUTION

Fuse and wire sizes are for reference only. The installation must conform to national and local codes
for the type and method of wire being used.

SPECIFICATIONS 2-2 Manual 0-5057

Art # A-04822

33 inch
840 mm

27 inch
680 mm

37.75 inch
960 mm

41.25 inch
1050 mm

27.5 inch
700 mm

48.75 inch
1238 mm

397 lb / 180 kg

2.07 Power Supply Dimensions

PAK 200

Manual 0-5057 2-3 SPECIFICATIONS

PAK 200

Terminal Cover

Support Panel

Coolant Tank

Coolant Filter

Coolant Connections

Input Power

Terminals

Pilot (Pos)

Terminal

Circuit Breaker Panel

Terminal Cover

AC Power Lamp

Ground Terminals

Gas Control Connector

RETURN

SUPPLY

Art # A-08378

Torch Control Connection

Arc Starter Connector

Work Cable Terminal

Torch (Neg)

Terminal

Torch Leads Port

Gas Entry Ports

Gas Control Connector

Arc Starter
Connector

Leads
Bracket

2.08 Power Supply Rear Panel Features

SPECIFICATIONS 2-4 Manual 0-5057

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-450­D-500, Single stage Station-stainless diaphragm regulator for low pressure (< 350 inlet psi) liquid or bulk tank
supply application (example Victor # LC-350DR).

PAK-200 Power Supply: Gas Pressures, Flows, and Quality Requirements

Gas Quality Minimum Pressure Flow

99.5% Purity

N2 (Nitrogen)

Compressed

Air

H35 (Argon-Hydrogen)

H35 = 35% Hydrogen,

65% Argon

H2O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)

Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease
contamination from compressed or bottled air can cause fires in conjunction with oxygen.

For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as
possible to the gas inlets on the Gas Control Module.

(Liquid recommended)

<1000 ppm O2, <32 ppm H2O)

Clean, Dry,

Free of Oil (see Note 1)

99.995% Purity

(gas recommended)

80 psi

5.5 bar / 827 kPa

90 psi

6.2 bar / 621 kPa

90 psi

6.2 bar / 827 kPa

350 scfh (165 l/min)

450 scfh (212 1/min)

100 scfh (47 1/min)

2.10 Gas Applications

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.

MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM

OPERATION

35-200 A Cut Air Air H35 N

PLASMA SHIELD PLASMA SHIELD PLASMA SHIELD

GAS TYPE GAS TYPE GAS TYPE

Manual 0-5057 2-5 SPECIFICATIONS

2

H35 N

2

PAK 200

17.4 in.

4.3 in.

(109.2mm)

2.5 in.

1.5 in.(38.1mm)

1.9 in. (48.3mm)

3.5 in.

14.3 in.

13.3 in.

3.3 in.

1.5 in.

1.4 in.

1.5 in.

1.4 in.

13.5 in.

A-02683

(337mm)

(342.9mm)

(38.1mm)

(363.2mm)

(35.6mm)

(83.8mm)

(38.1mm)

(88.9mm)

(35.6mm)

(44.2mm)

(86.4mm)

(68.5mm)

70°

90°

180°

3.4 in.

2.11 PCH/M 200 Torch Specifications

A. Torch Dimensions

B. Torch Leads Lengths

* Available as custom or-

Gas Lead Assemblies

Length

Feet Meters

25 7.6

50 15.2

SPECIFICATIONS 2-6 Manual 0-5057

PAK 200

Electrode

Shield Cup

Tip

Gas

Distributor

Torch Head

Water Tube Extension

(Gouging Only)

A-02188

C. Torch Parts (Generic Parts Shown)

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. If coolant return flow to the power supply is absent or insufficient the power supply will not provide
power to the

torch. Coolant leakage from the torch also indicates that torch parts are absent or installed improperly.

E. Type Cooling

Combination of gas stream through torch and liquid cooling.

Manual 0-5057 2-7 SPECIFICATIONS

PAK 200

This page is blank intentionally.

SPECIFICATIONS 2-8 Manual 0-5057

PAK 200

SECTION 3:

INSTALLATION

3.01 Installation Requirements

Electric Supply

The electrical supply network, the gas and water supply system must meet local safety standards. This conformity
shall be checked by qualified personnel.

PAK 200 Power Supply

Suggested Sizes

Input Power Input Current

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 60 47 130 160 #2
230 60 49 125 150 #2

400 50 54 77 100 #2
460 60 59 75 90 #2

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

1

Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW

2

Extra Hard Usage Type G, G-GC, W

(See Note)

2

2

1

1

CAUTION

Fuse and wire sizes are for reference only. The installation must conform to national and local codes
for the type and method of wire being used.

Gas Supply

The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure regulators
must be double-stage and installed as close as possible to the gas console. Contaminated gas can cause one or
more of the following problems:

• Reduced cutting speed • Poor cut quality

• Poor cutting precision • Reduced consumables life.
Oil or grease contamination from compressed

•

or bottled air can cause fires in conjunction with oxygen.

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 Mixture Protects To

7-3580 ‘Extra-CoolTM’ 25 / 75 10° F / -12° C
7-3581 ‘Ultra-CoolTM’ 50 / 50 27° F / -33° C

7-3582 ‘Extreme-CoolTM’ Concentrat* -65° F / -51° C

*For mixing with D-1 CoolTM 7-3583

Manual 0-5057 3-1 INSTALLATION

PAK 200

Primary power

Control

Cable

Ground

Cable

Work

Art # A-08376_AB

Torch

Work Cable

PAK 200

Power Supply

Arc Starter /

Gas Control Module

(GCM-200)

Pilot Return

Negative

Coolant Supply
Coolant Return

Control Cable

Torch Lead Set

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

- Control Cable

Maximum Length 100’ / 30.5 m

Primary Ground

3.02 Cables and Leads Identification

Refer to section 3.05 for ground connections and ground cables.

INSTALLATION 3-2 Manual 0-5057

3.03 Cables and Leads Identification

G

Torch Lead Set

Art # A-08377_AC

Green / Yellow #4 AWG

A

Green

Red

#8 AWG Cable

#1 AWG Cable

B

C

D

E

F

K

Work Cable

37

14

Coolant Leads, Power Supply
to Arc Starter

Pilot Return, Power Supply
to Arc Starter

Negative Lead, Power Supply
to Arc Starter

Control Cable, Power Supply
to Arc Starter

Ground Cable

O

Control Cable,
Power Supply to
Gas Control Module

Green

Red

4’ / 1.3 m

#1 AWG

PAK 200

Manual 0-5057 3-3 INSTALLATION

PAK 200

Art # A-04824

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.

Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and
vertical. Do not lift it any further than necessary to clear the shipping pallet.

Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a supporting fixture
with hardware passing through the horizontal parts of the power supply feet.

INSTALLATION 3-4 Manual 0-5057

PAK 200

Connections Cover
(Removed)

Connection Panel

Art # A-04827

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.

Manual 0-5057 3-5 INSTALLATION

PAK 200

Art # A-04856_AB

1. Unplug connector

2. Remove bolts.

3. Invert board.

4. Re-install board.

5. Plug in connector.

208/230V / 460V

Input Voltage Board

(Shown in 460V Position)

Inverter Module

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). Remove the power supply left side panel and locate the voltage configuration
board. The input voltage configuration is shown at the top of the board.

2. If necessary, disconnect the jumper from the top-right corner of the board, remove the board and re-install
withthe correct input voltage shown at the top of the board. Reconnect the jumper to the top-right corner of
theboard.

INSTALLATION 3-6 Manual 0-5057

PAK 200

P

IL

OT

WO

R

K

TO

R

C

H

Connection Panel

AC

INPUT

L1

L2

L3

Work Lead

Torch Lead -

To Arc Starter

Work

Torch

Lead Connection Detail

Connections Cover
Support Panel

Art # A-08500

Connections Cover

Pilot

To Cutting Table

Leads Bracket

Pilot Lead ­To Arc Starter

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.

2. Insert the individual wires into the proper lug and tighten the nut onto the wires.

3. Pass the ground and input power cables through the leads bracket as shown. Connect the individual wires as
shown Connect the power cable ground wire to the ground terminal block.

CAUTION

The clear connections cover must remain in place.

4. If required, pass a system ground cable (F1) through the last opening in the connections cover su port panel
next to the input power cable. Connect the cable to the ground terminal block on the power supply rear panel.
Refer to the Ground Connections Section for full details and procedures on proper system grounding.

5. Re-install the connections cover on the power supply. Snug the hardware securely by hand. Do not over-

Manual 0-5057 3-7 INSTALLATION

PAK 200

PILO

T

WO

R

K

TO

RC

H

Input power cable

Ground Terminal Block

Connections Cover
Support Panel

Art # A-08501

Connections Cover

Connection Panel

Leads Bracket

AC

INPUT

Input power cable ground

L1

L2

L3

L1

L2

L3

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.

WARNING

Ensure that lead attachment hardware is properly sized. Excess length may cause damage if hardware
contacts other parts of the system.

The clear connections cover must remain in place.

INSTALLATION 3-8 Manual 0-5057

3.07 Connect Gas Supply Lines

RETURN

SUPPLY

RETURN

SUPPLY

Art # A-08463

Plasma Gas - In

Shield Gas - In

1. Connect the gas supply lines to the appropriate input ports as shown.

PAK 200

Manual 0-5057 3-9 INSTALLATION

PAK 200

RETURN

SUPPLY

RETURN

SUPPLY

Art # A-08492

To Torch

3.08 Connect Torch Control Cable

1. Connect the Torch Control cable to the power supply receptacle marked ‘J15’.

INSTALLATION 3-10 Manual 0-5057

PAK 200

SW1

SW3

SW4

SW5

SW8

3

4

1

2

3

4

1

2

1

2

1

2

1

2

1

2

S

W-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled. (Factory default setting).
1 = OFF = Auto Pilot Function disabled
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds

SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds

SW-5-1: Tip Saver SW5-1 not used, Tip Saver always on.
SW-5-2: Off Plate Reserved for Factory use.

SW 8-1: Pilot Time 1 = ON = Short (85 ms.)

1 = ON = Long (3 s.)

O
N

O
N

Active only when
SW-1-1 is set to ON.

Art # A-08379_AB

Future Use

SW-3: Gas Preflow Time 1 = OFF, 2 = OFF: 2 seconds

(Factory default setting).

1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds

SW 8-2: Remote Current 2 = OFF = Front panel current control (Factory default setting).
2 = ON = (Remote Analog Current Control) See also SW11

SW 8-3, SW8-4: Reserved for Factory use.

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.

Manual 0-5057 3-11 INSTALLATION

PAK 200

SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or
DC Volts (16-18vdc@ up to 100 ma.)

SW-11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC.
Position A requires that SW-8-2 be ON.

SW-12-1/2/3/4: Divided Arc signal

All = OFF = 50:1 (Factory default setting)

1 = ON = 16.6:1
2 = ON = 30:1
3 = ON = 40:1
4 = Not used.

SW13-1:

1 = OFF

SW13-2:

1 = ON

Art # A-08502

Only 1 on at a time.

SW11

SW13

SW6

SW12

No external
connection cover

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.

NOTE

INSTALLATION 3-12 Manual 0-5057

Standoff Control SC-11 requires Switch 12-1 set to

PAK 200

Torch Leads: Coolant Supply & Return
Plasma Gas
Shield Gas

Art #: A-008382

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.

CAUTION

Use protective gloves when handling the leads. Do not kink or bend the leads.

3. Connect the leads to the module in the sequence shown. Coolant leads and connectors are color-tagged; red
for coolant return, green for coolant supply. Shield gas and plasma gas connections are left- and right- hand
threaded and will not interchange.

Manual 0-5057 3-13 INSTALLATION

PAK 200

Art # A-08383

Coolant Supply
Connection (Tagged Green)

Coolant Return
Connection (Tagged Red)

Art # A-04832

Plasma Gas
Connection

Shield Gas
Connection

Torch Leads

4. Re-install the module top cover.

INSTALLATION 3-14 Manual 0-5057

PAK 200

A-08385

Cutting Electrode Air/N2

Catalog No. 32-1310

Cutting Tip Air/N2/AR-H2

0.031" Orifice, 35 amps
Catalog No. 32-1320

Cutting Tip Air/N2/AR-H2

0.047" Orifice, 70 amps
Catalog No. 32-1321

Gouging Shield Cup

Gouging Only

Catalog No. 32-1527

Short Shield Cup

Standoff Cutting Only

Catalog No. 32-1325

Cutting Tip Air/N2/AR-H2

0.063" Orifice, 120 amps
Catalog No. 32-1322

Gouging Tip Air/N2/Ar-H2

0.110" Orifice

Catalog No. 32-1512

Gouging Tip Air/N2/Ar-H2

0.156" Orifice

Catalog No. 32-1514

Gouging Electrode,

N2/Ar-H2

Catalog No. 32-1505

Gouging Electrode

Air/N2

Catalog No.32-1504

Crown Shield Cup

Standoff Cutting Only

Catalog No.32-1326

Gas Distributor - Cutting

0.712" (18 mm) Length
Cat. No. 32-1315

Gas Distributor - Gouging

0.912" (23 mm) Length
Cat. No. 32-1509

Gouging Tip Air/N2/Ar-H2

0.125" Orifice

Catalog No. 32-1513

Gouging Tip Air/N2/Ar-H2

0.171" Orifice

Catalog No. 32-1515

Cutting Electrode N2, Ar-H2

Catalog No. 32-1311

Coolant Tube Extension

(Gouging)

3.35" (85 mm) Length
Cat No. 32-1502

Cutting Tip Air/N2/AR-H2

0.070” orifice150 amps
Catalog No. 32-1330

Cutting Tip Air/N2/AR-H2

0.073” orifice 200 amps
Catalog No. 32-1323

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).

Refer to Figure below for the various torch parts.

CAUTION

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma
and secondary in use and the type of operation (cutting or gouging).

Manual 0-5057 3-15 INSTALLATION

PAK 200

Multi-Purpose Wrench

(Catalog Number 20-0001)

Used for Electrodes

Used for 11/16" ( 17.5 mm)

Across Tip Flats

Gas Distributor Notch

Used with 11/16" (17.5 mm)Tip

Used for 5/8" (15.9 mm)

Across Tip Flats

Gas Distributor Notch

Used with 5/8" (15.9 mm)Tip

This Side

Towards Torch

A-01639

Electrode

Shield Cup

Tip

Gas

Distributor

Torch Head

Water Tube Extension

(Gouging Only)

A-02188

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.

1. Unscrew and remove the shield cup from the torch head.

2. Using the multi-purpose wrench (5/8 inch slot) remove the tip.

3. Tilt the torch head to remove the gas distributor. The end of the multi-purpose wrench can be used to help
remove the gas distributor.

Multi-Purpose Wrench

4. Using the multi-purpose wrench (electrode area) remove the electrode.

5. Remove gouging water extension tube, if used.

6. Install the desired electrode for the operation into the torch head. The circular area around the wrench used

for electrodes will also align the electrode in the torch head. This will prevent installing the electrode on an
angle and cross threading the electrode in the torch head.

7. Install gouging water extension tube if required.

8. Install the desired gas distributor and tip for the operation into the torch head.

Be careful not to overtighten the electrode and tip when reinstalling.

9. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup,
check the threads before proceeding.

NOTE

INSTALLATION 3-16 Manual 0-5057

PAK 200

RETURN

SUPPLY

RETURN

SUPPLY

Art # A-04803

COOLANT

Fill Range

Coolant Tank

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.

Coolant Capabiities

Cat. Number and Mixture Mixture Protects To

7-3580 ‘Extra-CoolTM’ 25 / 75 10° F / -12° C
7-3581 ‘Ultra-CoolTM’ 50 / 50 27° F / -33° C

7-3582 ‘Extreme-CoolTM’ Concentrat* -65° F / -51° C

3. After the complete system has been installed, check that the coolant has been pumped through the system as
follows (see NOTE):

Manual 0-5057 3-17 INSTALLATION

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.
c. Place the ON/OFF switch to OFF.
d. After 10 seconds place the ON/OFF switch to ON again.
e. Repeat steps ‘b’ through ‘d’ until the system no longer shuts down. Depending on the length of
the torch leads this sequence may need to be done three to five times.
f. After the system stays operational allow the pump to operate for ten minutes to properly purge
any air from the coolant lines before using the system.

4. Re-fill the reservoir and re-install the filler cap.

5. Purge coolant from the torch before firing the torch. Ensure there are no leaks before use. If
leaks are evident, consult the coolant leak trouble-shooting guide in the maintenance section of this
manual.

INSTALLATION 3-18 Manual 0-5057

4.01 Power Supply Indicators

Art # A-04813

AC Indicator

Temp Indicator

Gas Indicator

DC Indicator

Status Indicator

AC Power Indicator

PAK 200

SECTION 4:

OPERATION

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.

TEMP Indicator: Normally OFF. Indicator turns ON when the internal temperature sensors detect tempera-

tures above normal limits. Let the unit cool before continuing operation.

GAS Indicator: The indicator blinks when the gas control is not ready. Causes for not being ready are when
purging, Run/Set switch is not set to Run, gas pressure is not correct. When gas flow is called for (preflow,
cutting, postflow ) the indicator is on steady. It is off at all other times.

DC Indicator: Indicates the power supply is generating output DC voltage.

Status Indicator: Shows system status. The number of flashes indicates the status. Refer to the
Status Code Section for details. On power supply start-up, the indicator flashes to show the revision level of
the operating software installed in the system.

Manual 0-5057 4-1 OP-

PAK 200

R

U

N

S

E

T

P

L

A

S

M

A

S

H

IE

L

D

RUN

SET

PLASMA

SHIELD

A

CUT
OUT

Art # A-08384

Amperage

Selector

Run / Set Selector

Plasma Gas

Pressure Gauge

Shield Gas

Pressure Gauge

Plasma Gas Pressure

Control Knob

Shield Gas Pressure

Control Knob

GCM

200

A

C

U

T

O

U

T

4.02 Control Console Features

Run / Set Selector: Use SET position to adjust plasma and shield pressures and ows. Once these are

Plasma and Shield Gas Pressure Control Knobs: Adjust plasma and shield gas pressures. Turn knobs to

Plasma and Shield Gas Pressure Gauges: Display plasma and shield gas pressures.

Amperage Selector: Continuously adjustable up to 200 Amps.

OPERATION 4-2 Manual

set, switch to RUN position for operation.

set desired levels.

PAK 200

4.03 Operating Set-up

Follow this set-up procedure each time the system is
operated:

WARNING

Disconnect primary power at the source
before assembling or disassembling power
supply, torch parts, torch and leads assem­blies or adding coolant.

A. Coolant Level Inspection

Check the coolant level in the coolant tank at the rear of
the unit. If the tank is below 3/4 full, add coolant.

B. Torch Parts Selection

Check the torch for proper assembly. Install proper
torch parts for the application per the Torch section of
the manual..

C. Input Power

Check the power source for proper input voltage. Make
sure that Power Supply is set for the proper voltage.
Close main disconnect switch or plug unit in to supply
primary power to the system.

D. Work Cable Connection

Check for a solid and clean work cable connection to the
workpiece or cutting table. The connection area must be
free from paint and rust.

E. Torch Connection

Check that the torch is properly connected.

I. Pressure and Flow Settings

1. Default Settings
Pre-Flow:

When the cut demand is activated either via the

hand torch or remote pendant, the plasma and
shield gasses will flow from the torch before the
pilot arc is generated. The default pre-flow time
for the PAK 200 is 2 seconds.

Post-Flow:
After the plasma arc has terminated, a post-flow

occurs for 10 seconds. This feature enables
the operator to beginning cutting immediately
between cuts without having to wait again for
the pre-flow. In the event that the post flow time
has expired, the pre-flow will be activated prior
to the next cut.

Refer to section 3.10 in this manual if longer pre-flow or
post-flow times are desired. Add the attached cut charts
to section 4 (Operation). Please use the format for the
XT-300 cut charts.

2. Refer to the Torch manual for pressure and flow

details according to the material being cut. Move
the RUN/SET switch to SET position. (Gas will flow
through the torch). Set gas pressures and flows as
follows:

3. To set the Plasma Gas pressure:
a. Pull out the knob on the Plasma Gas pressure

control knob.

F. Gas Supplies

Connect desired plasma and shield gases. Make sure
gas sources meet requirements. Check connections and
turn gas supply on.

G. Plasma Gas Purge

Move the Power Supply ON/OFF switch to the ON posi­tion. An automatic gas purge will remove any condensa­tion that may have accumulated in the torch and leads
while the system was shut down. After the purge is
complete, if the RUN/SET switch is in SET position,
gases will flow.

H. Amperage Selection

Select the desired output amperage.

Manual 0-5057 4-3 OP-

c. Turn the knob to adjust gas pressure.
d. Push the knob back in to lock the pressure set

ting.

4. To set the Shield Gas pressure:
a. Pull out the Shield Gas Pressure Control Knob.
c. Turn the knob to adjust gas pressure.
d. Push the knob back in to lock the pressure set

ting.

NOTE

Unless the installation includes gas selection
equipment between the gas supplies and the
control console, switching between gases
requires disconnecting the gas supply line(s)

-

-

PAK 200

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Kerf Width

Cut Surface
Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

4.04 Cut Quality

Cut quality requirements differ depending on applica­tion. For instance, nitride build-up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross-free cutting is important when finish
cut quality is desired to avoid a secondary cleaning
operation. Cut quality will vary on different materials
and thicknesses.

Bevel Angle

The angle between the surface of the cut edge and a plane
perpendicular to the surface of the plate. A perfectly

perpendicular cut would result in a 0° bevel angle.

Top-Edge Rounding

Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece.

Dross Build-up and Top Spatter

Dross is molten material which is not blown out of the cut
area and re-solidifies on the plate. Top spatter is dross
which accumulates on the top surface of the workpiece.
Excessive dross may require secondary cleanup opera­tions after cutting.

Kerf Width

The width of material removed during the cut.

Nitride Build-up

Nitride deposits which may remain on the cut edge of
the carbon steel when nitrogen is present in the plasma
gas stream. Nitride buildups may create difficulties if the
steel is welded after the cutting process.

Cut Surface

The condition (smooth or rough) of the face of the cut.

OPERATION 4-4 Manual

Direction of Cut

The plasma gas stream swirls as it leaves the torch
to maintain a smooth column of gas. This swirl effect
results in one side of a cut being more square than the
other. Viewed along the direction of travel, the right side
of the cut is more square than the left.

POWER

ON

OFF

O

I

OFF

O

Art # A-04842

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Scrap

Clockwise

Counter-

Clockwise

Art # A-04182

Workpiece

Scrap

Swirl Effect on Side Characteristics Of Cut

PAK 200

4.05 System Operation

This section contains operating information which is
specific to the power supply.

WARNING

F r e q u e n t l y r e v i e w t h e s a f e ­t y p r e c a u t i o n s i n S e c t i o n 1 .
Disconnect primary power at the source
befo re ass emblin g or disasse mbling
power supply, torch parts, or torch and
leads assemblies, or adding coolant.
It is not enough to simply move the ON/OFF
switch on the unit to OFF position when cut­ting operations have been completed. Always
open the power supply disconnect switch
five minutes after the last cut is made.

1. Connect system to primary input power.

To make a square - edged cut along an inside diameter
of a circle, the torch should move counterclockwise
around the circle. To keep the square edge along an
outside diameter cut, the torch should travel in a clock­wise direction.

2. Turn ON/OFF switch to ON (up) position. AC Lamp
turns ON. Fan and coolant pump turn on. There is a
start-up purge of gas through the system.

Manual 0-5057 4-5 OP-

PAK 200

3. Check the AC lamp. If lamp is ON, AC input power
is present in the power supply. Within 4 seconds
of the AC lamp illuminating there will be a series of
flashes from the four operation status lamps to show
the firmware revision in use. This will be a two part
indication. An example would be two flashes followed
by a short pause then four flashes then a longer
pause. This would indicate firmware revision 2.4. If
there is a third group diplayed, it is for Engineering
Development only and not for customer use without
written agreement from Thermadyne. This sequence
of AC lamp then firmware revision status will happen
at every power up.

Circuitry in the power supply monitors the status of

various conditions. If the circuitry detects a situa­tion requiring operator attention, the status lamp on
the control panel flashes a 2-part code to indicate a
code group and then a particular condition within the
group. After 4 seconds, the sequence repeats.

Example: Lamp flashes 4 times; the condition is in

group 4. After a .2 second delay, the lamp blinks 3
times; the status code is 4-3. After a 4-second delay,
the lamp repeats the sequence until the condition is
corrected.

Some conditions can be active indefinitely, while

others are momentary. The power supply latches
momentary conditions; some momentary errors can
shut down the system. The lamp may show multiple
conditions in sequence; it is important to recognize
all possible conditions that may be displayed. The

Error Code section provides explanations of status
codes.

4. Place RUN/SET switch to SET mode.
a. Gases flow to set pressures.

5. Place RUN/SET switch to RUN mode.
a. Gas flow stops.

6. Move torch within transfer distance of work piece.

7. Protect eyes and start torch.
a. Power supply enabled. DC lamp turns ON..
b. Gas pre-flows starts.

8. Wait for gas pre-flow to complete:
a. Pilot arc is established.

9. Main arc transfers to the workpiece.
a. Pilot arc shuts off.

10. Complete cutting operation.

11. Stop the torch.
a. Main arc stops.

12. Gas will flow briefly (‘post-flow’).
a. Gas solenoid closes; gas flow stops:

13. Set the ON/OFF power switch on the front panel of

the unit to OFF.

a. AC Power lamp turns OFF.
b. Fan and pump turn OFF.

14. Place the main power disconnect to open.
a. Main AC power is removed from the system.

4.06 Operational Suggestions

1. Wait five minutes before setting the ON/OFF switch

to OFF after operation. This allows the cooling fan
to run

OPERATION 4-6 Manual

Status Code Key for PAK 200

Status
Code

1-1

1-2 Pilot Ignition Failure

1-3 Lost Pilot

1-4 Loss of Transfer

1-5 Of the Plate Function not currently enabled.

1-6 Pilot Timed out w/o Transfer

1-7 Not used

1-8 Tip to Electrode Voltage too low

2-1 Missing Phase Blown fuse, Broken or loose connection on power cable

Message Cause/Remedy

System not Enabled or Missing AC
Input Phase

External E-Stop Activated or CCM TB1-1&2 jumper missing;
Missing AC Phase; GCM200 control cable not connected.

Pilot did not start within 15 seconds.
Plasma pressure too high; Defective Arc Starter

Pilot went out without shutoff signal; Plasma pressure too high;
cut current set too low for consumables.

Arc transfer (>50 ms.) then arc lost with START still on. Standoff
too high; Current set too low.

Must transfer from Pilot to Cutting Arc in 85 ms. (SW8-1 OFF)
or 3 sec. (SW8-1 ON). Standoff too high or void in work under
torch; cut current too low for consumables; Plasma pressure
too low.

Detected tip voltage too close to electrode voltage. Plasma flow/
pressure too low; Plasma leak; cut current too high; shorted
torch body; consumable parts worn out.

Inverter(s) not configured correctly for input voltage;

PAK 200

2-2 Wrong input voltage

2-3

2-4 Power Supply not Ready Defective inverter

2-5 DC Output Low

2-6

2-7 Unexpected current

2-8

2-9 Unexpected current in work lead

Inverter or Pilot Regulator Over
Temperature

Inverter primary over current or
cap voltage imbalance fault

Unexpected current in pilot cir­cuit

Poor power quality (brownouts, dropouts);
Input power capacity / wiring too small causing voltage drop;

broken or loose power cable connections.

Failed fan; Ambient above 40 deg C. (104 F); Blocked airflow

Output less than 60 VDC; Defective inverter, shorted output;
Shorted pilot regulator (chopper); CCM voltage sense (J6) wire
open or disconnected.

Over current detected in inverter primary circuit, remove power
to reset; defective inverter; voltage surge;

Current >20A in work or pilot leads before pilot ignition; Possible
shorted torch; Defective current sensor.

Current > 5A in pilot circuit; wrong or mismatched consumables;
Pilot lead shorted to negative in torch tube; Possible shorted
torch

Current > 5A in work lead; Short to chassis in RAS; Negative
lead short to gnd.

Manual 0-5057 4-7 OP-

PAK 200

Status Code Key (cont.)
Status

Code

3-1

3-2

3-3 Gas Pressure Low Plasma < 51 PSI; faulty or disconnected pressure SW.
3-4 Gas Control not ready Purging; RUN/SET in SET position;
3-5 Gas Control Protocol Fault Does not apply to PAK200, if displayed CCM defective.

3-6

3-7

3-8

3-9

3-10

4-1 Coolant Level low fault Check coolant level, add as needed.

Message Cause/Remedy

Gas Control Communication
fault, Cannot establish Commu­nication with gas control.

Gas Control Communication
reply fault,

Invalid Current Control level
from GCM

Gas Control returns wrong com­mand sequence

CCM and Gas Control type (Au­tocut-Ultracut) mismatch

Gas Control Communication
reply fault

Warning. -- Gas Control firm­ware needs update

GCM 200 Control cable not connected or Basic ID signal open;
CCM not PAK 200 (SW13-1 should be off) or
CCM defective, replace.

Does not apply to PAK200, if displayed CCM defective.

Does not apply to PAK200, if displayed CCM defective.

Does not apply to PAK200, if displayed CCM defective.

CCM not PAK200 (SW13-1 should be off) or CCM defective.

Does not apply to PAK200, if displayed CCM defective.

Does not apply to PAK200, if displayed CCM defective.

4-2

4-3

4-4

Low coolant flow after power on
purge. < 0.4gal/min;

Coolant overheated (>70
deg. C, 158 deg F)

Coolant System not ready.
During power on purge / prim-

ing, flow did not reach 0.4 gal/
min for at least 5 seconds

Suction leak introducing air into coolant, suspect rear panel filter
seal; clogged filter; defective pump.

Coolant fan failed; radiator fins clogged with dirt; Ambient tempera­ture > 40 deg C.

If new installation recycle power to restart pump, may take a few
times to fill hoses;

Damaged torch coolant tube; Suction leak introducing air into cool­ant, suspect rear panel filter seal; clogged filter; defective pump.

OPERATION 4-8 Manual

PAK 200

Status Code Key (cond)
Status

Code

5-1

5-2

5-3

5-4 CCM Message not sent Does not apply to PAK200, if displayed CCM defective.
6-1 CCM Analog Voltage Error Replace CCM
6-2 CCM ADC or DAC error Replace CCM

Message Cause/Remedy

CANBUS Failure to Acknowledge
fault.

CANBUS Off due to
excessive data errors;

CANBUS data error warning.
Errors increasing, will soon fault.

Does not apply to PAK200, if displayed CCM defective.

Does not apply to PAK200, if displayed CCM defective.

Does not apply to PAK200, if displayed CCM defective.

Manual 0-5057 4-9 OP-

PAK 200

4.07 Recommended Cutting Speeds

Type Torch: PCH-200 Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Air

Thickness Tip Output

Inches mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

0.032 0.8 32-1320 100 35 400 10.2 0.13 3.2 63 4.3 60 4.1 50 340 0.13 3.2

0.050 1.3 32-1320 100 35 250 6.4 0.13 3.2 63 4.3 60 4.1 50 340 0.13 3.2

0.063 1.6 32-1320 100 35 125 3.2 0.13 3.2 63 4.3 60 4.1 50 340 0.13 3.3

0.091 2.3 32-1320 110 35 90 2.3 0.13 3.2 63 4.3 60 4.1 50 340 0.13 3.3

0.125 3.2 32-1320 115 35 60 1.5 0.13 3.3 63 4.3 60 4.1 50 340 0.13 3.3

0.063 1.6 32-1321 118 70 200 5.1 0.13 3.3 50 3.4 60 4.1 60 332 0.13 3.3

0.125 3.2 32-1321 125 70 125 3.2 0.13 3.3 70 4.8 60 4.1 82 332 0.13 3.3

0.188 4.8 32-1321 125 70 85 2.2 0.13 3.3 70 4.8 60 4.1 82 332 0.13 3.3

0.25 6.4 32-1321 130 70 65 1.7 0.13 3.3 70 4.8 60 4.1 82 332 0.13 3.3

0.375 9.5 32-1321 140 70 25 0.6 0.13 3.3 70 4.8 60 4.1 82 332 0.25 6.4

0.500 12.7 32-1321 145 70 15 0.4 0.13 3.3 70 4.8 60 4.1 82 332 0.25 6.4

0.25 6.4 32-1322 125 120 125 3.2 0.19 4.7 60 4.1 60 4.1 78 340 0.25 6.4

0.375 9.5 32-1322 130 120 70 1.8 0.19 4.8 60 4.1 60 4.1 78 340 0.25 6.4

0.500 12.7 32-1322 145 120 35 0.9 0.19 4.8 60 4.1 60 4.1 78 340 0.25 6.4

0.625 15.9 32-1322 150 120 30 0.8 0.19 4.8 60 4.1 60 4.1 78 340 0.38 9.7

0.750 19.1 32-1322 160 120 20 0.5 0.19 4.8 60 4.1 60 4.1 78 340 0.38 9.7

0.500 12.7 32-1323 165 200 90 2.3 0.15 3.8 70 4.8 60 4.1 83 340 0.40 10.2

0.750 19.1 32-1323 170 200 55 1.4 0.18 4.6 70 4.8 60 4.1 83 340 0.45 11.4

Amper-

age

Speed

(Per Minute) Standoff

Plasma

Gas Press

Sec Gas

Press Total Flow (SCFH)

Pierce
Height

Type Torch: PCH-200 Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Air

Thickness Tip

Output

Inches mm (Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

20 ga. 0.9 32-1320 110 35 100 2.5 0.13 3.2 65 4.5 60 4.1 50 340 0.13 3.3

18 ga. 1.2 32-1320 110 35 50 1.3 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

0.063 1.6 32-1320 110 35 40 1.0 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

0.125 3.2 32-1320 110 35 30 0.8 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

0.188 4.8 32-1320 110 35 20 0.5 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

0.063 1.6 32-1321 120 70 225 5.7 0.13 3.2 70 4.8 60 4.1 80 340 0.13 3.3

0.125 3.2 32-1321 120 70 135 3.4 0.13 3.2 70 4.8 60 4.1 80 340 0.13 3.3

0.188 4.8 32-1321 120 70 100 2.5 0.13 3.3 70 4.8 60 4.1 80 340 0.13 3.3

0.250 6.4 32-1321 125 70 65 1.7 0.13 3.3 70 4.8 60 4.1 80 340 0.13 3.3

0.375 9.5 32-1321 130 70 30 0.8 0.13 3.3 70 4.8 60 4.1 80 340 0.25 6.4

0.500 12.7 32-1321 140 70 20 0.5 0.19 4.7 70 4.8 60 4.1 80 340 0.25 6.4

0.250 6.4 32-1322 130 120 135 3.4 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4

0.375 9.5 32-1322 130 120 80 2.0 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4

0.500 12.7 32-1322 135 120 40 1.0 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4

0.625 15.9 32-1322 140 120 30 0.8 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4

0.750 19.1 32-1322 145 120 25 0.6 0.19 4.8 75 5.2 60 4.1 90 340 N/R N/R

1.250 31.8 32-1322 160 120 10 0.3 0.19 4.8 75 5.2 60 4.1 90 340 N/R N/R

0.500 12.7 32-1323 150 200 110 2.8 0.2 5.1 70 4.8 60 4.1 85 340 0.40 10.2

0.750 19.1 32-1323 165 200 35 0.9 0.2 5.1 70 4.8 60 4.1 85 340 0.50 12.7

Volts

Amper-

age

Speed (Per

Minute) Standoff

Plasma Gas

Press

Sec Gas

Press Total Flow (SCFH) Pierce Height

OPERATION 4-10 Manual

PAK 200

Type Torch: PCH-200 Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Air

Output

Thickness Tip

Inches mm (Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

21 ga 0.8 32-1320 95 35 400 10.2 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

18 ga 1.2 32-1320 100 35 300 7.6 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

16 ga 1.5 32-1320 100 35 275 7 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

13 ga 2.2 32-1320 105 35 150 3.8 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

11 ga 2.9 32-1320 110 35 90 2.3 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

7 ga 4.8 32-1320 110 35 60 1.5 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

0.125 3.2 32-1321 120 70 180 4.6 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4

0.188 4.8 32-1321 120 70 140 3.6 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4

0.250 6.4 32-1321 122 70 75 1.9 0.19 4.7 70 4.8 60 4.1 77 340 0.25 6.4

0.375 9.5 32-1321 125 70 55 1.4 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4

0.500 12.7 32-1321 132 70 35 9 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4

0.250 6.4 32-1322 125 120 125 3.2 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7

0.375 9.5 32-1322 130 120 80 2 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7

0.500 12.7 32-1322 135 120 55 1.4 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7

0.625 15.9 32-1322 140 120 40 1 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7

0.750 19.1 32-1322 145 120 30 0.8 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7

1.000 25.4 32-1322 160 120 15 0.4 0.25 6.4 65 4.5 60 4.1 78 340 N/R N/R

1.250 31.8 32-1322 165 120 12 0.3 0.25 6.4 65 4.5 60 4.1 78 340 N/R N/R

1.500 38.1 32-1322 180 120 5 0.1 0.25 6.4 62 4.3 60 4.1 78 340 N/R N/R

0.50 12.7 32-1323 144 200 85 2.2 0.15 3.8 70 4.8 60 4.1 83 340 0.30 7.6

0.75 19.05 32-1323 150 200 50 1.3 0.18 4.6 70 4.8 60 4.1 83 340 0.35 8.9

1.00 25.4 32-1323 158 200 30 0.8 0.25 6.4 70 4.8 60 4.1 83 340 0.40 10.2

1.50 38.1 32-1323 168 200 15 0.4 0.25 6.4 70 4.8 60 4.1 83 340 N/R N/R

2.00 50.8 32-1323 188 200 10 0.3 0.25 6.4 70 4.8 60 4.1 83 340 N/R N/R

Volts

Amper-

age

Speed

(Per Minute) Standoff

Plasma Gas

Press

Sec Gas

Press Total Flow (SCFH) Pierce Height

Type Torch: PCH-200 Type Material: Stainless Steel

Type Plasma Gas: Ar-35H2 Type Secondary Gas: Nitrogen

Output

Thickness Tip

Inches mm (Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

0.750 19.1 32-1322 140 120 20 0.5 0.19 4.8 62 4.3 60 4.1 78 340 0.40 10.2

1.000 25.4 32-1322 145 120 15 0.4 0.19 4.8 62 4.3 60 4.1 78 340 N/R N/R

1.250 31.8 32-1322 150 120 10 0.3 0.19 4.8 62 4.3 60 4.1 78 340 N/R N/R

1.500 38.1 32-1322 155 120 7 0.2 1.9 48.3 62 4.3 60 4.1 78 340 N/R N/R

0.500 12.7 32-1323 155 200 50 1.3 0.27 6.9 70 4.8 60 4.1 84 340 0.40 10.2

0.750 19.1 32-1323 160 200 30 0.8 0.3 7.6 70 4.8 60 4.1 84 340 0.50 12.7

Volts

Amper-

age

Speed

(Per Minute) Standoff

Plasma Gas

Press

Sec Gas

Press Total Flow (SCFH) Pierce Height

Manual 0-5057 4-11 OP-

PAK 200

Type Torch: PCH-200 Type Material: Aluminum

Type Plasma Gas: Ar-35H2 Type Secondary Gas: Nitrogen

Thickness Tip

Output

Inches mm (Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

0.250 6.4 32-1322 130 120 100 2.5 0.25 6.4 65 4.5 60 4.1 75 340 0.25 6.4

0.500 12.7 32-1322 135 120 60 1.5 0.25 6.4 65 4.5 60 4.1 75 340 0.38 9.7

0.750 19.1 32-1322 135 120 30 0.8 0.25 6.4 65 4.5 60 4.1 75 340 0.38 9.7

1.000 25.4 32-1322 140 120 20 0.5 0.25 6.4 65 4.5 60 4.1 75 340 N/R N/R

0.500 12.7 32-1323 145 200 110 2.8 0.3 7.6 70 4.8 60 4.1 82 340 0.40 10.2

0.750 19.1 32-1323 150 200 50 1.3 0.4 10.2 70 4.8 60 4.1 82 340 0.45 11.4

Volts

Amper-

age

Speed (Per

Minute) Standoff

Plasma Gas

Press Sec Gas Press Total Flow (SCFH) Pierce Height

OPERATION 4-12 Manual

This Page Intentionally Blank

PAK 200

Manual 0-5057 4-13 OP-

PAK 200

This Page Intentionally Blank

OPERATION 4-14 Manual

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; clean as needed.
Check gas hoses for cracks, leaks, or abrasion.

Replace as needed.
Check all electrical connections for cracks or

abrasion. Replace as needed.

PAK 200

Six Months

Replace coolant filter.
Clean coolant tank.
Vacuum out any dust buildup inside power

supply.

5.01 Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inef­ficient torch parts cooling with consequent faster consumable wear.

Clean the coolant filter as follows:

1. Disconnect system from maintenance input power.

2. Unscrew and remove the filter bowl by hand. Be sure to keep the O-ring.

3. Remove and clean the filter. Re-install the bowl, tightening it by hand. Be sure the O-ring is in place.

4. Turn the system on and check for leaks.

Manual 0-5057 5-1 MAINTENANCE

PAK 200

RETURN

SUPPLY

RETURN

SUPPLY

Art # A-04803

COOLANT

Fill Range

Coolant Tank

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. This procedure may
be repeated a few times until the tank is completely empty.

3. Connect the coolant line fitting and fill the tank with fresh coolant until the right level is reached.

4. Turn system on, let it run for a few minutes and check coolant level, refill if necessary.

MAINTENANCE 5-2 Manual 0-5057

5.03 Arc Starter Service

Arc Starter Service Chart

Symptom Cause Check Remedy

No Pilot Ignition:

Spark in Arc

Starter, but not

ignition

Coolant has become con­ductive

Pilot return wre not con­nected

Spark gap set too close Check with feeler gauge Set to 0.063” ±0.002”
High frequency cap (CA)

Possibly open
Broken or missing ferrites Vissual inspection Replace.
Short across in indicator

(L1)
Spark gap bus caps (C1, C2,

C3) broken or defective
Negative supply not con-

neted correctly
Spark gap set too large Check with feler gauge Set to 0.063” ±0.002”
Faulty transformer Resistance measurement Replace.

Use conductivity meter Flush system, replace cool-

ant.

Visual inspection Connect wire.

Use capacitance meter Reconnect or replace.

Visual inspection Remove short, increase

coil gaps.

Capacitance meter Replace.

Visual inspection Reconnect.

PAK 200

No Pilot Ignition:

No Spark

in Arc Starter

No cooling or

insuficient cooling:

Leaks coolant

No cooling or

insuficient cooling:

No Coolant Flow

No 120V supply Check input voltage at

EMI filter

No / loose connection to
spark gap

Faulty EMI filter Voltage / Resistor mea-

Loose fitting(s) Visual inspection Tighten fittings.
Failure to braze jionts (L1) Visual inspection Replace HF Coil
Damaged or punchured

coolant line(s)
Supply & return hoses

reversed

Blockage in coil or suooly
return hoses

Visual inspection Reconnect.

surement

Visual inspection Replace coolant line(s).

Visual inspection o color­coded connections

loosen fitting slightly and
check for ooolant flow

Make connections; replace
harness.

Replace.

Match coolant connection
colors to ark starter fittings
colors.

Flush system.

Manual 0-5057 5-3 MAINTENANCE

PAK 200

0.063" ± 0.002"

1.6 ± 0.05 mm

Art # A-04835

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.

MAINTENANCE 5-4 Manual 0-5057

SECTION 6:

REPLACEMENT ASSEMBLIES & PARTS

6.01 Replacement Power Supply

Complete Unit / Component
Catalog#

PAK 200

Pak 200 Power Supply, 208/230 460V

Pak 200 Power Supply, 400V 3-0004

Pak 200 Power Supply, 400V (CE) 3-0005

OPTIONAL EQUIPMENT:

Wheel Kit 9-9379

3-0003

Manual 0-5057 6-1 PARTS LIST

PAK 200

9

10

11

16

Art # A-08471_AB

6.02 System Componants and Accessories

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
9 1 Two Stage Air Line Filter Assembly 7-3139
10 1 First Stage Filter Element Replacement 9-1021
11 1 Second Stage Filter Element Replacement 9-1022
1 Nitrogen Regulator 9-2722
1 CO2 Regulator 9-2759
1 Argon/Hydrogen Regulator 9-3053
16 1 Remote Pendant Control Assembly 7-3460
1 High Pressure Air Regulator 9-3022

PARTS LIST 6-2 Manual 0-5057

6.03 Leads and Cables

Primary power

Control

Cable

Ground

Cable

Work

Art # A-08376_AB

Torch

Work Cable

PAK 200

Power Supply

Arc Starter /

Gas Control Module

(GCM-200)

Pilot Return

Negative
Coolant Supply
Coolant Return

Control Cable

Torch Lead Set

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

- Control Cable

Maximum Length 100’ / 30.5 m

Primary Ground

PAK 200

Leads Catalog Numbers; PAK 200 Power Supply, PCH/M 200 Torch

Leads Length

Key Description

A,B,C,D,E Supply Lead Set 4-3027

A Pilot Return Cable (only)

(4 ft / 1.2 m)
B Negative Cable (only) 9-4892
C Hose, Coolant Supply (only) 9-4886
D Hose, Coolant Return (only) 9-4888
E Control Cable (only),

Power Supply

to Arc Starter (4 ft / 1.2 m)

F Ground Wire (only), Power

Supply to Gas Control

Module, 4 ft / 1.2 m
G Torch Lead Assembly 4-0014 4.0015 4-0016
K Control Cable, Power Supply

to Gas Control Module
O Work Cable w/Clamp 9-0020

Supply lead set includes Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and

3 ft

1 m

9-4890

9-4941

9-4923

9-9331

Control Cable.

10 ft

3.05 m

15 ft

4.5 m

25 ft

7.6 m

35 ft

10.6 m

NOTE

50 ft

15.2 m

75 ft

22.8 m

30.5 m

100 ft

125 ft

38.1 m

Manual 0-5057 6-3 PARTS LIST

PAK 200

G

Torch Lead Set

Art # A-08377_AC

Green / Yellow #4 AWG

A

Green

Red

#8 AWG Cable

#1 AWG Cable

B

C

D

E

F

K

Work Cable

37

14

Coolant Leads, Power Supply
to Arc Starter

Pilot Return, Power Supply
to Arc Starter

Negative Lead, Power Supply
to Arc Starter

Control Cable, Power Supply
to Arc Starter

Ground Cable

O

Control Cable,
Power Supply to
Gas Control Module

Green

Red

4’ / 1.3 m

#1 AWG

6.04 Leads and Cables

PARTS LIST 6-4 Manual 0-5057

6.05 Optional Gas Supply Leads

HOSE ASSEMBLIES

Lengh (feet) 10’ 15’ 25’ 35’ 50’ 75’ 100’

Length (meters) 3.05 4.6 7.6 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”

3/8”

SYNFLEX HOSE FITTINGS

ID

1/4” 9-3743 9-3556 9-2776 9-2775 8-5518 8-5015 8-0327 8-0384
3/8” 9-3616 8-6473 N/A N/A N/A 8-6617 N/A 8-0384
1/2” 9-2551 8-6470 N/A N/A 9-3831

02 B (RH) 9-9008 9-9009 9-9010 9-9011

Inert B (RH)

Inert B (LH) 9-9012 9-9013 9-9014 9-9015

CATALOG #

per foot

NUT

Inert B

(LH)

NUT

Inert B

(RH)

NIPPLE

Inert

NUT

FUEL B

(LH)

NUT
02 B

(RH) NIPPLE CLAMP

PAK 200

ADAPTER FITTINGS Catalog #

Inert B (RH) 8-0330

1/4” NPT

Inert B (LH) 8-0329

02 B (RH) 8-0260

1/4” Barb 8-4264

Manual 0-5057 6-5 PARTS LIST

PAK 200

6.06 Power Supply External - Replacement Parts

Item # Qty Description Catalog #

1 Power Supply Front Panel 9-9380
1 Power Supply Rear Panel 9-9381
1 Power Supply Top Panel 9-9382
1 Power Supply Right Side 9-9383
1 Power Supply Left Side 9-9384
1 Louver Panel 9-9385
1 Power Supply Connections Cover 9-9386
1 Lifting Eye 9-9373
1 Touch-Up Paint (Not Shown) 9-9388

PARTS LIST 6-6 Manual 0-5057

PAK 200

1

2

Art # A-04790

6.07 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Heat Exchange Fan FAN 1 9-9338
2 1 Radiator 9-9339

Manual 0-5057 6-7 PARTS LIST

PAK 200

1

2

Art # A-08309

4

5

6

3

6.08 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Output Filter PC PCB8 9-9341
2 1 Sensor HCT2 9-9368
3 1 Magnetic Contactor, pilot MC2 9-9343
4 1 Resisto R6 9-9340
5 1 Resisto R9
6 1 Capacit C2

PARTS LIST 6-8 Manual 0-5057

PAK 200

Chopper Module

Art # A-08311

HCT1

6.09 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 Chopper Module 9-9389
1 Sensor HCT1 9-9342

Manual 0-5057 6-9 PARTS LIST

PAK 200

7

Art # A-08312

6.10 Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344
for 230-400-460 VAC units

PARTS LIST 6-10 Manual 0-5057

PAK 200

PCB3

PCB4

PCB6

Art # A-08313

6.11 Power Supply Replacement Parts - Left Side/Front Panel

Item # Qty Description Ref. Des. Catalog #

1 PC Board PCB3 9-9365
1 PC Board 230/460VAC PCB4 9-9370
1 Display PC Board PCB6 9-9347

Manual 0-5057 6-11 PARTS LIST

PAK 200

Art # A-08314

1

2

2

6.12 Power Supply Replacement Parts - Left Side

Item # Qty Description Ref. Des. Catalog #

1 1 PCBoard 230-400-460VAC PCB1 9-9362
2 1 Magnetic Contactor MC1,MC3 9-9364

PARTS LIST 6-12 Manual 0-5057

PAK 200

RAS

125V 2.5A

CCM

125V3.15A

GCM

125V 10A

GCM

125V2.5A

GCM

125V2.5A

PUMP

250V 10A

FAN

125V 3.15A

CIRCUIT

BREAKERS

J55

J59

J15

G
C
M

C
N
C

R
A
S

CP2

CP3

CP4

CP5

CP6

CP7

CP8

12

13

14

15

16

17

18

Art # A-06017_AC

RETURN

SUPPLY

Art # A-04932_AB

COOLANT

Coolant Tank

Tank Cap

Filter

6.13 Power Supply Replacement Parts - Rear Panel

Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #

12 1 Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A CP2 9-9348
13 1 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 1A CP3 9-9349
14 1 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A CP4 9-9350
15 1 Circuit Breaker (AGC) 125V, 2.5A 120VAC @ 1A CP5 9-9348
16 1 Circuit Breaker (AGC) 125V, 2.5A 15VDC @ 1A CP6 9-9348
17 1 Circuit Breaker (Pump) 250V, 10A 200VAC @ 3A CP7 9-9351
18 1 Circuit Breaker (Fan) 125V, 3.15A 24VDC @ 1A CP8 9-9349
1 Coolant Tank 9-5948
1 Tank Cap 8-5142
1 Filter, Coolant 8-4276

Manual 0-5057 6-13 PARTS LIST

PAK 200

Art # A-08310

1

2

3

4

5

6.14 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Resistor R7 9-9363
2 1 Rectifier (Diode) D1 9-9345
3 1 Transformer T1 9-9355
for 230/460 VAC units
4 1 Diode D2 9-9486
5 1 Terminal Strip TB3 N/A

PARTS LIST 6-14 Manual 0-5057

6.15 Power Supply Replacement Parts

Art # A-04786_AB

Item # Qty Description Catalog #

29 2 Inverter Module 460 and 208/230V 9-9360D
2 Inverter Module 400 9-9482D

PAK 200

Manual 0-5057 6-15 PARTS LIST

PAK 200

30

Art # A-04787

6.16 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

30 1 Sensor (Thermistor) TH1 9-9361

PARTS LIST 6-16 Manual 0-5057

PAK 200

Art # A-08315

1

2

3

6.17 Power Supply Replacement Parts

Item # Qty Description Ref. Des. Catalog #

1 1 Relay PC Board PCB7 9-9366
3 1 Internal Control PC Board PCB5 9-9346

Manual 0-5057 6-17 PARTS LIST

PAK 200

27

22

25

24

26

28

Art # A-08236

6.18 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

22 1 Sensor (Level Switch) LSW1 9-9354
24 1 Motor M 9-9381
25 1 Pump/Check Valve/Bypass Valve Assembly 9-9380
26 1 Bypass Valve (part of assembly)
27 1 Pump (part of assembly)
28 1 Sensor (Flow Indicator) F1 9-9359
Illustration is for Reference ONLY

PARTS LIST 6-18 Manual 0-5057

PAK 200

1

2

6.19 Power Supply Replacement Parts - Right Side

Item # Qty Description Catalog #

1 1 Pilot Resistor Mounting Bracket 9-0032
2 6 Pilot Resistor 3.6 ohms, 300W 9-0039

Manual 0-5057 6-19 PARTS LIST

PAK 200

Art # A-08386

Right Side

Left Side

6

8

10

13

12

3

7

16

15

14

5

11

2

6.20 Arc Starter & Gas Control Module (GCM-200) Replacement Parts

Item # Qty Description Catalog #

1 1 GCM-200, Gas Box/Arc Starter 9-4997
2 1 Base 9-4979
3 1 Front Panel 9-4980
4 1 Lid (not shown) 9-4981
5 1 Gas Bulkhead 9-4982
6 1 Bulkhead 9-4983
7 1 Solenoid Mount 9-4984
8 1 Lid Bracket 9-4985
9 * Not Included
10 1 Bulkhead 9-4988
11 1 Bulkhead, Gas Box/Arc Starter 9-4989
12 1 Mount, Neg Lead Attach 9-4990
13 1 Bracket, Gas Box/Arc Starter 9-4991
14 1 Hose Package 9-4993
15 1 Harness, Gas Controls 9-4994
16 1 Harness, Arc Starter 9-4995
17 1 Wire List, Arc Starter (Not shown) 9-4996

PARTS LIST 6-20 Manual 0-5057

PAK 200

3

4

2

1

Art # A-06798

6.21 Command & Control Module - Replacement Parts

Item # Qty Description Catalog #

1 1 Assembly, CCM (PAK200) 9-9418
2 1 Plate, CCM Face 9-9419
3 1 Panel, CCM Mount Not Available
4 1 Harness, CCM I/O Board 9-9421

Manual 0-5057 6-21 PARTS LIST

PAK 200

This Page Intentionally Blank

PARTS LIST 6-22 Manual 0-5057

!

SECTION 7:

TORCH MAINTENANCE

PAK 200

7.01 Introduction

This section describes basic maintenance procedures
performable by operating personnel. No other adjust­ments or repairs are to be attempted by other than properly
personnel.

WARNING

Disconnect primary power at the source before
disassembling the torch or torch leads.

Frequently review the Important Safety Precau­tions (page 1). Be sure the operator is equipped
with proper gloves, clothing, eye and ear protection.
Make sure no part of the operator’s body comes
into contact with the workpiece while the torch is
activated.

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

Handle torch leads with care and protect them
from damage.

7.02 General Torch Maintenance

The inside of the torch should be cleaned with electrical
contact cleaner using a cotton swab or soft wet rag.
In severe cases, the torch can be removed from the
leads (refer to Section 5.07, Servicing Machine Torch
Components, or Section 5.06, Servicing Hand Torch
Components) and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing it
through with compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

B. Checking Center Insulator

The center insulator separates the negative and posi­tive sections of the torch. If the center insulator does
not provide adequate resistance, current which is
intended for the pilot arc may be dissipated into the
torch head, resulting in torch failure.

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.

A. Cleaning Torch

Even if precautions are taken to use only clean air with
a torch, eventually the inside of the torch becomes
coated with residue. This buildup can affect the pilot
arc initiation and the overall cut quality of the torch.

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.

DO NOT touch any internal torch parts while
the AC indicator light on the front panel of the
power supply is ON.

DO NOT touch any internal torch parts while
the AC indicator light on the front panel of the
power supply is ON.

1. Remove the shield cup, tip, gas distributor, and
electrode from the torch. Disconnect the torch
leads from the power supply to isolate the torch
from power supply circuits.

2. Using an ohmmeter (set to 10K or higher), check
for continuity between the positive and negative
torch fittings. Infinite resistance (no continuity)
should be found. If continuity is found, refer to
Section 5.08, Torch and Leads Troubleshooting.

Manual 0-5057 7-1 TORCH MAINTENANCE

PAK 200

C. Torch O-ring Lubrication

The internal o-rings on the torch head assembly
(electrode, gas distributor and tip) require lubrication
on a scheduled basis. This will allow the o-rings to
remain pliable and provide a proper seal. The o-rings
will dry out, becoming hard and cracked, if the o-ring
lubricant is not used on a regular basis. This can lead
to potential leaks internally and externally. Failure of
o-rings that seal against outside “air” entering the torch
assembly can cause severe contamination. These
contaminants can destroy or shorten the parts life of
tips, electrodes, and internal torch parts.

It is recommended to apply a very light film of o-ring
lubricant, (Catalog Number 8-4025), to the internal
torch head assembly o-rings on a weekly basis.

NOTE

DO NOT use other lubricants or grease, they
may not be designed to operate within high
temperatures or may contain “unknown ele­ments” that may react with the atmosphere.
This reaction can leave contaminants inside the
torch. Either of these conditions can lead to
inconsistent performance or poor parts life.

e. Worn torch parts
f. Non-Genuine Thermal Dynamics Parts

3. Excessive Dross Formation

a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
f. Output current too high
g. Torch tip contacting workpiece
h. Damaged or loose torch head components

7.03 Common Operating Faults

The following lists the more common cutting faults and
what is the possible cause:

1. Insufficient Penetration

a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected

i. Non-Genuine Thermal Dynamics Parts

TORCH MAINTENANCE 7-2 Manual 0-5057

5. Poor Pilot Starting

Multi-Purpose Wrench

(Catalog Number 20-0001)

Used for Electrodes

Used for 11/16" ( 17.5 mm)

Across Tip Flats

Gas Distributor Notch

Used with 11/16" (17.5 mm)Tip

Used for 5/8" (15.9 mm)

Across Tip Flats

Gas Distributor Notch

Used with 5/8" (15.9 mm)Tip

This Side

Towards Torch

A-01639

Electrode

Shield Cup

Tip

Gas

Distributor

Torch Head

Water Tube Extension

(Gouging Only)

A-02188

Good Tip

Worn Tip

A-02195

Worn Electrode

New Electrode

A-02208

a. High coolant conductivity (Refer to Power Supply

Manual)

b. Non-Genuine Thermal Dynamics Parts

7.04 Inspection and Replacement
Consumable Torch Parts

PAK 200

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.

DO NOT touch any internal torch parts while
the AC indicator light on the front panel of the
Power Supply is ON.

Remove the consumable torch parts per the following
procedure (See Note):

NOTE

A multipurpose wrench is supplied for chang­ing the tip, electrode and gas distributor in the
torch head.

Torch Consumable Parts

2. Inspect the cup for damage. Wipe it clean or replace
if damaged.

3. Using the multipurpose wrench (5/8 inch slot) re
move the tip. Check for excessive wear (indicated by
an elongated or oversized orifice). Replace the tip if
necessary.

NOTE

The tip, electrode and gas distributor have
o-rings on each part. The o-rings should be
removed and a light coating of o-ring lubricant
(catalog number 8-4025) applied.

-

Multi-Purpose Wrench

1. Unscrew and remove the shield cup from the torch.

Slag built up on the shield cup that cannot be
removed may effect the performance of the

system.

Manual 0-5057 7-3 TORCH MAINTENANCE

NOTE

Tip Wear

4. Tilt the torch head to remove the gas distributor. The
end of the multipurpose wrench can be used to help
remove the gas distributor. Check for excessive wear,
plugged gas holes, or discoloration. Replace if neces­sary.

5. Using the multipurpose wrench (electrode area) remove
the electrode. Refer to Figure 5-4 and check the face
of the electrode for excessive wear.

PAK 200

Electrode Wear

6. Install the electrode and tighten with multipurpose
wrench. Do not over tighten the electrode. The circular
area around the wrench used for electrodes will also
align the electrode in the torch head. This will prevent
installing electrodes on an angle and cross threading
the electrode in the torch head.

7. Install the gas distributor.

8. Install the tip and tighten with the multipurpose wrench.
Do not over tighten the tip.

CAUTION

Make sure both the tip and electrode corre­spond with the plasma and secondary gases
being used, the current range, and the type of
operation. Refer to Section 4.04, Torch Parts
Selection.

9. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the cup,

check the threads before proceeding.

7.05 Troubleshooting Guide

A. Troubleshooting

a. Place RUN/SET switch to RUN position.

2. Torch switch activated during 20 second pre-flow

a. Release torch switch and wait at least 20 sec-

onds before activating switch again.

3. Coolant return lead clogged or plugged.

a. Check coolant return into unit reservoir. Inspect

torch assembly and replace if necessary.

4. Faulty torch parts.

a. Inspect torch parts and replace if necessary.

Refer to Section 5.04, Inspection and Replace­ment Consumable Torch Parts

5. Plasma gas pressure too high.

a. Refer to torch consumables information for

correct pressure.

6. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads
Troubleshooting.

7. Faulty components in power supply system com­ponents

a. Return for repair or have qualified technician

repair per Service Manual.

This Sub-Section covers troubleshooting that requires
disassembly and electronic measurements. It is helpful
for solving many of the common problems that can arise
with this torch assembly.

B. How to Use This Guide

The following information is a guide to help the Customer/
Operator determine the most likely causes for various
symptoms.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

Locate your symptom, check the causes (easiest listed
first) then remedies. Repair as needed being sure to verify
that unit is fully operational after any repairs.

A. Torch will not pilot when torch switch is activated

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached to

power supply.

2. Poor Work Cable Connection.

a. Inspect work cable connection and adjust if

necessary.

3. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads
Troubleshooting.

4. Faulty components in power supply system com­ponents

a. Return for repair or have qualified technician

repair per Service Manual.

1. Power Supply RUN/SET switch in SET position

TORCH MAINTENANCE 7-4 Manual 0-5057

PAK 200

C. Low cutting output with no control

1. Incorrect setting of AMPERAGE control on power
supply.

a. Check and adjust to proper setting.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads
Troubleshooting.

3. Faulty components in power supply system com­ponents

a. Return for repair or have qualified technician

repair per Service Manual.

D. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads
Troubleshooting.

3. Faulty components in power supply system com­ponents

a. Return for repair or have qualified technician

repair per Service Manual.

E. Improper cutting output

1. Current set too low at power supply

a. Check source for at least 100-125 psi (6.9- 8.6

bar) maximum pressure.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.09, Torch and Leads
Troubleshooting.

3. Faulty components in power supply system com­ponents

a. Return for repair or have qualified technician

repair.

G. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting.

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix 1, Cut-

ting Speed Charts).

3. Oil or excessive moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface

while purging and observe oil or moisture
buildup (do not activate torch).

7.06 Servicing Hand Torch Components

A. Removing Torch Switch and Torch Head Assembly

Removing the torch control switch assembly requires
gaining access to the switch wiring and partially disas­sembling the torch handle, as follows:

a. Increase current setting.

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix 1, Cut-

ting Speed Charts).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface

while purging and observe oil or moisture
buildup (do not activate torch)

4. Poor input or output connections to power supply

a. Check all input and output connections.

F. No gas flow

1. Gas not connected or pressure too low

Manual 0-5057 7-5 TORCH MAINTENANCE

1. Remove the shield cup, tip, gas distributor and
electrode from the torch head assembly.

2. Roll the torch switch sheath back over the handle
to expose the tape covering the torch switch con­nectors.

NOTE

Use a soap and water solution on the sheath
to assist in rolling.

PAK 200

Sheath

Connectors From

Torch Switch

Torch Handle

Torch Control

Switch

A-02196

Threaded Locking Nut

A-02197

Secondary Lead

Plasma (+) Lead

Coolant Return Lead

Coolant (-) Supply Lead

11. If the torch switch is defective, remove the switch
from the torch handle.

B. Reassembling Torch Switch and Torch Head

Assembly

NOTE:

Verify that small rubber duck valve is in torch
plasma fitting.

To install the torch switch or torch head assembly use
the following procedure:

Switch Wiring

3. Carefully cut and remove the tape from the leads
and the end of the leads sheathing.

4. Slide the sheathing back to expose the torch switch
connectors.

5. Remove the tape securing the two connectors
together.

6. Disconnect the torch switch leads.

NOTE

The torch switch connectors are made to fit
into the matching connectors.

7. Remove torch from handle.

NOTE

Keep the lock nut threaded on the torch head.

8. Disconnect all four leads to disconnect the torch
head.

1. Slide the torch handle with torch switch and sheath
ing over the torch leads.

2. Connect all four leads to connect to the replacement
torch head assembly.

3. Remove the rigid insulator from the old Torch Head
Assembly from between the layers of Estermat
paper and install replacement insulator. Refer to
illustration pg. 7-7 for location and orientation of
rigid insulator.

NOTE

Over a period of time there may be a breakdown
of the estermat paper causing the Torch Head to
short out if the rigid insulator is not installed.

4. Secure the rigid insulator in place with electrical
tape.

5. Tighten the threaded locking nut with the flat
(non-chamfered) edge against the torch head,
then loosen the nut slightly by turning it back ap­proximately one-half turn.

-

9. Remove torch head assembly.

Torch Head Removal (PCH-200)

10. Remove the torch handle and switch from the
leads.

TORCH MAINTENANCE 7-6 Manual 0-5057

6. Install the torch head on the handle.

NOTE

The torch switch connectors are made to fit
into the matching connectors.

7. Connect the two torch switch leads.

8. Tape the two control cable connector leads to
gether.

9. Pull the leads sheathing over the connectors and
secure with electrical tape to the torch leads.

10. Roll the torch switch sheath back over the han
dle.

11. Install torch parts in torch.

12. Align the Torch Control Switch on the handle in
the desired position for cutting, position the torch

-

-

head then tighten the threaded locking nut against

Positioning Tube

Torch Adaptor

Lead Connections

A-00663

Bushing

Pinion Assembly

Machine

Torch Head

Plasma Lead (+)

Coolant Return Lead

(LH Threads)

Secondary Lead

Coolant (-)

Supply Lead

A-02198

the torch handle.

NOTE

There will be a slight gap between the torch
head and the lock nut.

7.07 Servicing Machine Torch
Components

PAK 200

Torch Mounting Assembly

WARNINGS

Disconnect primary power to the system before
disassembling the torch or torch leads.

DO NOT touch any internal torch parts while
the AC indicator light on the front panel of the
Power Supply is ON.

A. Removing Machine Torch Head

1. Remove the shield cup, tip, gas distributor and
electrode from the torch head assembly.

2. Remove shrink on tubing.

3. Locate the tape at the back end of the torch posi
tioning tube. Remove the tape from the torch lead
sleeving and slide the sleeving back (see NOTE).

NOTE

The positioning tube will not slide over the torch
lead sleeving.

4. Unscrew the positioning tube from the torch
adaptor on the torch head assembly and slide the
positioning tube back over the leads.

5. Unscrew the torch adaptor from the torch head
assembly. Slide the torch adaptor back over the
leads to expose the plasma (+), secondary, coolant
supply (-), and coolant return connectors.

6. Disconnect the plasma (+), secondary, coolant
supply (-), and coolant return connectors to allow
removal of the torch head. Note the location of the
torch leads insulator which separates the negative
and positive leads.

-

Torch Head Removal

B. Reassembling Machine Torch Assembly

NOTE

Verify that the small rubber duck valve is in
torch plasma fitting.

1. Remove the rigid insulator from the old Torch Head
Assembly from between the layers of estermat
paper.

Manual 0-5057 7-7 TORCH MAINTENANCE

PAK 200

Two Layers Of

Estermat Paper

Rigid Torch

Leads Insulator

A-01577

2. Slide the rigid insulator between the layers of
estermat paper on the replacement Torch Head
Assembly (see note).

NOTE

Over a period of time there may be a breakdown
of the estermat paper causing the Torch Head to
short out if the rigid insulator is not installed.

Rigid Insulator Installation

3. Secure the rigid insulator in place with electrical
tape.

4. Slide replacement shrink on tubing on leads.

7.08 Torch And Leads Troubleshooting

A. General Information

Failures in the Torch and Leads can be isolated to the Torch
Head or Torch Lead components. To properly isolate the
failed part requires the use of an ohmmeter and a Hi-Pot
Tester.

WARNING

The use of a Hi-Pot Tester should be performed
only by a qualified electronic technician.

In the Torch Head the center insulator separates the nega­tive and positive charged sections of the torch. If the center

insulator does not provide adequate resistance, current
which is intended for the pilot arc may be dissipated into
the torch head, resulting in torch failure.

In the Torch Leads the negative and positive leads are iso­lated from each other. If there is not adequate resistance
between the leads then torch failure may occur.

5. Connect the plasma (+), secondary, coolant supply,
(-) and coolant return connectors.

6. Secure leads and tubing with single layer of electri
cal tape.

7. Slide the torch adapter down over the leads and
screw the adaptor securely onto the back of the
torch head assembly.

8. Slide the positioning tube down over the leads and
thread it into the torch adaptor on the torch head
assembly.

9. Apply tape to the torch leads sleeving at the back
end of the positioning tube.

10. Position shrink on tubing over the tape and
shrink.

11. Install the front end torch parts.

B. Quick Check Procedure

This quick check will identify major isolation failures in
the Torch Head or Torch Lead components using an ohm-

­meter.

The actual assembly and consumables may vary for dif­ferent torches but the basic procedure is the same for all
torches. Make the quick check on the Torch Head and
Leads as follows:

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.

1. Remove the consumables from the torch.

2. Disconnect the torch leads from the power supply
to isolate the torch from power supply circuits.

TORCH MAINTENANCE 7-8 Manual 0-5057

3. Using an ohmmeter (set to 10K or higher), check
for continuity between the positive and negative
torch fittings.

PAK 200

WARNING

• If there is continuity between the two torch

fittings proceed to Step 4.

• If no continuity (infinite resistance) is found

between the two torch fittings proceed to para­graph C.

4. Remove the torch head from the leads (refer to
the proper Section on servicing the Torch Com­ponents).

5. With the torch head disconnected from the leads,
measure the resistance between negative fitting or
cathode body of the torch head and the positive
fitting or anode body of the torch head.

No continuity (infinite resistance) should be mea­sured between negative and positive sections of
the torch head.

• If there is continuity, torch head must be re

placed.

• If no continuity (infinite resistance) is found

proceed to Step 6.

6. Check the torch leads by measuring the resistance
between the positive pilot lead connector and the
negative lead fitting.

• If there is continuity, torch leads must be re

placed.

• If no continuity (infinite resistance) is found

proceed to paragraph ‘C’ (see NOTE).

NOTE

It is possible that the Torch Head and Torch
Leads will test properly with an ohmmeter. The
Torch Head and Torch Leads should be tested
further for insulation breakdown if no other
fault can be found.

C. Checking Proper Insulation Resistance Procedure

The Torch Head and Torch Leads should be tested further
for insulation breakdown if no other fault has been found.
This procedure requires the use of a Hi-Pot Tester.

This procedure should be performed only by a
qualified electronic technician.

1. To test the Torch Head center insulator for insula
tion breakdown use the following procedure:

a. Remove the Torch Head Assembly from the

Torch Leads if not already done.

b. Remove the consumables from the Torch Head

Assembly if not already done.

c. Connect a Hi-Pot Tester capable of producing

2500 VAC between the positive pilot lead and
the negative lead fittings.

d. Increase the output of the Hi-Pot Tester to a

maximum of 2500 VAC.

• If the voltage drops to 0 VAC or leakage current

-

2. To test the Torch Leads for insulation breakdown

-

3. Visually check that the torch switch wires, pilot

is detected, then the Torch Head center insula­tor is breaking down and the Torch Head must
be replaced.

• If the Torch Head center insulator passes the

test, then proceed to Step 2.

use the following procedure:
a. Connect the Hi-Pot Tester between the positive

pilot lead and the negative lead fittings. The fit­ting on the other end of the Torch Leads must
be separated (isolated) from each other.

b. Increase the output of the Hi-Pot Tester to a

maximum of 2500 VAC.

• If the voltage drops to 0 VAC or leakage cur
rent is detected, then the insulation between
the Torch Leads is breaking down and the
Torch Leads must be replaced.

• If the Torch Leads passes the test, then
proceed to Step 3.

lead connection, and negative lead connections
are properly connected and in good condition (no
shorts or arcing).

-

-

Manual 0-5057 7-9 TORCH MAINTENANCE

• If problems are evident, repair or replace as
required.

This Page Intentionally Blank

APPENDIX 1:

3 Run / Set Sw

5 Current Control Pot

6 Current Control Pot

7 Current Control Pot

8 Jumper to 9

10

13

19 Ground

11 Run / Set Sw

12

18

20
21

25

23 Jumper to 15

28

22

26

24 Sol 1

29

27

30

31

32

36

37

POWER SUPPLY J55

Art # A-04848

ARC STARTER / GAS CONTROL MODULE J56

1 Jumper to 2

2 Jumper to 1

15 Jumper to 23

14 Run / Set Sw

16

17

33 Ground

34

35

4 Gas Pr Sw (SW1)

9 Jumper to 8

3

9

5 + 10 vdc

1

6 Pot Wiper

10 Gas On

13

19

15 E-Stop

14 E-Stop

11 Gas On

12

16 24VAC

17 24 VAC Ret

18

20

25

23

28

26

24 24 VAC Ret

29

27

30

31

34 120VAC

35 120VAC Ret

32

36

37

4 Ground

2

7 Ground

8 Ground

21

22

33 Ground

Control Cable Pinouts

Power Supply J55 to Gas Control Console J56

Manual 0-5057 A-1 APPENDIX

APPENDIX 2:

3

9: 120 VAC RET

5

1 - Jumpered to 4

6

7 - 120 VAC

8

10

13

14

11

12

Art # A-04849

2: Ground

POWER SUPPLY J59

ARC STARTER / GAS CONTROL MODULE J58

3

5

4

1

6

8

10

16

15

11

12

14

13

4 - Jumpered to 1

2: Ground

9: 120 VAC RET

7 - 120 VAC

Control Cable Pinouts

Power Supply J59 to Arc Starter / Gas Control
Console J58

Manual 0-5057 A-2 APPENDIX

Command-Control PC Board Layout (A)

H1

J4

U6

1

TP11TP10TP9

TP1

TP3

TP6

TP4

TP7

TP5

TP2

TP8

44

23

22

1

U4

1

2

1

SW3

C18

D10

R69

C19

C41

R30

R23

C15

C26

C12

C22

R65

R74

U26

R17

C3

J5

R1

R34

D6

C16

C33

R47

R81

U25

R77

U24

1

R22

R9

R46

C13

C49

+

R73

1

2

1

SW9

R19

R24

R64

C56

C58

U12

R35

R28

L2

C21

C5

R5

C40

R80

U18

C57

C20

R43

R29

R52

C50

+

C27

R6

C38

C36

R82

C4

R15

R88

R45

6

9

5

1

J1

R56

U16

1

R71

C54

R67

C17

+

C32

L4

R68

R54

D1

R72

R50

L3

C43

C35

1

2

1

SW5

U9

D9

H3

R87

H4

R26

R86

PRE

FLOW

POST

R10

FLOW FUNC

SYS
CONT

R42

AUTO PILOT

OK TO

MOVE/D

R11

19X2169 REV

C 2004 TDC

Y1

C30

C55

R90

R25

R66

C6

C42

+

U30

1

D8

D15

R70

R2

U27

R79

C2

+

U5

R91

D11

R51

C25

R89

R18

R8

C51

D3

D13

U28

1

C8

R31

R40

C34

+

R85

R38

C48

D7

R92

R57

R7

R4

C1

R36

1

2

1

SW4

C9

R3

R62

R63

U17

R13

160

U14

1

40

120

80

R27

C31

R59

R55

R32

U13

1

C45

C39

L1

R44

R84

R61

R20

R58

R78

U29

C14

D2

R33

C7

U22

C52

R76

C46

R21

U11

1

R37

R16

C10

R41

D4

R83

R49

U15

R93

R39

C53

C59

+

C47

U23

1

U19

1

C24

C29

R94

D5

R48

R60

D14

C28

R75

R12

C11

U10

C44

+

R53

C23

L6

1

U21

C37

D12

R14

L5

+15V

DAC DAC

-15V
+3.3V

CLKO

GND

AGND

+5.0V

TEMP
SENSE

+3.3VA

/WR

/RD

R C

GP1

U20

GP2

U31

NC

U32

U7

1

3

2

1

1

SW1

4

3

2

1

1

TPAD1

SW8

4

U8

1

1

1

1

H6

H2

H5

1

CPU/COMMUNICATIONS

29

2

1

J3

30

3029

21

J2

Art # A-06906

O
N

Note: Switch Settings May Vary.

AC

Switches

O
N

TP9 TP10 TP11

TP2

TP1

TP3

TP4

TP5

TP6

TP7

TP8

J2

J3

J1

1

2

1

SW3

1

2

1

SW9

1

2

1

SW5

PRE

FLOW

POST

FLOW FUNC

SYS

CONTAUTO PILOT

OK TO

MOVE/D

1

2

1

SW4

3

2

1

1

SW1

4

3

2

1

1

SW8

4

APPENDIX 3:

Manual 0-5057 A-3 APPENDIX

APPENDIX 4:

H1

C75

C79

C41

R149

R144

R148

R103

C11

U1

1

D34

1

U10

R88

R128

R39

R73

R118

R120

C16

R81

29

2

1

J3

30

R11

1

U12

D8

D10

TP6

SW6

U7

1

R75

K5-E-STOP

R20

R1

R151

D37

J5

U14

1

U5

1

R139

U13

1

C56

C22

C50

U6

1

R10

R14

R2

D6

D29

D12

R104

C6

R125

D20

R47

R5

R82

J36

J4

D18

R77

R72

R9

TP7

1

2

1

SW13

J35

C3

R131

R13

C53

C78

R62

C39

C77

C87

C33

R23

R132

U22

1

R145

C17

K1-PSR

D22

R69

D21

TP9

R76

C26

C58

R64

U3

1

R117

R6

R79

R55

C40

C68

C7

R41

R44

R8

R66

R121

D25

D23

R31

R28

R45

R123

R102

R135

C2

D14

C24

TP3

U18

1

R67

R49

TP12

U23

1

C45

R57

R138

R127

C76

C66

R12

D26

C19

TP5

R38

D7

R53

C18

D30

R27

C47

D17

C30

B

A

SW11

H2

R71

U20

H5

J1

H4

R97

H6

H8

R99

H9

C84

19X2174

D2

1 1

R141

1

1

11

1

1

R15

1

1

REV

C TDC 2005

C8

ALL SW OFF FOR 50:1 (DEFAULT)

SW12-1 ON FOR 16.7:1 (SC-11)

U16

OK TO MOVE SELECT

CONTACTS

1

DC VOLTS

+

+

+

C93

+

+

U17

1

1

+

+

+

R43

H10

H11

OK CNC

R46

PSR

CNC_E-STOP

CNC_START

HOLD_START

R115

CNC PREFLOW

GAS ON

E-STOP_PS

C65

C35

U24

1

+

GND

+5V

R80

+15V

-15V

+15V

-15V

R87

+18VGND

ISOLATED

PILOT

R56

DEMAND

CUT

DEMAND

ARC V-

R114

PILOT V

CC POT

D3

TP8

R26

K7-GAS ON

C34

U19

L2

C27

R29

C83

+

R90

C69

+

C52

U2

1

C48

U9

1

R129

R50

C15

TB1

R59

C20

R83

C82

D9

C4

C23

C55

R147

C88

C95

+

K2-START

C46

R61

R109

D4

D32

J9

Q1

R143

C71

C49

R91

R24

R60

J6

R22

R142

R21

R7

R108

R63

R40

R101

R37

C5

C64

C92

T1

R30

J8

R134

R119

R116

R89

R48

+

K3-E-STOP CNC

R78

D36

D31

R140

R107

C37

R65

R100

C28

R84

U11

1

K4-OK

D1

C73

R25

R110

C54

D15

R133

R150

R122

R19

C31

TP11

D39

29

2

1

J2

30

D38

R86

R68

R42

D13

R126

R70

R3

C80

R96

U4

TB2

1

C21

K6

C85

+

R33

C70

D40

R17

C51

R136

TP4

D28

R93

R52

C9

TP14

D16

C61

D35

C13

R58

D5

R85

R98

R94

C89

C62

C25

R74

R130

TP1

J7

TP13

C91

R35

TP10

R18

C29

C72

C42

C74

D19

R4

+

R124

R95

C81

D11

R54

C36

D24

C12

C86

U21

1

U15

R16

1

L1

TP2

C60

R32

+

R51

U8

C32

1

C14

D27

R113

D33

C38

R105

R34

R92

C59

R112

R106

H3

R146

R111

R36

C10

C57

1

2

25

26

1

2

33

34

+29-41 VDC

C67

C63

C90

R223

C94

R155

C1

R158

D60

R156

3

2
1

1

SW12

4

R154

R157

D61

SW12-2 ON FOR 30:1

SW12-3 ON FOR 40:1

SW12-4 SPARE

+

+

R152

C44

H7

R224

R225

C43

R227

R228

Q2

R226

Q3

AD+

Art # A-06901

TP14

TP7

TP6

J1

SW6

SW12

J36

TB1

TB2

J4

J9

TP11

J5

J6

J7

SW11

TP9

J8

TP12

J2

TP10

TP8

J35

TP4

TP3

TP2

SW13

TP5

TP1

TP13

J3

Command-Control PC Board Layout (B)

Manual 0-5057 A-4 APPENDIX

APPENDIX 5:

Art # A-04900

TB1-1 E-Stop (Com)

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 (-)

TB1-8 Divided Arc Voltage (+)

TB1-9 Remote Analog Current Control (0-10V) (-)

TB1-10 Remote Analog Current Control (0-10V) (+)
TB1-11
TB1-12

TB2-1 Hold Start (-)

TB2-2 Hold Start (+)

TB2-3 Preflow On (-)

TB2-4 Preflow On (+)

TB2-5

TB2-6 Pilot On (Relay Contacts NO)
TB2-7

TB2-8 Pilot On (Relay Contacts NO)

TB2-9

TB2-10 OK to Move (Contacts or DC Volts) (-)
TB2-11
TB2-12 OK to Move (Contacts or DC Volts) (+)

TB2

TB1

Sustained Start / Stop

TB1-5

TB1-6

Momentary Start / Stop

TB1-4

TB1-5

TB1-6

Stop

Start

Start / Stop Circuit Configurations

These points are jumpered together at the factory.
Remove the jumper to use existing E-Stop circuits.

CNC - Control Module Board PCB Connections

Manual 0-5057 A-5 APPENDIX

APPENDIX 6:

5

5

4

4

3

3

D D

C

B B

A

NEG (from PS)

120 VAC120 VAC

120 VAC RET120 VAC RET

CHASSIS GNDCHASSIS GND

(1)

(2)

(8) (8)

(10)

(10)

(9)

(6) (6)

(5)

(5)

(7)

(7)

(9)

(12)

(11)

(14)

(14)

(13)

(13)

(13)

(15)

(4)

(12)(12)(12)(12)

(15)(15)(15)(15)(15)(15)(15)(15)(15)(15)

+10VDC

120 VAC

120 VAC RET

24 VAC RET

24 VAC

POT WIPER

GCM 200 GAS CONTROL & ARC STARTER

T1 Assembly

8X290

POWER SUPPLY

RUN

SET

PLASMA

JUMPER for BASIC GAS CONTROL ID

JUMPER for Plasma Enable

C2

1900 pfC21900 pf

NEGNEG

J55J55

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

T1

11X16T111X16

1

2

3

4

SW1
GAS PRESSURE

SW1
GAS PRESSURE

1 2

C1

1900 pfC11900 pf

SW3

RUN / SET

SW3

RUN / SET

2

1

3

5

4

6

SOL2SOL2

C3

1900 pfC31900 pf

WORKWORK

GAP1

SPARK GAP 0.062"

GAP1

SPARK GAP 0.062"

R1 6.8K 1WR1 6.8K 1W

Line Filter 1phLine Filter 1ph

Line1

Line2

Load1

Load2

GND

J58

16 PIN

J58

16 PIN

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16

J59 RAS

14 PIN

J59 RAS

14 PIN

1
2
3
4
5
6
7
8
9
10
11
12
13
14

CURRENT CONTROL POTCURRENT CONTROL POT

1

2

3

E-STOPE-STOP

PILOT2PILOT2

R2 6.8K 1WR2 6.8K 1W

J56J56

1

2

3

4

5

6

7

8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

GAS ONGAS ON

SOL1SOL1

Art # A-08503

Arc Starter / Gas Control Module Schematic

Manual 0-5057 A-6 APPENDIX

2

2

1

1

C

A

PILOT RETURN (from torch)

SHLD

NEG

PLT

CGND

DWG No:

Sheet

of

SupersedesScale

Create Date:

Drawn:

Reference

Date

ByChange Description

Rev

Information Proprietary to THERMADYNE INDUSTRIES

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS OTHERWISE SPECIFIED -

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

Chk: App:

TITLE:

Last Modified:

SCHEMATIC,

NONE

42X1309

Thursday, April 17, 2008

1 1

82 BENNING STREET
W. LEBANON, NH 03781
[phone]

GCM 200 GAS CONTROL & ARC STARTER

14:51:05

THERMADYNE

INTRO ECO B731 GAC 04/17/08

GAC

AA

DWG No:

Sheet

of

SupersedesScale

Create Date:

Drawn:

Reference

Date

ByChange Description

Rev

Information Proprietary to THERMADYNE INDUSTRIES

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS OTHERWISE SPECIFIED -

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

Chk: App:

TITLE:

Last Modified:

SCHEMATIC,

NONE

42X1309

Thursday, April 17, 2008

1 1

82 BENNING STREET
W. LEBANON, NH 03781
[phone]

GCM 200 GAS CONTROL & ARC STARTER

14:51:05

THERMADYNE

INTRO ECO B731 GAC 04/17/08

GAC

AA

DWG No:

Sheet

of

SupersedesScale

Create Date:

Drawn:

Reference

Date

ByChange Description

Rev

Information Proprietary to THERMADYNE INDUSTRIES

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS OTHERWISE SPECIFIED -

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

Chk: App:

TITLE:

Last Modified:

SCHEMATIC,

NONE

42X1309

Thursday, April 17, 2008

1 1

82 BENNING STREET
W. LEBANON, NH 03781
[phone]

GCM 200 GAS CONTROL & ARC STARTER

14:51:05

THERMADYNE

INTRO ECO B731 GAC 04/17/08

GAC

AA

TORCH

Water Cooled
Inductor

L1

TORCH LEAD
OUTER SHIELD

NEG & HF (to Torch)

TORCH LEAD
INNER SHIELD

04/17/2008

NEG (from PS)NEG (from PS)

CHASSIS GNDCHASSIS GND

C4

0.1 uf 1000VDC

C4

0.1 uf 1000VDC

WORKWORK

C8

0.047 uf 1000VDC

C8

0.047 uf 1000VDC

C6

0.1 uf 1000VDC

C6

0.1 uf 1000VDC

PILOTPILOT

C5

0.047 uf 1000VDC

C5

0.047 uf 1000VDC

Art # A-08503

Manual 0-5057 A-7 APPENDIX

APPENDIX 7:

1

1

2

2

3

3

4

4

5

5

A A

B B

C C

D D

E E

F F

/ 460

/ 460

460

230

COM

PGND2

/ 230

INPUT_NG

-15V

+5V

GND

+15V

+15V

GND_C

PGND1

TEMP_C

+15V

MISSING_PHASE

COM_A

230_A

460_A

E

L1

L2

L3

+12VDC+12VDC

+15V

+12VDC

To PCB7 TB3

To T1 PRI - 0

FAN + (24 VDC)

To PCB7 CN2-5

FAN - (24 VDC)

From CN9 on PCB7

To PCB7 CN2-4

To PCB7 CN2-2

To PCB7 CN2-1

RIBBON CABLE SIGNALS

CN6 - 16 Ckt Ribbon Cable

2,4- I_REF (Scaled Cut Demand)
5- PS_START (Start)
6- REDUNDANT_START (Start2)
8- INV_READY
9- / PS_START disabled by Input_NG
12- / OCR
13- / PS_START disabled by OCR
14- /TEMP_ERR
15- / PS_START disabled by Temp _Err

--230--

--230--

208-230/460 VAC 3 Phase

CN4

CN6

CN5

CN1

DETECTOR PCB

BIAS SUPPLY PCB

INPUT POWER
INDICATOR
REAR PANEL

CN5

INPUT POWER
INDICATOR
INTERNAL

VAC_IN

(A1 Sht2)

(A1 Sht2)

CN6

FILTER PCB

INTERFACE PCB

P_GND

(A1 Sht 2)

(A1 Sht 2)

(D2, Sht 2)

V_CHANGE PCB

ON / OFF

LINE to LINE,
LINE TO GND
CAPS & VARISTORS

PCB 1
WK-5630

16 CKT RIBBON CABLE

100A INVERTER MODULE # 1 (top)

/ OVERTEMP <

CN6

MISSING PHASE

(pulses)<

PCB 5 WK-5602 (partial)

LED1 DIM = LOW, BRIGHT = OK
LED2 DIM = OK, BRIGHT = FAULT
LED3 DIM = OK, BRIGHT = FAULT
LED4 OFF = OK, ON = FAULT
LED5 OFF = OK, ON + FAULT

CN6 16 CKT

CN6

VAC_IN

P_GND

PCB4 WK-5604

PCB3 WK-5694

BIAS SUPPLY
FOR PCB5

(F2 -Sht2)

100A INVERTER MODULE # 2 (bottom)
(same as #1)

--460--

DC FAN
POWER

(A2 Sht 2)

(A2 Sht 2)

AC

AC

AC

+-

D1

AC

AC

AC

+-

D1

CN32CN32

123

4

C.P1C.P1

P (+)P (+)

CN7CN7

12345

P1P1

CN3CN3

1

2

MC3-AMC3-A

CN1-230VCN1-230V

1

2

3

4

INRUSHINRUSH

MC3-BMC3-B

NE1NE1

+

RY2

RY2

+

RY2

RY2

N (-)N (-)

MC1-CMC1-C

CN2-460VCN2-460V

1

2

3

4

TB3TB3

MC1-BMC1-B

N2N2

CN32CN32

123

4

CN4 - PCB12CN4 - PCB12

123

4

CN17CN17

123

CN4CN4

1

4

- +- +

3

1

2

4

TT

LED2

MISSING PHASE

LED2

MISSING PHASE

CN10CN10

1

2

N (-)1N (-)1

MC3-CMC3-C

MC1-AMC1-A

1

2

34

NE2NE2

TB1TB1

RR

CN1CN1

1

5

8

CN2CN2

123

CN1CN1

1

2

3

4

5

6

7

CN1-230V6CN1-230V

6

123

4

CN2CN2

1

2

3

CN3CN3

1

4

T1T1

CN2-460VCN2-460V

123

4

P (+)1P (+)1

CN2CN2

1

2

CN18CN18

123

CN4 - PCB1CN4 - PCB1

123

4

CN7CN7

12345

R1R1

TB2TB2

+-+

-

1

2

3

45

6

SS

LED3

INPUT NG

LED3

INPUT NG

RY2RY2

++

LED5

ERROR

LED5

ERROR

C4C4

230V230V

TB4TB4

++

S1S1

CN4CN4

123

4

LED4

CHOPPER TEMP

LED4

CHOPPER TEMP

- +- +

3

1

2

4

1

2

3

4

TB1TB1

Art # A-08474

Power Supply Schematic,460V / 208 - 230V

Manual 0-5057 A-8 APPENDIX