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Thermal Dynamics
Welding System
PAK 200
Thermal Dynamics PAK 200 User Manual
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460V /
208-
230
PLASMA CUTTING SYSTEM
P
AK
®
Operating
Manual
Rev
. AB
Date:
October 8, 2008
Manual #
0-5057
Operating Features:
200
2
Table of Contents
Table of Contents
5
Section 1: General Information
9
Notes, Cautions and Warnings
9
Important Safety Precautions
9
Publications
10
Note, Attention Et Avertissement
11
Precautions de Securite Importantes
11
Documents de Reference
13
Declaration of Conformity
14
Statement of Warranty
15
Section 2: Specifications
17
General Description of the System
17
Plasma Power Supply
17
Gas Control Module / Arc Starter
17
Plasma Cutting Torch
17
System Component Layout
17
Power Supply Specifications & Electrical Requirements
18
Power Supply Dimensions
19
Power Supply Rear Panel Features
20
Gas Requirements
21
Gas Applications
21
PCH/M 200 Torch Specifications
22
Section 3: Installation
25
Installation Requirements
25
Cables and Leads Identification
26
Cables and Leads Identification
27
Position the Power Supply
28
Primary Power Connections
29
Connect Work Cable
32
Connect Gas Supply Lines
33
Connect Torch Control Cable
34
Set Switches for Command-Control Module
35
Connect Torch Leads to the Gas Control Module / Arc Starter
37
Torch Parts Selection
39
Complete the Installation
41
Section 4: Operation
43
Power Supply Indicators
43
Control Console Features
44
Operating Set-Up
45
Cut Quality
46
System Operation
47
Operational Suggestions
48
Recommended Cutting Speeds
52
Section 5: Maintenance
57
Coolant Filter Cleaning Procedure
57
Coolant Replacement Procedure
58
Arc Starter Service
59
Arc Starter Spark Gap Adjustment
60
Section 6: Replacement Assemblies & Parts
61
Replacement Power Supply
61
System Componants and Accessories
62
Leads and Cables
63
Control Cable
63
Parts List
63
Leads and Cables
64
Optional Gas Supply Leads
65
Power Supply External - Replacement Parts
66
Power Supply Replacement Parts - Right Side
67
Power Supply Replacement Parts - Right Side
68
Power Supply Replacement Parts - Right Side
69
Power Supply Replacement Parts - Front Panel
70
Power Supply Replacement Parts - Left Side/Front Panel
71
Power Supply Replacement Parts - Left Side
72
Power Supply Replacement Parts - Rear Panel
73
Power Supply Replacement Parts - Right Side
74
Power Supply Replacement Parts
75
Power Supply Replacement Parts
77
Power Supply Replacement Parts - Right Side
78
Arc Starter & Gas Control Module (GCM-200) Replacement Parts
80
Command & Control Module - Replacement Parts
81
Section 7: Torch Maintenance
83
Introduction
83
General Torch Maintenance
83
Common Operating Faults
84
Troubleshooting Guide
86
Servicing Hand Torch Components
87
Servicing Machine Torch Components
89
Torch and Leads Troubleshooting
90
APPENDIX 1: Control Cable Pinouts
93
APPENDIX 2: Control Cable Pinouts
93
APPENDIX 3: Command-Control PC Board Layout (A)
95
APPENDIX 4: Command-Control PC Board Layout (B)
96
APPENDIX 5: CNC - Control Module Board PCB Connections
100
APPENDIX 6: Arc Starter / Gas Control Module Schematic
100
APPENDIX 7: Power Supply Schematic,460V / 208 - 230V
100
APPENDIX 7: Power Supply Schematic,460V / 208 - 230V Cont
102
APPENDIX 8: Power Supply Schematic, 400V
104
APPENDIX 8: Power Supply Schematic, 400V Cont
106
APPENDIX 9: Power Supply Schematic, CSA 600V
108
APPENDIX 9: Power Supply Schematic, CSA 600V Cont
110
Appendix 10: Publication History
112
Global Customer Service Contact Information
113
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Thermal Dynamics PAK 200 Specifications
General
Brand
Thermal Dynamics
Model
PAK 200
Category
Welding System
Language
English
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