PAK® OperatingManual 200 - Victor Technologies - Europe

200 

Operating Manual 

PAK 

PLASMA CUTTING SYSTEM 

® 

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

Operating Features: 

460V / 

208- 

230

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 1-800-426- 

1888, 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 

(603) 298-5711 

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 ...................................................................1-1 

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 ...........................................................2-1 

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

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

2.04 Plasma Cutting Torch ..................................................................................2-1 

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 

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


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

4.01 Power Supply Indicators .............................................................................4-1 

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 


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

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



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

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


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

7.01 Introduction .................................................................................................7-1 

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 

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

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 

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. 

PAK 200 

• 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 chlorinated 

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.) 

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 workplace. 

Manual 0-5057 1-1 GENERAL INFORMATION


• 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. 

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 Subsection 

1.03, Publications, in this manual. 

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. 

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.). 

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 

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 

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 WELD- 

ING, 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 


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 

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 


GENERAL INFORMATION 1-2 Manual 0-5057

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 

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. 

• 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. 


• 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. 

• 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 5, article 9.) 

• Débranchez l’alimentation électrique avant tout travail d’entretien 

ou de réparation. 

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

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 



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. 

• 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 recommendation 

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 

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 laver les mains après toute manipulation. 

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

suivants)

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 


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 


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 


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 



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 


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 



This Page Intentionally Blank 


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 

Pilot Return 

Negative 

Coolant Supply 

Coolant Return 

Control Cable 

Arc Starter / 

Gas Control Module 

(GCM-200) 


Power Supply 

SECTION 2: 

SPECIFICATIONS 

Control 

Cable 

Maximum Length 100’ / 30.5 m 

Primary power 

Manual 0-5057 2-1 SPECIFICATIONS 

Ground 

Cable 

Primary Ground 

Work Cable 

Torch Lead Set 

- Coolant Supply w/ Negative 

- Coolant Return 

- Pilot Return 

- Plasma Gas 

- Shield Gas 

- Control Cable 

Torch 

Work 

Art # A-08376_AB


2.06 Power Supply Specifications & Electrical Requirements 

Max OCV (U0) 380 vdc 

Max Output Current 200 Amps 

Output Voltage 160 vdc 

PAK 200 Power Supply Specifications 

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 2 

230 60 49 125 150 #2 2 

400 50 54 77 100 #4 1 

400 (CE) 50 54 77 100 #4 1 

460 60 59 75 90 #4 1 

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 

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

2.07 Power Supply Dimensions 

27.5 inch 

700 mm 

27 inch 

680 mm 

33 inch 

840 mm 

37.75 inch 

960 mm 

Art # A-04822 

41.25 inch 

1050 mm 

48.75 inch 

1238 mm 

397 lb / 180 kg 


Manual 0-5057 2-3 SPECIFICATIONS


2.08 Power Supply Rear Panel Features 

Gas Entry Ports 

Circuit Breaker Panel 

Gas Control Connector 

Torch Control Connection 

Arc Starter Connector 

Coolant Connections 

Coolant Filter 

Coolant Tank 

Pilot (Pos) 

Terminal 

Gas Control Connector 

Arc Starter 

RETURN SUPPLY 

Connector 

Torch (Neg) 

Terminal 

Work Cable Terminal 

Torch Leads Port 

Input Power 

Terminals 

Art # A-08378 

AC Power Lamp 

Ground Terminals 

Terminal Cover 

Terminal Cover 

Support Panel 

Leads 

Bracket 


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-450- 

D-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 

N 2 (Nitrogen) 

Compressed 

Air 

H35 (Argon-Hydrogen) 

H35 = 35% Hydrogen, 

65% Argon 

99.5% Purity 

(Liquid recommended) 


2.11 PCH/M 200 Torch Specifications 

A. Torch Dimensions 

B. Torch Leads Lengths 

Gas Lead Assemblies 

Length 

Feet Meters 

25 7.6 

50 15.2 

(35.6mm) 

1.4 in. 

1.4 in. 

(35.6mm) 

A-02683 

* Available as custom or- 

3.4 in. 

(86.4mm) 

14.3 in. 

(363.2mm) 

70° 

13.3 in. 

(337mm) 

13.5 in. 

(342.9mm) 

90° 

2.5 in. 

(68.5mm) 

17.4 in. 

(44.2mm) 

1.5 in. 

(38.1mm) 

3.3 in. 

(83.8mm) 

1.5 in. 

(38.1mm) 

3.5 in. 

(88.9mm) 

4.3 in. 

(109.2mm) 

1.5 in.(38.1mm) 

1.9 in. (48.3mm) 

180° 


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 

Torch Head 

Electrode 

Water Tube Extension 

(Gouging Only) 

Combination of gas stream through torch and liquid cooling. 

Shield Cup 

Manual 0-5057 2-7 SPECIFICATIONS 

Tip 

Gas 

Distributor 

A-02188


This page is blank intentionally. 


3.01 Installation Requirements 

Electric Supply 

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 

SECTION 3: 

INSTALLATION 

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 

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 2 

230 60 49 125 150 #2 2 

400 50 54 77 100 #2 1 

460 60 59 75 90 #2 1 

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 

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


3.02 Cables and Leads Identification 

Refer to section 3.05 for ground connections and ground cables. 

Pilot Return 

Negative 



Control Cable 

Arc Starter / 




Power Supply 

Control 

Cable 


Primary power 

INSTALLATION 3-2 Manual 0-5057 

Ground 

Cable 


Work Cable 





- Plasma Gas 

- Shield Gas 


Torch 

Work 

Art # A-08376_AB

3.03 Cables and Leads Identification 

A 

B 

C 

D 

E 

F 

G 

K 

O 

14 

37 

Green 

Red 

#8 AWG Cable 

#1 AWG Cable 

Green / Yellow #4 AWG 

4’ / 1.3 m 

#1 AWG 


Art # A-08377_AC 


Manual 0-5057 3-3 INSTALLATION 

Green 

Red 

Pilot Return, Power Supply 

to Arc Starter 

Negative Lead, Power Supply 


Coolant Leads, Power Supply 


Control Cable, Power Supply 


Ground Cable 

Control Cable, 

Power Supply to 


Work Cable


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. 

Art # A-04824 

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

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. 

Art # A-04827 

Connection Panel 

Connections Cover 

(Removed) 



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. 

Inverter Module 

208/230V / 460V 

Input Voltage Board 

(Shown in 460V Position) 

Art # A-04856_AB 

1. Unplug connector 

2. Remove bolts. 

3. Invert board. 

4. Re-install board. 

5. Plug in connector. 


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. 

The clear connections cover must remain in place. 

CAUTION 

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. 

Pilot 

Work 

PILOT WORK TORCH 

Art # A-08500 


Torch 

Work Lead 

Pilot Lead - 

To Arc Starter 


AC INPUT 

L1 L2 L3 

Torch Lead - To Arc Starter 

To Cutting Table 

Lead Connection Detail 


Support Panel 

Leads Bracket 

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



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. 



Art # A-08501 

PILOT WORK TORCH 

AC INPUT 

L1 L2 L3 

Input power cable 

Ground Terminal Block 

Input power cable ground 


Support Panel 

Leads Bracket 


L1 

L2 

L3

3.07 Connect Gas Supply Lines 

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

Shield Gas - In 

Plasma Gas - In 

Art # A-08463 

RETURN SUPPLY 

RETURN SUPPLY 




3.08 Connect Torch Control Cable 

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

To Torch 

RETURN SUPPLY 

RETURN SUPPLY 

Art # A-08492 


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. 

O 

N 

SW1 SW3 SW4 SW5 SW8 

1 2 3 4 1 2 1 2 1 2 1 2 3 4 1 2 

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

1 = ON, 2 = OFF: 4 seconds 

1 = OFF, 2 = ON: 6 seconds 

1 = ON, 2 = ON: 8 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 = OFF = Short (85 ms.) 

1 = ON = Long (3 s.) (Factory default setting). 

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. 

Future Use 


O 

N 

Active only when 

SW-1-1 is set to O N. 

Art # A-08379_AB


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. 

SW6 

SW12 

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) 

SW13-1: 1 = OFF 

SW13-2: 1 = ON 

SW13 

1 = ON = 16.6:1 

2 = ON = 30:1 

3 = ON = 40:1 

4 = Not used. 

NOTE 

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

Only 1 on at a time. 

Art # A-08502 


SW11 

No external 

connection cover

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. 

Art #: A-008382 

Torch Leads: Coolant Supply & Return 

Plasma Gas 

Shield Gas 



4. Re-install the module top cover. 


Connection (Tagged Red) 

Art # A-08383 


Connection (Tagged Green) 

Torch Leads 

Plasma Gas 

Connection 

Shield Gas 

Connection 

Art # A-04832 


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). 

Short Shield Cup 

Standoff Cutting Only 

Catalog No. 32-1325 

Cutting Tip Air/N2/AR-H2 

0.031" Orifice, 35 amps 


Gouging Tip Air/N2/Ar-H2 

0.110" Orifice 


Cutting Electrode Air/N2 


Gouging Electrode 

Air/N2 

Catalog No.32-1504 

Coolant Tube Extension 

(Gouging) 

3.35" (85 mm) Length 

Cat No. 32-1502 

Crown Shield Cup 

Standoff Cutting Only 

Catalog No.32-1326 







Cutting Electrode N2, Ar-H2 


Gouging Electrode, 

N2/Ar-H2 


Gouging Shield Cup 

Gouging Only 








Gas Distributor - Cutting 

0.712" (18 mm) Length 

Cat. No. 32-1315 


0.073” orifice 200 amps 



0.070” orifice150 amps 





Gas Distributor - Gouging 

0.912" (23 mm) Length 

Cat. No. 32-1509 


A-08385


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 

(Catalog Number 20-0001) 

Gas Distributor Notch 

Used with 11/16" (17.5 mm)Tip 

Used for 11/16" ( 17.5 mm) 

Across Tip Flats 

This Side 

Towards Torch 




Used for Electrodes 

Used for 5/8" (15.9 mm) 


A-01639 

Torch Head 

Electrode 



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

5. Remove gouging water extension tube, if used. 

Shield Cup 


Tip 

Gas 

Distributor 

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. 

NOTE 

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. 

A-02188

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 

Fill Range 

Coolant Tank 

COOLANT 

RETURN SUPPLY 

RETURN SUPPLY 

Art # A-04803 

3. After the complete system has been installed, check that the coolant has been pumped through the system as 

follows (see NOTE): 



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. 


4.01 Power Supply Indicators 

AC Indicator 

Art # A-04813 

Temp Indicator 

AC Power Indicator 

Gas Indicator 

SECTION 4: 

OPERATION 

DC Indicator 

Status Indicator 


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 temperatures 

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-


4.02 Control Console Features 

Plasma Gas 

Pressure Gauge 

Run / Set Selector 

Amperage 

Selector 

CUT 

OUT 

A 

GCM 


RUN 

RUN 

SET 

PLASMA SHIELD 

SET PLASMA SHIELD 

Plasma Gas Pressure 

Control Knob 

CUT 

OUT 

A 

Shield Gas Pressure 

Control Knob 

Shield Gas 

Pressure Gauge 

Art # A-08384 

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

set, switch to RUN position for operation. 

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

set desired levels. 

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

Amperage Selector: Continuously adjustable up to 200 Amps. 

OPERATION 4-2 Manual

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. 

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. 

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. 

c. Turn the knob to adjust gas pressure. 

d. Push the knob back in to lock the pressure setting. 

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 setting. 

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) 

Manual 0-5057 4-3 OP-


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. 

Top 

Spatter 

Cut Surface 

Left Side 

Cut Angle 

Dross 

Build-Up 

Kerf Width 

Cut Surface 

Drag Lines 

Right Side 

Cut Angle 

A-00512 

Cut Surface 

Bevel Angle 

Top Edge 

Rounding 

A-00007 

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

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. 

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. 


Left Side 

Cut Angle 

Clockwise 

Counter- 

Clockwise 

Scrap 

Scrap 

Workpiece 

Art # A-04182 

Right Side 

Cut Angle 

A-00512 

Swirl Effect on Side Characteristics Of Cut 

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. 

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 

before assembling or disassembling 

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. 

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. 

Art # A-04842 

POWER 

Manual 0-5057 4-5 OP- 

I 

O 

OFF 

O 

ON 

OFF


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 


Status 

Code 

1-1 

Status Code Key for PAK 200 

Message Cause/Remedy 

System not Enabled or Missing AC 

Input Phase 

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 


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. 

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

2-2 Wrong input voltage 

2-3 

Inverter or Pilot Regulator Over 

Temperature 

2-4 Power Supply not Ready Defective inverter 

2-5 DC Output Low 

2-6 

Inverter primary over current or 

cap voltage imbalance fault 

2-7 Unexpected current 

2-8 

Unexpected current in pilot circuit 

2-9 Unexpected current in work lead 

Inverter(s) not configured correctly for input voltage; 

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-


Status Code Key (cont.) 

Status 

Code 

3-1 

3-2 

Message Cause/Remedy 

Gas Control Communication 

fault, Cannot establish Communication 

with gas control. 


reply fault, 

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. 

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 

Invalid Current Control level 

from GCM 


3-7 

Gas Control returns wrong command 

sequence 


3-8 

CCM and Gas Control type (Autocut-Ultracut) 

mismatch 

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

3-9 


reply fault 


3-10 

Warning. -- Gas Control firmware 

needs update 


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

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 / priming, 

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. 


Status Code Key (cond) 

Status Message Cause/Remedy 

Code 

5-1 

5-2 

5-3 

CANBUS Failure to Acknowledge 

fault. 

CANBUS Off due to 

excessive data errors; 

CANBUS data error warning. 

Errors increasing, will soon fault. 




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 


Manual 0-5057 4-9 OP-


4.07 Recommended Cutting Speeds 

Thickness Tip Output 

Type Torch: PCH-200 Type Material: Aluminum 

Type Plasma Gas: Air Type Secondary Gas: Air 

Amperage 

Speed 

(Per Minute) Standoff 

Plasma 

Gas Press 

Sec Gas 

Press Total Flow (SCFH) 

Pierce 

Height 

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 

Thickness Tip 

Type Torch: PCH-200 Type Material: Stainless Steel 


Output 

Volts 

Amperage 

Speed (Per 

Minute) Standoff 

Plasma Gas 

Press 

Sec Gas 

Press Total Flow (SCFH) Pierce Height 

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 


Thickness Tip 

Type Torch: PCH-200 Type Material: Mild Steel 


Output 

Volts 

Amperage 

Speed 


Plasma Gas 

Press 


Sec Gas 



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 

Thickness Tip 

Type Torch: PCH-200 Type Material: Stainless Steel 

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

Output 

Volts 

Amperage 

Speed 


Plasma Gas 

Press 

Sec Gas 



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 

Manual 0-5057 4-11 OP-


Thickness Tip 

Type Torch: PCH-200 Type Material: Aluminum 

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

Output 

Volts 

Amperage 

Speed (Per 

Minute) Standoff 

Plasma Gas 

Press Sec Gas Press Total Flow (SCFH) Pierce Height 


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 




Manual 0-5057 4-13 OP-




SECTION 5: 

MAINTENANCE 

Perform the following checks periodically to ensure proper system performance. 

5.01 Coolant Filter Cleaning Procedure 

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. 

Six Months 

Replace coolant filter. 

Clean coolant tank. 

Vacuum out any dust buildup inside power 

supply. 


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


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. 

Fill Range 

Coolant Tank 

COOLANT 

RETURN SUPPLY 

RETURN SUPPLY 

Art # A-04803 

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 

No Pilot Ignition: 

No Spark 

in Arc Starter 

No cooling or 

insuficient cooling: 

Leaks coolant 

No cooling or 

insuficient cooling: 

No Coolant Flow 

Coolant has become conductive 

Pilot return wre not connected 


Use conductivity meter Flush system, replace coolant. 

Visual inspection Connect wire. 

Spark gap set too close Check with feeler gauge Set to 0.063” ±0.002” 

High frequency cap (CA) Use capacitance meter 

Possibly open 

Reconnect or replace. 

Broken or missing ferrites Vissual inspection Replace. 

Short across in indicator Visual inspection Remove short, increase 

(L1) 

coil gaps. 

Spark gap bus caps (C1, C2, Capacitance meter 

C3) broken or defective 

Replace. 

Negative supply not conneted 

correctly 

Visual inspection Reconnect. 

Spark gap set too large Check with feler gauge Set to 0.063” ±0.002” 

Faulty transformer Resistance measurement Replace. 

No 120V supply Check input voltage at 

EMI filter 

No / loose connection to 

spark gap 

Faulty EMI filter Voltage / Resistor measurement 

Visual inspection Reconnect. 

Make connections; replace 

harness. 

Replace. 

Loose fitting(s) Visual inspection Tighten fittings. 

Failure to braze jionts (L1) Visual inspection Replace HF Coil 

Damaged or punchured Visual inspection 

coolant line(s) 

Replace coolant line(s). 

Supply & return hoses 

reversed 

Blockage in coil or suooly 

return hoses 

Visual inspection o colorcoded 

connections 

loosen fitting slightly and 

check for ooolant flow 

Match coolant connection 

colors to ark starter fittings 

colors. 

Flush system. 

Manual 0-5057 5-3 MAINTENANCE


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. 

0.063" ± 0.002" 

1.6 ± 0.05 mm 

Art # A-04835 

MAINTENANCE 5-4 Manual 0-5057

6.01 Replacement Power Supply 

Complete Unit / Component 

Catalog# 

SECTION 6: 

REPLACEMENT ASSEMBLIES & PARTS 


Pak 200 Power Supply, 208/230 460V 3-0003 

Pak 200 Power Supply, 400V 3-0004 

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

OPTIONAL EQUIPMENT: 

Wheel Kit 9-9379 

Manual 0-5057 6-1 PARTS LIST


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 

16 

PARTS LIST 6-2 Manual 0-5057 

11 

Art # A-08471_AB 

9 

10

6.03 Leads and Cables 

Pilot Return 

Negative 



Control Cable 

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

Key Description 3 ft 

1 m 

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

A Pilot Return Cable (only) 

(4 ft / 1.2 m) 

9-4890 

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 

9-4941 

9-4923 

10 ft 

3.05 m 

15 ft 

4.5 m 

25 ft 

7.6 m 

Leads Length 

35 ft 

10.6 m 

50 ft 

15.2 m 

75 ft 

22.8 m 

100 ft 

30.5 m 

G Torch Lead Assembly 4-0014 4.0015 4-0016 

K Control Cable, Power Supply 

to Gas Control Module 

Arc Starter / 




Power Supply 

9-9331 

Control 

Cable 

Primary power 

O Work Cable w/Clamp 9-0020 


NOTE 


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

Control Cable. 

125 ft 

38.1 m 

Manual 0-5057 6-3 PARTS LIST 

Ground 

Cable 


Work Cable 





- Plasma Gas 

- Shield Gas 


Torch 

Work 

Art # A-08376_AB


6.04 Leads and Cables 

A 

B 

C 

D 

E 

F 

G 

K 

O 

14 

37 

Green 

Red 

#8 AWG Cable 

#1 AWG Cable 

Green / Yellow #4 AWG 

4’ / 1.3 m 

#1 AWG 


Art # A-08377_AC 


Green 

Red 

Pilot Return, Power Supply 


Negative Lead, Power Supply 


Coolant Leads, Power Supply 


Control Cable, Power Supply 


Ground Cable 

Control Cable, 

Power Supply to 


Work Cable

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 

1/4” 

3/8” 

Inert B (RH) 9-2146 9-5061 9-5073 9-5085 9-5097 9-5109 9-5121 

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

Inert B (RH) 

SYNFLEX HOSE FITTINGS 

ID 

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 

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 

ADAPTER FITTINGS Catalog # 

1/4” NPT 

Inert B (RH) 8-0330 

Inert B (LH) 8-0329 

02 B (RH) 8-0260 

1/4” Barb 8-4264 



6.06 Power Supply External - Replacement Parts 


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

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 

2 


1 

Art # A-04790




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 

Art # A-08309 

3 


1 

6 

5 

4 

2




1 Chopper Module 9-9389 

1 Sensor HCT1 9-9342 

HCT1 

Chopper Module 

Art # A-08311 



6.10 Power Supply Replacement Parts - Front Panel 


7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344 

for 230-400-460 VAC units 

Art # A-08312 

7 


6.11 Power Supply Replacement Parts - Left Side/Front Panel 



1 PC Board PCB3 9-9365 

1 PC Board 230/460VAC PCB4 9-9370 

1 Display PC Board PCB6 9-9347 

PCB4 

PCB3 


PCB6 

Art # A-08313


6.12 Power Supply Replacement Parts - Left Side 


1 1 PCBoard 230-400-460VAC PCB1 9-9362 

2 1 Magnetic Contactor MC1,MC3 9-9364 

1 

2 2 

Art # A-08314 


6.13 Power Supply Replacement Parts - Rear Panel 

Tank Cap 


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 

Coolant Tank 

COOLANT 

RETURN SUPPLY 

Filter 

Art # A-04932_AB 

CIRCUIT 

BREAKERS 


12 

13 

14 

15 

16 

17 

18 

J55 

G 

C 

M 

J15 

C 

N 

C 

J59 

R 

A 

S 

RAS 

125V 2.5A 

CCM 

125V3.15A 

GCM 

125V 10A 

GCM 

125V2.5A 

GCM 

125V2.5A 

PUMP 

250V 10A 

FAN 

125V 3.15A 

CP2 

CP3 

CP4 

CP5 

CP6 

CP7 

CP8 

Art # A-06017_AC




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 

2 

1 

Art # A-08310 


3 

4 

5

6.15 Power Supply Replacement Parts 


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

2 Inverter Module 400 9-9482D 

Art # A-04786_AB 




6.16Power Supply Replacement Parts - Right Side 


30 1 Sensor (Thermistor) TH1 9-9361 

Art # A-04787 


30

6.17 Power Supply Replacement Parts 



1 1 Relay PC Board PCB7 9-9366 

3 1 Internal Control PC Board PCB5 9-9346 

Art # A-08315 

2 

1 


3




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 

26 

Art # A-08236 

25 

27 

24 


28 

22




1 1 Pilot Resistor Mounting Bracket 9-0032 

2 6 Pilot Resistor 3.6 ohms, 300W 9-0039 

1 

2 



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


Art # A-08386 

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 

11 5 2 

8 

Left Side 

6 

3 7 

Right Side 

10 13 12 


14 

15 

16

6.21 Command & Control Module - Replacement Parts 



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 

1 

3 


4 

Art # A-06798 

2




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 

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 


DO NOT touch any internal torch parts while 

the AC indicator light on the front panel of the 

power supply is ON. 

SECTION 7: 

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 





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


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. 

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 

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 

i. Non-Genuine Thermal Dynamics Parts 

TORCH MAINTENANCE 7-2 Manual 0-5057

5. Poor Pilot Starting 

a. High coolant conductivity (Refer to Power Supply 

Manual) 

b. Non-Genuine Thermal Dynamics Parts 

7.04 Inspection and Replacement 

Consumable Torch Parts 

WARNING 





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. 


(Catalog Number 20-0001) 

Used for 11/16" ( 17.5 mm) 


This Side 

Towards Torch 






Used for Electrodes 

Used for 5/8" (15.9 mm) 


A-01639 

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

NOTE 

Slag built up on the shield cup that cannot be 

removed may effect the performance of the 

system. 

Torch Head 

Electrode 




Shield Cup 

Manual 0-5057 7-3 TORCH MAINTENANCE 

Tip 

Gas 

Distributor 

Torch Consumable Parts 

A-02188 

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

if damaged. 

3. Using the multipurpose wrench (5/8 inch slot) remove 

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. 

Good Tip Worn Tip 

Tip Wear 

A-02195 

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. 

New Electrode 

Worn Electrode 

A-02208


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 

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 

1. Power Supply RUN/SET switch in SET position 

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 seconds 

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 necessary. 

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. 

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. 









C. Low cutting output with no control 

1. Incorrect setting of AMPERAGE control on power 

supply. 

a. Check and adjust to proper setting. 








D. Limited output with no control 

1. Poor input or output connections to power supply 

a. Check all input and output connections. 








E. Improper cutting output 

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, Cutting 

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 


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

bar) maximum pressure. 







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, Cutting 

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: 

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. 

Manual 0-5057 7-5 TORCH MAINTENANCE 

NOTE 

Use a soap and water solution on the sheath 

to assist in rolling.


Sheath 

A-02196 

Connectors From 

Torch Switch 

Torch Handle 

Threaded Locking Nut 

Switch Wiring 

Torch Control 

Switch 

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. 

9. Remove torch head assembly. 

Plasma (+) Lead 

A-02197 

Coolant Return Lead 

Secondary Lead 

Coolant (-) Supply Lead 

Torch Head Removal (PCH-200) 

10. Remove the torch handle and switch from the 

leads. 

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: 

1. Slide the torch handle with torch switch and sheathing 

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. 

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 together. 

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 handle. 

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 

the torch handle. 

NOTE 

There will be a slight gap between the torch 

head and the lock nut. 

7.07 Servicing Machine Torch 

Components 

WARNINGS 





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 positioning 

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. 

Machine 

Torch Head 

Pinion Assembly 

Positioning Tube 

Torch Adaptor 


Bushing 

Lead Connections A-00663 

Torch Mounting Assembly 

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. 

Coolant Return Lead 

(LH Threads) 

Coolant (-) 

Supply Lead 

Plasma Lead (+) 

A-02198 

Torch Head Removal 

B. Reassembling Machine Torch Assembly 

Secondary Lead 

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. 



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. 

Two Layers Of 

Estermat Paper 

Rigid Torch 

Leads Insulator 

Rigid Insulator Installation 

A-01577 

3. Secure the rigid insulator in place with electrical 

tape. 

4. Slide replacement shrink on tubing on leads. 

5. Connect the plasma (+), secondary, coolant supply, 

(-) and coolant return connectors. 

6. Secure leads and tubing with single layer of electrical 

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. 

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 nega- 

tive 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. 

B. Quick Check Procedure 

This quick check will identify major isolation failures in 

the Torch Head or Torch Lead components using an ohmmeter. 

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 



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. 


3. Using an ohmmeter (set to 10K or higher), check 

for continuity between the positive and negative 

torch fittings. 

• 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 replaced. 


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 replaced. 


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. 

WARNING 


This procedure should be performed only by a 

qualified electronic technician. 

1. To test the Torch Head center insulator for insulation 

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 

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. 

2. To test the Torch Leads for insulation breakdown 

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 current 

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. 

3. Visually check that the torch switch wires, pilot 

lead connection, and negative lead connections 

are properly connected and in good condition (no 

shorts or arcing). 

• If problems are evident, repair or replace as 

required. 


This Page Intentionally Blank

Power Supply J55 to Gas Control Console J56 

4 Ground 

6 Current Control Pot 


11 Run / Set Sw 

10 

18 

16 

23 Jumper to 15 

13 

14 E-Stop 

15 E-Stop 

19 

20 

21 

22 

28 

17 

12 

27 

26 

33 Ground 

1 Jumper to 2 

24 Sol 1 

25 

7 Ground 

8 Ground 

9 

2 Jumper to 1 

29 

30 

APPENDIX 1: 

Control Cable Pinouts 

32 37 36 

31 


34 35 

3 

35 120VAC Ret 


8 Jumper to 9 

9 Jumper to 8 

13 


36 37 

1 6 Pot Wiper 

5 + 10 vdc 

19 Ground 

Manual 0-5057 A-1 APPENDIX 

2 

31 

32 

30 

34 120VAC 

29 

12 

26 

POWER SUPPLY J55 

ARC STARTER / GAS CONTROL MODULE J56 

4 Gas Pr Sw (SW1) 

27 

15 Jumper to 23 

20 

21 

22 

28 

33 Ground 

11 Gas On 

10 Gas On 

18 

17 24 VAC Ret 

16 24VAC 

23 

24 24 VAC Ret 

25 

Art # A-04848

Power Supply J59 to Arc Starter / Gas Control 

Console J58 

Art # A-04849 

3 

6 

7 - 120 VAC 

11 

10 

1 

14 

APPENDIX 2: 

Control Cable Pinouts 

4 

13 

2: Ground 

8 

9: 120 VAC RET 


5 

1 - Jumpered to 4 

12 

POWER SUPPLY J59 

ARC STARTER / GAS CONTROL MODULE J58 

3 5 

6 

8 

10 

7 - 120 VAC 

9: 120 VAC RET 

11 

12 

15 

16 

2: Ground 

13 

4 - Jumpered to 1 

14


APPENDIX 3: 

Command-Control PC Board Layout (A) 

H1 

J4 

U6 

1 

TP11 

TP10 

TP9 

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 

30 

29 

2 

1 

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 

CONT 

AUTO PILOT 

OK TO 

MOVE/D 

1 

2 

1 

SW4 

3 

2 1 

1 

SW1 

4 

3 

2 

1 

1 

SW8 

4

SW6 

J36 

TP14 

SW12 

TP7 

TP6 

OK TO MOVE SELECT 

H2 

DC VOLTS 

CONTACTS 

D14 

H9 

H1 

R55 

1 

SW6 

R73 

R79 

R82 

R88 

R93 

ALL SW OFF FOR 50:1 (DEFAULT) 

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

SW12-2 ON FOR 30:1 

SW12-3 ON FOR 40:1 

SW12-4 SPARE 

R128 

C64 

R129 

C65 

U18 

SW12 

1 

C33 

K1-PSR 

C72 

R131 

D31 

4 

R157 

3 

R156 

2 

R155 

1 

R158 

ISOLATED 

C84 

TP6 TP7 

1 

R228 

Q2 

R226 

R100 

R109 

R114 

C76 

D17 

D7 

+15V -15V 

GND +18V 

TP10 

R227 

TP10 TP8 

J1 

Q3 

+ 

R56 

TP8 C95 

TB1 

J1 

R30 

+ 

APPENDIX 4: 

Command-Control PC Board Layout (B) 

1 

D20 

D22 

D25 

1 

C66 

R138 

C85 

K2-START 

C93 

R149 

C68 

1 

+ 

U23 

1 

U19 

U20 

R148 

R1 

+ 

1 

D3 

R15 

OK CNC 

R31 

R132 

R14 

D6 

D15 

R43 

PSR C31 

C34 

D4 

D9 R40 

R83 

C69 

C77 

C35 

R135 

C78 

1 

C15 

+ 

D29 

R102 

D10 

J4 

R75 

R103 

R104 

R8 

D8 

D12 

25 

R130 

TP1 

C70 GND 

C74 

TP3 

+15V 

TP5 

-15V 

TP2 

+29-41 VDC 

+ 

1 

1 

TP11 

ARC V- 

C40 

C45 

C56 

D21 

R80 

CNC_E-STOP 

1 U11 

D23 

D24 

CNC_START 

D26 

C46 

1 

U15 

HOLD_START 

R101 

D28 

CNC PREFLOW TP4 R110 

+5V 

J35 

U13 

U9 

R84 

+ 

R89 

R96 

R95 

1 

C58 

C41 

PILOT 

DEMAND 

TP14 

33 

J3 

34 

CUT 

DEMAND TP13 

R105 

R106 

U16 

R111 + C59 

29 

D30 

1 

R126 

2 

26 

R134 

TB1 TB2 J4 J9 

D27 

K4-OK 

+ 

K3-E-STOP CNC 

C92 

C73 

R136 

J35 

1 

D38 

1 

C94 

R58 

R94 

U21 

C28 

C61 

C57 

T1 

D39 

R7 

TB2 

C29 

D11 

+ 

D16 

J9 

K6 

R59 

R72 

U8 

R74 

C32 

1 

L1 

D19 

C36 

1 2 

SW13 

1 

2 

J36 


TP11 

R154 

H6 

H5 

J5 

1 1 

R152 

R133 

J2 

H7 

H10 

H11 

1 2 

29 30 

1 2 

1 

30 

C71 

Q1 

R2 

R11 

R77 

R81 

C11 

R41 

C16 C17 C18 

R44 R45 C19 

R60 

R46 

C47 C48 

R115 

R3 

R76 

R97 

R141 

D40 

R62 

C50 

R139 

PILOT V 

TP12 

R4 

R117 

1 

U5 

U6 

R47 

R64 

R48 

R118 

R9 

C6 

C22 C23 C24 C25 

C87 

C8 

R66 

R67 

U10 

1 

U12 

C53 

C3 

R49 R50 

R68 

+ 

R12 R13 

1 

D34 D35 

U22 

1 

R145 

R123 

1 

R69 

L2 

1 

U1 

R5 

C4 

R10 

R18 

R19 

R20 

R21 

R22 

R23 

R24 

R25 

R26 

R27 

R28 

R29 

R16 

C9 

R85 

R90 

C86 

R116 

R224 

R91 

R61 

C49 

R86 

R122 

D32 

C81 

R63 

J6 

C20 

C51 

C21 

C82 

R140 

TP12 

J5 J6 J7 

TP4 TP3 TP2 SW13 TP5 TP1 TP13 

J2 

R65 

C38 

R92 

C52 

R119 

D33 

R225 

R51 

R52 

C88 

C26 

R53 

R70 

+ 

C7 

C27 

R71 

C79 

+ 

C89 

R142 

R33 

C2 

R223 

1 

U7 

U17 

C83 

1 

U3 

1 

C30 

R127 

R147 

R125 

TP9 

CC POT 

R6 

C75 

C5 

R37 

C55 

+ 

+ 

+ 

+ 

D36 

R144 

C91 

R146 R143 1 

U24 

B 

SW11 

K5-E-STOP 

R151 

U2 

D18 

1 

R78 

C37 

R87 

C42 

C39 

C43 

C44 

R98 

1 

R99 

C54 R107 

R108 

U14 

C60 

R112 

R113 

R121 C63 

R120 

R124 

C1 

R32 

C12 

D61 

+ 

C62 

R54 

R150 

1 

J3 

J7 

U4 

C80 

C10 

R17 

D5 

C13 

R34 

C14 

R35 

R36 

D60 

R42 

C67 

C90 

SW11 TP9 

D1 

D2 

A 

R38 

GAS ON 

E-STOP_PS 

1 

D13 

D37 

R57 

R39 

K7-GAS ON 

C TDC 2005 

19X2174 

REV AD+ 

1 

J8 

J8 

H8 

H4 

H3 

Art # A-06901

Art # A-04900 

APPENDIX 5: 

CNC - Control Module Board PCB Connections 

TB1 

TB2 

TB1-1 E-Stop (Com) These points are jumpered together at the factory. 

TB1-2 E-Stop 

Remove the jumper to use existing E-Stop circuits. 

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) (+) 

Start / Stop Circuit Configurations 

Stop 

Start 

Sustained Start / Stop 


TB1-5 

TB1-6 

TB1-4 

TB1-5 

TB1-6 

Momentary Start / Stop

D 

C 

B 

A 

24 VAC 

24 VAC RET 

120 VAC 

120 VAC RET 

+10VDC 

POT WIPER 

APPENDIX 6: 

Arc Starter / Gas Control Module Schematic 

5 

POWER SUPPLY 

E-STOP 

Art # A-08503 

GAS ON 

5 

NEG 

PILOT2 

WORK 

J55 

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 

J59 RAS 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

14 PIN 

CHASSIS GND 

120 VAC 

120 VAC RET 

J56 

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 

J58 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

16 PIN 

(1) 

(2) 


4 

(4) 

(5) 

JUMPER for Plasma Enable 

SW1 

GAS PRESSURE 

(6) 

(8) 

(9) 

(10) 

(8) 1 

(6) 1 2 (7) 

(11) 

(12) 

JUMPER for BASIC GAS CONTROL ID 

(9) 2 CURRENT CONTROL POT 

(13) 

(13) 

(14) 

(10) 

3 

SW3 

RUN / SET 

(7) 1 RUN 

2 

3 

(14) 

(15) 

NEG (from PS) 

4 

Line1 

GND 

Line2 

8X290 

Load1 

Load2 

Line Filter 1ph 

1 

2 

(13) 

3 

GCM 200 GAS CONTROL & ARC STARTER 

T1 

11X16 

3 

T1 Assembly 

4 

R1 6.8K 1W 

R2 6.8K 1W 

3 

(12) 

PLASMA 

GAP1 

SOL1 

(15) 

5 

SPARK GAP 0.062" 

C1 

1900 pf 

C2 

1900 pf 

C3 

1900 pf 

4 

6 SET 

(5) 

SOL2

L1 

Water Cooled 

Inductor 

NEG (from PS) 

NEG 

C5 

C4 

0.047 uf 1000VDC 

2 

2 

NEG & HF (to Torch) 

0.1 uf 1000VDC 

0.1 uf 1000VDC 

C6 

CGND 

PILOT RETURN (from torch) 


C8 

PLT 

0.047 uf 1000VDC 

SHLD 

Rev Change Description By Date 

AA INTRO ECO B731 GAC 04/17/08 

Last Modified: Thursday, April 17, 2008 

14:51:05 

PILOT 

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). 

SCHEMATIC, 

GCM 200 GAS CONTROL & ARC STARTER 

TITLE: 

TORCH LEAD 

INNER SHIELD 

CHASSIS GND 

TORCH LEAD 

OUTER SHIELD 

1 

TORCH 

WORK 

Scale Supersedes 

THERMADYNE 

82 BENNING STREET 

NONE 

W. LEBANON, NH 03781 Create Date: 

(603) 298-5711 

04/17/2008 

1 

Art # A-08503 

Drawn: Reference 

GAC 

Chk: App: 

DWG No: 

Sheet 

1 of 1 

42X1309 

D 

C 

B 

A

A 

B 

C 

D 

E 

F 

208-230/460 VAC 3 Phase 

NE1 

INPUT POWER 

INDICATOR 

REAR PANEL 

To T1 PRI - 0 

(A1 Sht2) 

L1 

L2 

L3 

E 

CN3 

Art # A-08474 

1 

4 

To PCB7 TB3 

(A1 Sht2) 

1 

CN1 1 

TB1 

CN4 1 

NE2 

1 

LINE to LINE, 

LINE TO GND 

CAPS & VARISTORS 

4 

5 

8 

INPUT POWER 

INDICATOR 

INTERNAL 

PCB 1 

WK-5630 

FILTER PCB 

To PCB7 CN2-2 

(A1 Sht 2) 

To PCB7 CN2-1 

(A1 Sht 2) 

ON / OFF 

VAC_IN 

P_GND 

CN2 1 

2 

C.P1 

APPENDIX 7: 

Power Supply Schematic,460V / 208 - 230V 

To PCB7 CN2-5 

(A2 Sht 2) 

To PCB7 CN2-4 

(A2 Sht 2) 

2 

From CN9 on PCB7 

(D2, Sht 2) 

D1 

AC AC AC 

- + 

2 

C4 

MC3-A 

MC3-B 

MC3-C 

MC1-B 

MC1-C 

+12VDC 

RY2 

RY2 

+ 

+12VDC 

/ 460 

3 

CN4 - PCB12 

T 

CN10 1 

2 

1 

2 

3 

460 

230 

COM 

COM_A 

230_A 

460_A 

3 

4 

+12VDC 

CN3 1 

INRUSH 

CN2-460V 


/ 230 

/ 460 

CN2 

1 VAC_IN 

V_CHANGE PCB 

--230-- 

--230-- 

P_GND 

CN4 

CN1 

DETECTOR PCB 

+15V 

INTERFACE PCB 

PGND1 

PGND2 

CN5 

CN5 

PCB4 WK-5604 

2 

1 

2 

3 

LED2 

4 

MISSING PHASE 

CN7 1 

+15V 

MISSING_PHASE 

+15V 

INPUT_NG 

MISSING PHASE 

(pulses)< 

CN6 

4 

BIAS SUPPLY PCB 

CN6 

PCB 5 WK-5602 (partial) 

--460-- 

TB3 

2 

3 

N2 

100A INVERTER MODULE # 1 (top) 

TB1 

MC1-A 

T1 

6 

P1 

1 2 

+ 

TB2 

+ 

4 

3 

CN2 1 

2 

3 

S 

R1 

1 

2 

3 

S1 

CN4 - PCB1 

R 

CN4 1 

1 

2 

2 

3 

3 

230V 

- 

4 

4 

5 

4 

CN1 

7 

6 

5 

4 

3 

2 

1 

2 

3 

CN1-230V 

6 

4 

CN2-460V 1 

RY2 

3 

2 

1 

CN7 

2 

3 

1 

TB4 

2 

4 

PCB3 WK-5694 

4 

BIAS SUPPLY 

FOR PCB5 

+15V 

+5V 

GND 

-15V 

FAN + (24 VDC) 

CN6 

100A INVERTER MODULE # 2 (bottom) 

(same as #1) 

CN1-230V 

3 

4 

4 

5 

5 

1 

2 

3 

4 

+ 

CN32 1 

1 

CN32 

LED3 

INPUT NG 

2 

2 

3 

3 

4 

4 

1 2 

4 

CN18 1 

3 

DC FAN 

POWER 

2 

CN6 

3 

FAN - (24 VDC) 

(F2 -Sht2) 

3 

5 

4 

- + 

1 

2 

3 

4 

- + 

1 

2 

16 CKT RIBBON CABLE 

CN6 16 CKT 

5 

N (-)1 

P (+)1 

N (-) 

P (+) 

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 

LED4 

CHOPPER TEMP 

LED1 DIM = LOW, BRIGHT = OK 

LED2 DIM = OK, BRIGHT = FAULT 


LED4 OFF = OK, ON = FAULT 

LED5 OFF = OK, ON + FAULT 

TEMP_C 

1 

CN17 

/ OVERTEMP < 

2 

GND_C 

3 

LED5 

ERROR

6 

PILOT REGULATOR 

(CHOPPER) 

For this 

version 

of the 

power supply 

Pilot 

Regulator 

is not used 

except to 

provide power 

and pass 

signals from 

HCT1, the 

pilot current 

sensor. 

Pilot 

Resistors, 

R1a-f, are 

used instead. 

6 

PILOT REG. 

(CHOPPER ) 

PCB2 

WK-5754 

P_ena 

P_ref 

Iref_G 

< /OVER_TEMP 

TEMP_C 

N2 

GND_C 

P1 

BIAS 

POWER 

PILOT REG. 

(CHOPPER ) 

PCB1 

WK-5750 

CN3 2 

1 

CN8 

1 

CN33 

2 

1 

2 

3 

/PILOT ENABLE > 

PILOT DEMAND > 

CN5 

CN4 1 

23 

4 

4 

3 

2 

1 

CN4 2 

1 

CN7 

5 

4 

3 

5 

4 

3 

2 

1 

7 

> P_Enable (P_ena) 

> P_DEM (P_Iref) 

P_ena 

P_ref 

I_senseP 

GNDP 

7 

Iref_G 

I_DET 

< 

I_SE 

I_senseP 

GNDP 

+15Vw 

-15Vw 

Isense_W 

GNDW 

HALL SENSOR 

+12V 

-12V 

SIGNAL 

COMMON 

C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2) 

C2 Capacitor, 2 uf, 430VAC (A9, Sht 1) 

C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 

15A, 460V, 3P 

C.P2 Circuit protector 2.5A 125V (D2, Sht 1) 


C.P4 Circuit protector 10A 125V (E2, Sht 1) 

C.P5 Circuit protector 2.5A 125V (E2, Sht 1) 

C.P6 Circuit protector 2.5A 125V (F2, Sht 1) 



D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1) 

D2 Diode, Dual, 2x100A, 600V (B8, Sht 1) 

FAN1 Fan, Coolant, 24 VDC (F4, Sht 2) 

FAN3 Fan, Chopper, 24 VDC (A8, Sht 1) 

FL1 Flow sensor (B5, Sht 2) 

1 

CN3 

TB5 

CN2 1 

2 

3 

PILOT CURRENT SIGNAL < 

2 

TB2 

CN2 1 

4 

3 

3 

2 

CN6 1 

3 

2 

4 

THS1 

SW_TEMP_NC 

CN9 

1 

2 

CN5 1 

23 

1 

CN4 

4 

2 

3 

WORK CURRENT SIGNAL < 

CN1 

4 

2 

1 

HCT1 

TB4 R1 a-f 3.6 

TB1 

CN1 

1 

2 

3 

4 

5 

+ - 

FAN3 

1 

2 

3 

4 


4 

3 

K2 

A2 

8 

8 

2 

1 

K1 

A1 

R6 

20K 

30W 

CN1 

1 

2 

3 

4 

(6 x 0.6 in series) 

D2 

MC2-A 

MC2-B 

MC2-C 

+15Vw 

-15Vw 

Isense_W 

GNDW 

9 

NEG ARC VOLTS 

(C7 & A9,Sht 2) 

TB2 TB3 

PCB 8 

WK-5687 

RC & 

RF CAPS 

CN2 1 

2 

HCT2 

HALL SENSOR 

1 

2 

3 

4 

COMPONENT LOCATOR 

3 

PILOT (TIP) VOLTS 

(C7, Sht 2) 

WORK 

(C7 & A9,Sht 2) 

TORCH (-) 

PILOT 

WORK (+) 

Rev Revisions 

AA ECO-B731 (REL) 

By Date 

DAT 1-18-08 

THERMAL DYNAMICS 

INDUSTRIAL PARK #2 

WEST LEBANON NH, 03784 

603-298-5711 

PCB No: 

Assy No: 

Scale 

Last Modified: Friday, January 18, 2008 

CN3 1 

TB1 

Power Supply 

Rear Panel 

C2 

2 UF 

R9 

50 

RAS 

HCT1 Hall Current Sensor, Pilot (B8, Sht 1) 

HCT2 Hall Current Sensor, Work (C9, Sht 1) 

LSW1 Level SW, coolant, NC (B5, Sht 2) 

MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) 

" Contacts (A2, B2, Sht 1) 

" Aux Contact (B3, Sht 2) 

MC2 Contactor, pilot, Coil (B3, Sht 2) 

" Contacts (C8, Sht 1) 


" Contacts (B2,C2, Sht 1) 


MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2) 

NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1) 

NE2 Neon indicator, internal, 220VAC (D1, Sht 1) 

R1 a-f Resistor, Pilot, 0.6, 300W , (B8, sht 1) 

(6 in series) 

R6 Resistor, 20K ,30W (A8, Sht 1) 

R7 Resistor, 1K ,30W (E2, Sht 2) 

R9 Resistor, 50 ,40W (A9, Sht 1) 

T1 Aux Transformer (D-F1, Sht 2) 

TH1 Thermal Sensor, coolant return (B5, Sht 2) 

10 

WORK 

Art # A-08474 

Supersedes 

Information Proprietary to THERMAL DYNAMICS CORPORATION. 


Date: 

Thursday, January 10, 2008 



Drawn: 

DAT 

References 

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App: Sheet 

TITLE: SCHEMATIC, 

1 of 2 

Size DWG No: 

12:19:03 PAK 200 Power Supply 208-230/460V D 42X1311 

9 

10 

A 

B 

C 

D 

E 

F

A 

B 

C 

D 

E 

F 

To T1 PRI - 0 

(F1 Sht 1) 

To PCB7 TB3 

(F1 Sht 1) 

Art # A-08487 

460 

220 

0___ 

1 

1 

To PCB7 CN2-1 

(F1 Sht 1) 

T1 

To PCB7 CN2-2 

(F1 Sht 1) 

APPENDIX 7: 

Power Supply Schematic,460V / 208 - 230V Cont. 

To PCB7 CN2-5 

(F2 Sht 1) 

To PCB7 CN2-4 

(F2 Sht 1) 


(C2, Sht 1) 

120. 

0___ 

24_ 

0__ 

24. 

0_ 

120. 

0... 

110 

0.. 


0. 

100 

0,, 

13 

0, 

C.P2 

C.P3 

C.P4 

C.P5 

R8 

1K 30W 

C.P7 

C.P6 

2 

AC24V-GCM 

(D9, A10) 

0V-A (24V ret) 

AC120V-GCM 

(D9, A10) 

0V-B (120V ret) 


FROM CN18 PCB3 

sht 1 


2 

INPUT CONTACTORs 

MC1 

MC3 

CN6 

AC120V @ 1A 

1 

AC200V @ 3A 

C.P8 

AC13V @ 2A 

230 

460 

CN9 

460_A 

1 

230_A 

2 

COM_A 

3 

CN2 

460 

230 

COM 

460 

230 

COM 

3 

MC2 

PILOT 

CONTACTOR 

CN10 

1 

2 

3 

2 

3 

4 

CN3 

1 

2 

3 

1 

2 

CN11 

2 

1 

CN9 

TB3 

TB4 

TB5 

1 

2 

3 

4 

5 

PCB7 WK-5628 

RELAY PCB 

RY5 

TB1 

TB2 

3 

RY4 


RY2 

+ 

TO AC 

INDICATOR 

(on PCB6) 

MC1 AUX 

MC3 AUX 

1 

CN2 

+ 

RY1 

RY5 

CN12 1 

RY3 

RY4 

2 

RY3 

3 

4 

2 

5 

RELCOL_0 

3 

+15V 

/PUMP 

/FAN 

/RAS 

+15V 

4 

PCB 5 WK-5602 (partial) INTERFACE PCB 

CN8 

1 

2 

3 

4 

CN7 

1 

2 

3 

4 

CN20 

1 

2 

3 

CN10 

1 

2 

3 

4 

5 

6 

CN12 

1 

2 

1 

CN8 

AC120V-RAS 

0V-RAS 

1 1 

2 2 

3 3 

1 1 

2 2 

DC 15V 

DC 0V 

4 

2 

3 

4 

(C9) 

+ - 

FAN1 

+15V 

+V 

SIG 

GND 

COOLANT TEMP 

LSW1-1 

(ON COOLANT 

RETURN) 

FL1 

SW_LIQUID_LEVEL_NC 

FLOW_TURBINE_PULSE 

' PUMP . 

MOT1 

CN1 1 

2 

CN13 1 

TH1 

t 

1 

2 

1 

2 

TP1 

TP2 

TP3 

TP4 

TP5 

TP9 

TP11 

TP12 

TP13 

TP14 

TP6 

TP7 

TP8 

TP10 

2 

3 

3 

3 

R G B 

5 

CCM MODULE 

I/O PCB 

CIRCUIT COMM (GND) 

29-41 VDC 

+15VDC 

+5VDC 

-15VDC 

ANALOG DEM to CPU 

NEG ARC VOLTS 

PILOT (TIP) VOLTAGE 

CUT DEM to PS 

PILOT DEM to PS 

+15VDC_ISO 

-15VDC_ISO 

+16 to +18VDC 

ISOLATED COMM 

D1 GAS_ON 

5 

1 

2 

ISOLATED 

VOLTAGES 

SW6 - OK to MOVE CONTACTS / VOLTS 

SW11 - ANALOG CURRENT SELECT 

"B" DEFAULT, "A" REMOTE 

SW12 - DIVIDED ARC V RATIO SELECT 

SW13 - FACTORY ONLY 

CPU PCB 

LED1 

LEVEL 

D23 CNC_START 

D26 HOLD_START 

D11 INITIALIZING / PROGRAMMING 

D12 STATUS CODE 

D13 +5V 

1 

CN14 

1 

2 

D2 E-STOP_PS 

D15 PSR 

D21 CNC_E-STOP 

D28 CNC_PREFLOW 

2 

D4 OK_CNC

CN10 26 CKT 

RIBBON CABLE 

TEST SOCKET 

J35 26 CKT 

6 

6 

CN11 34 CKT 

MOMENTARY START / STOP 

STOP 

START 

RIBBON CABLE 

TEST SOCKET 

J36 34 CKT 


/ = active low digital signal 

CN10-J35 - 26 Ckt Ribbon Cable 

2-Cut Demand 

4-Pilot Demand 

6-/ Start 

7-/ Start2 

9-/ Pilot Enable 

10-/ HF Enable 

12-/ Pump Enable 

13-/ Fan Enable 

15-/ DC Indicator 

16-/ Over Temperature Indicator 

18-/ Gas-Coolant OK Indicator 

19-/ Status Lamp 


1- Output Current Signal 

3- / Arc Transferred (CSR) 

4- / Pilot On 

6- Coolant Flow (freq) 

7- Coolant Temp (analog) 

9- / Temp OK (Inverter/Chopper) 

10- / Coolant Level OK 

12- Missing Phase 

13- / Ready to Operate 

15- / Input Volts OK 

16- / Inverter OCR 

18- / PS ID "00*" 

19- / PS ID "0*0" 

20- / PS ID "*00" 

21- E-Stop 

22- E-Stop 

29,31,33 - 24 VAC Supply 

30,32,34 - 24 VAC Return 

7 

NEG ARC VOLTS 

(A9 SHT1) 


(B9 SHT1) 

J6 

1 

- ARC V 

START / STOP 

7 

5 

TP11 TP12 

WORK 

(C9 SHT1) 

E-STOP - 

TB1 

1 

E-STOP + 2 

- 

+ 

8 

TB2 

24VAC 

24 VAC RET 

+15V 

/ AC 

/ TEMP 

/ GAS - COOLANT 

/ DC 

/ STATUS 

Signal - Basic ID 

Used to identify 

GCM 1000 present 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

1 

2 

3 

4 

5 

6 

7 

8 

9 

CN23 

1 

2 

3 

4 

5 

6 

10 

11 

12 

TP1 

J9 

1 

PSR 

2 

3 

K6 

GAS ON 

E-STOP 

1K 

- ARC V 

4 

5 

100K 

100K 

6 

K6-1 

Art # A-08487 


8 

CN24 

J5 

1 

2 

3 

4 

5 

PCB6 DISPLAY 

WK-5603 

PLASMA ENABLE 

1 

PLASMA ENABLE 

2 

PRESS OK (GCM 1000) 

3 

J8 

1 

2 

3 

4 

J1 

1 

2 

3 

4 

5 

6 

7 

8 

9 

1 

2 

3 

4 

5 

6 

J7 

4 

5 

6 

7 

8 

9 

J4 

1 

3 

5 

7 

8 

GREEN AC 

YELLOW TEMP 

GREEN1 

GREEN2 

RED 

POT HI (GCM1000) 

POT WIPER (GCM1000) 

POT LOW (GCM 1000) 

GAS 

DC 

STATUS 

(E4) 

9 

DC 15V 

(F4) 

DC 0V 

AC120V-RAS 

0V-RAS (120V ret) 

AC24V-GCM 

(E2) 


AC120V-GCM 

(E2) 

0V-B (120V ret) 


AC24V-GCM 

0V-B (120V ret) 

AC120V-GCM 

WORK 

(C9, sht 1) 

NEG ARC VOLTS 

(A9, sht 1) 

Rev 

AA 

Revisions 

By Date 

ECO-B731 (REL) DAT 1-18-08 

THERMAL DYNAMICS 

INDUSTRIAL PARK #2 

WEST LEBANON NH, 03784 

603-298-5711 

PCB No: 

Assy No: 

Scale 


(E2) 

INTERNAL TERMINAL 

STRIP TB3 

(Not in all units) 

1 

4 

5 

6 

7 

10 

11 

12 

24 VAC @ 1A 

KEY PLUG 

10 

120 VAC @ 100ma. 

UNDIVIDED ARC VOLTS 

FOR HEIGHT CONTROLS 

POWER SUPPLY 

REAR PANEL 

J54-REMOTE HMI 

1 

2 

3 

4 

5 

6 

7 

J55-GCM 

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 

J15-CNC 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

2 

8 

9 

J59-RAS 

1 

2 

3 

4 

5 

6 

7 

8 

3 

9 

10 

11 

12 

13 

14 

JUMPER IN 

REMOTE 

HMI 

PLASMA ENABLE 

START / STOP 

Other CNC 

functions 

disabled 

for hand torch 

system 

Supersedes 



Date: 




Drawn: References 

DAT 



2 of 2 

Size DWG No: 

12:19:03 PAK 200 Power Supply 208-230/460V D 42X1311 

9 

10 

A 

B 

C 

D 

E 

F

A 

B 

C 

D 

E 

F 

400 VAC 3 Phase 

NE1 

INPUT POWER 

INDICATOR 

REAR PANEL 

To T1 PRI - 0 

(A1 Sht2) 

Art # A-08488 

L1 

L2 

L3 

E 

CN3 

1 

4 

To PCB7 TB3 

(A1 Sht2) 

1 

CN1 1 

TB1 

CN4 1 

NE2 

1 

LINE to LINE, 

LINE TO GND 


4 

5 

8 

INPUT POWER 

INDICATOR 

INTERNAL 

PCB 1 

WK-5630 

FILTER PCB 

To PCB7 CN2-2 

(A1 Sht 2) 

To PCB7 CN2-1 

(A1 Sht 2) 

ON / OFF 

P_GND 

VAC_IN 

CN2 1 

2 

C.P1 

To PCB7 CN2-5 

(A2 Sht 2) 

To PCB7 CN2-4 

(A2 Sht 2) 

2 

2 

APPENDIX 8: 

Power Supply Schematic, 400V 


(D2, Sht 2) 

D1 

AC AC AC 

- + 

C4 

MC3-A 

MC3-B 

MC3-C 

MC1-A 

MC1-B 

MC1-C 

CN2 1 

+12VDC 

2 

RY2 

3 

+ 

T1 

S 

R1 

S 

RY2 

+12VDC 

CN10 1 

1 

2 

3 

2 

/ 400 

3 

CN4 - PCB12 

T 

1 

400 


COM 

CN4 - PCB12 

R 

CN4 1 

1 

2 

COM_A 

200_A 

400_A 

2 

2 

3 

3 

3 

3 

200V 

- 

4 

4 

4 

5 

4 

+12VDC 


INRUSH 

+ 

CN3 1 

/ 200 

6 

/ 400 

CN2 

1 VAC_IN 

P_GND 

CN4 

DETECTOR PCB 

+15V 

INTERFACE PCB 

V_CHANGE PCB 

400V only 

PGND1 

PGND2 

CN5 

CN1 CN5 CN6 

PCB4 WK-5604 

LED2 

MISSING PHASE 

CN1- not used 

6 

4 

CN2 400V 1 

CN2-400V 

CN1 

2 

7 

6 

5 

4 

3 

2 

1 

2 

3 

1 

2 

RY2 

3 

4 

3 

2 

CN7 1 

1 

CN7 

+15V 

MISSING_PHASE 

+15V 

INPUT_NG 

MISSING PHASE 

(pulses)< 

TB2 

4 


CN6 


2 

3 

--400-- 

2 

2 

1 

TB1 

TB3 

TB4 

4 

3 

3 

P1 

N2 


PCB3 WK-5694 

4 

+ 

BIAS SUPPLY 

FOR PCB5 

+15V 

+5V 

GND 

-15V 


CN6 


(same as #1) 

4 

4 

5 

5 

1 

2 

3 

4 

+ 

CN1- not used 

CN32 1 

1 

CN32 

LED3 

INPUT NG 

2 

2 

3 

3 

4 

4 

1 2 

4 

1 

CN18 

3 

1 2 

4 

3 

DC FAN 

POWER 

2 

CN6 

3 


(F2 -Sht2) 

3 

5 

4 - + 1 

2 

3 

4 

- + 

1 

2 

5 


CN6 16 CKT 

N (-)1 

P (+)1 

N (-) 

P (+) 











8- INV_READY 


12- / OCR 


14- /TEMP_ERR 


LED4 

CHOPPER TEMP 

TEMP_C 

1 

CN17 

/ OVERTEMP < 

2 

GND_C 

3 

LED5 

ERROR

6 


(CHOPPER) 

For this 

version 

of the 

power supply 

Pilot 

Regulator 

is not used 

except to 

provide power 

and pass 

signals from 

HCT1, the 

pilot current 

sensor. 

Pilot 

Resistors, 

R1a-f, are 

used instead. 

6 

PILOT REG. 

(CHOPPER ) 

PCB2 

WK-5754 

1 

CN33 

P_ena 

P_ref 

Iref_G 

< /OVER_TEMP 

TEMP_C 

N2 

GND_C 

P1 

BIAS 

POWER 

PILOT REG. 

(CHOPPER ) 

PCB1 

WK-5750 

CN3 2 

1 

CN8 

2 



2 

1 

3 

4 

CN5 

CN4 1 

23 

4 

3 

2 

1 

CN4 2 

1 

CN7 

5 

4 

3 

5 

4 

3 

2 

1 

I_senseP 

GNDP 

7 



P_ena 

P_ref 

7 

Iref_G 

I_DET 

< 

I_SE 

I_senseP 

GNDP 

+15Vw 

-15Vw 

Isense_W 

GNDW 

HALL SENSOR 

+12V 

-12V 

SIGNAL 

COMMON 




15A, 460V, 3P 













1 

CN3 

TB5 

CN2 1 

2 

3 


2 

4 

TB2 

C2 23 

1 

CN6 23 

1 

3 

4 

THS1 

SW_TEMP_NC 

CN9 

1 

2 

CN5 1 

23 

1 

CN4 

2 

4 


TB4 

TB1 

3 

4 

CN1 

CN1 

5 

2 

1 

1 

2 

3 

4 

+ - 

FAN3 

HCT1 

1 

2 

3 

4 


8 

8 

4 

3 

K2 

A2 

R6 

20K 

30W 

CN1 

1 

2 

3 

4 

R1 a-f 3.6 

(6 x 0.6, 300W in series) 

2 

1 

K1 

A1 

D2 

MC2-A 

MC2-B 

MC2-C 

+15Vw 

-15Vw 

Isense_W 

GNDW 

9 

NEG ARC VOLTS 

(C7 & A9,Sht 2) 

TB2 TB3 

PCB 8 

WK-5687 

CN2 CN21 RC & 

RF CAPS 

2 

3 

HCT2 

HALL SENSOR 

1 

2 

3 

4 


9 


(C7, Sht 2) 

TORCH (-) 

PILOT 

WORK (+) 

WORK 

(C7 & A9,Sht 2) 

Rev Revisions 


By Date 

DAT 1-18-08 

Thermal Dynamics 

Industrial Park #2 

West Lebanon NH 03784 

603-298-5711 

PCB No: 

Assy No: 

Scale 


CN3 1 

12:56:07 

TB1 

Power Supply 

Rear Panel 

C2 

2 UF 

R9 

50 

Thermal 

Dynamics 

RAS 





" Contacts (A2, B2, Sht 1) 









NE2 Neon indicator, internal, 220VAC (C1, Sht 1) 

R1a-f Resistor Pilot 0.6, 300W , (B8, sht 1) 

(6 in series) 








Date: 




Drawn: 

DAT 

References 



1 of 2 

Size DWG No: 

PAK 200 Power Supply 400V non-CE 

10 

10 

WORK 

Art # A-08488 

Supersedes 

D 42X1312 

A 

B 

C 

D 

E 

F

A 

B 

C 

D 

E 

F 

To T1 PRI - 0 

(F1 Sht 1) 

To PCB7 TB3 

(F1 Sht 1) 

400 


0___ 

Art # A-08489 

1 

1 

To PCB7 CN2-1 

(F1 Sht 1) 

T1 

To PCB7 CN2-2 

(F1 Sht 1) 

To PCB7 CN2-5 

(F2 Sht 1) 

To PCB7 CN2-4 

(F2 Sht 1) 


(C2, Sht 1) 

120. 

0___ 

24_ 

0__ 

24. 

0_ 

120. 

0... 

110 

0.. 


0. 

100 

0,, 

13 

0, 

C.P2 

C.P3 

C.P4 

C.P5 

R8 

1K 30W 

C.P7 

C.P6 

APPENDIX 8: 

Power Supply Schematic, 400V Cont. 


AC120V-GCM 

0V-B (120V ret) 

2 

AC24V-GCM 

(D9, A10) 

(D9, A10) 



sht 1 


2 


MC1 

MC3 

CN6 

AC120V @ 1A 

1 


AC13V @ 2A 

200 (not used) 

C.P8 

400 

CN9 

400_A 

1 

200_A 

2 

COM_A 

3 

400 


COM 

400 


COM 

3 

MC2 

PILOT 

CONTACTOR 

CN10 

1 

2 

3 

2 

3 

4 

CN3 

1 

2 

3 

1 

2 

CN11 

CN2 

TB3 

TB5 

2 

1 

CN9 

1 

2 

3 

4 

5 

TB4 

PCB7 WK-5628 

RELAY PCB 

RY5 

TB1 

TB2 

3 

1 

CN2 

RY4 


RY4 

TO AC 

INDICATOR 

(on PCB6) 

MC3 AUX 

+ 

RY1 

CN12 1 

MC1 AUX 

2 

RY2 

RY5 

+ 

RY3 

RY3 

3 

4 

2 

5 

3 

CN8 

1 

2 

3 

4 

CN8 

1 

2 

3 

4 

CN7 

1 

2 

3 

CN10 

1 

2 

3 

4 

5 

6 

CN12 

1 

2 

+15V 

/PUMP 

/FAN 

/RAS 

+15V 

4 


1 

CN8 

AC120V-RAS 

0V-RAS 

1 1 

2 2 

3 3 

1 1 

2 2 

2 

DC 15V 

DC 0V 

4 

3 

4 

(C9) 

CN1 1 

+15V 

2 

COOLANT TEMP 

(ON COOLANT 

RETURN) 

' PUMP . 

MOT1 

+ - 

FAN1 

CN1 1 

TH1 

t 

1 

2 

TP1 

TP2 

TP4 

TP5 

TP9 

TP11 

TP12 

TP13 

TP14 

TP7 

TP8 

2 

+V 

SIG 

GND 

FL1 

1 

2 

3 

3 

R G B 

CCM MODULE 

5 

1 

CN14 

FLOW_TURBINE_PULSE 

TP3 

TP6 

TP10 

3 

I/O PCB 


29-41 VDC 

+15VDC 

+5VDC 

-15VDC 


NEG ARC VOLTS 


CUT DEM to PS 


+15VDC_ISO 

-15VDC_ISO 

+16 to +18VDC 

ISOLATED COMM 



5 

1 

2 

D1 GAS_ON 

ISOLATED 

VOLTAGES 






CPU PCB 

D11 INITIALIZING / PROGRAMMING 


D13 +5V 

1 

2 

LED1 

LEVEL 

2 

LSW1-1 

SW_LIQUID_LEVEL_NC 

D2 E-STOP_PS 

D4 OK_CNC 

D15 PSR 

D23 CNC_START 

D26 HOLD_START

CN10 26 CKT 

RIBBON CABLE 

TEST SOCKET 

J35 26 CKT 

6 

6 

CN11 34 CKT 


STOP 

START 

RIBBON CABLE 

TEST SOCKET 

J36 34 CKT 




2-Cut Demand 


6-/ Start 

7-/ Start2 












4- / Pilot On 









18- / PS ID "00*" 

19- / PS ID "0*0" 

20- / PS ID "*00" 

21- E-Stop 

22- E-Stop 

29,31,33 - 24 VAC Supply 

30,32,34 - 24 VAC Return 

TP11 

- ARC V 

7 

NEG ARC VOLTS 

(A9 SHT1) 


(B9 SHT1) 

J6 

1 

START / STOP 

5 

TP12 

7 

WORK 

(C9 SHT1) 

E-STOP - 

TB1 

1 

E-STOP + 2 

- 

+ 

8 

3 

4 

5 

6 

7 

8 

9 

TB2 

CN23 

1 

2 

3 

4 

5 

6 

10 

11 

12 

24VAC 

24 VAC RET 

+15V 

/ AC 

/ TEMP 


/ DC 

/ STATUS 




1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

TP1 

J9 

1 

PSR 

2 

3 

K6 

1K 

- ARC V 

4 

5 

GAS ON 

E-STOP 

100K 

6 

K6-2 

100K3 

CN24 


J7 

8 

PCB6 DISPLAY 

WK-5603 

PLASMA ENABLE 

1 

PLASMA ENABLE 

2 


3 

J8 

1 

2 

3 

4 

J4 

1 

3 

5 

7 

4 

5 

6 

7 

8 

9 

1 

2 

3 

4 

5 

6 

J5 

J1 

1 

2 

3 

4 

5 

6 

7 

8 

9 

1 

2 

3 

4 

5 

8 

GREEN AC 

YELLOW TEMP 

GREEN1 

GREEN2 

RED 




GAS 

DC 

STATUS 

(E4) 

9 

AC24V-GCM 

(E2) 

DC 15V 

(F4) 

DC 0V 

9 


AC24V-GCM 

0V-B (120V ret) 

AC120V-GCM 

WORK 

(C9, sht 1) 

NEG ARC VOLTS 

(A9, sht 1) 

AC120V-RAS 



AC120V-GCM 

(E2) 

0V-B (120V ret) 

Rev Revisions 


By Date 

DAT 1-18-08 




603-298-5711 

PCB No: 

Assy No: 

Scale 


(E2) 

12:56:07 


STRIP TB3 


1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

POWER SUPPLY 

REAR PANEL 

J59-RAS 

Thermal 

Dynamics 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

24 VAC @ 1A 



Date: 





DAT 



PAK 200 Power Supply 400V non CE 

2 of 2 

Size DWG No: 

10 

120 VAC @ 100ma. 




1 

2 

3 

4 

5 

6 

7 

KEY PLUG 

J55-GCM 

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 

J15-CNC 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

JUMPER IN 

REMOTE 

HMI 

PLASMA ENABLE 

START / STOP 

Other CNC 

functions 

disabled for 

hand torch 

system 

10 

Art # A-08489 

Supersedes 

D 42X1312 

A 

B 

C 

D 

E 

F

A 

B 

C 

D 

E 

F 

600 VAC 3 Phase 

NE1 

INPUT POWER 

INDICATOR 

REAR PANEL 

To T1 PRI - 0 

(A1 Sht2) 

Art # A-08490 

L1 

L2 

L3 

E 

CN3 

1 

4 

To PCB7 TB3 

(A1 Sht2) 

1 

CN1 1 

TB1 

1 

5 

CN4 1 

NE2 

LINE to LINE, 

LINE TO GND 


4 

8 

INPUT POWER 

INDICATOR 

INTERNAL 

PCB 1 

WK-5857 

FILTER PCB 

To PCB7 CN2-2 

(A1 Sht 2) 

To PCB7 CN2-1 

(A1 Sht 2) 

ON / OFF 

P_GND 

VAC_IN 

CN2 1 

2 

C.P1 

To PCB7 CN2-5 

(A2 Sht 2) 

To PCB7 CN2-4 

(A2 Sht 2) 

APPENDIX 9: 

Power Supply Schematic, CSA 600V 

2 


(D2, Sht 2) 

D1 

AC AC AC 

- + 

2 

C4 

MC3-A 

MC3-B 

MC3-C 

MC1-A 

MC1-B 

MC1-C 

CN2 1 

+12VDC 

2 

RY2 

3 

+12VDC 

1 

2 

3 

600 

600_A 

CN4 1 

+ 

T1 

S 

R1 

2 

/ 600 

3 

CN4 - PCB12 

T 

1 

2 

3 

230 

COM 

230_A 

COM_A 

3 

3 

4 

- 

4 

4 

5 

CN4 - PCB12 

R 

RY2 

CN10 1 

S1 

2 

1 

2 

3 

230V 

CN3 

4 

+12VDC 


INRUSH 

+ 

/ 230 

CN1 

7 

6 

5 

4 

3 

2 

1 

6 

/ 600 

CN2 

1 VAC_IN 

/ 230 

PGND1 

/ 600 

PGND2 

P_GND 

CN4 

DETECTOR PCB 

CN1 CN5 CN6 

+15V 

INTERFACE PCB 

V_CHANGE PCB 

600V only 

CN5 

PCB4 WK-5604 

1 

2 

CN1- not used 

6 

4 

CN2 600V 1 

CN2-400V 

2 

3 

1 

2 

RY2 

3 

LED2 

4 

MISSING PHASE 

3 

2 

CN7 1 

1 

CN7 

TB1 

+15V 

MISSING_PHASE 

+15V 

INPUT_NG 

MISSING PHASE 

(pulses)< 

4 


CN6 


2 

--600-- 

TB4 

2 

1 

TB2 

TB3 

3 

2 

4 

3 

3 

P1 

N2 


PCB3 WK-5694 

4 

BIAS SUPPLY 

FOR PCB5 

+15V 

+5V 

GND 

-15V 


CN6 


(same as #1) 

4 

4 

5 

5 

1 

2 

3 

4 

+ 

+ 

CN1- not used 

CN32 1 

1 

CN32 

LED3 

INPUT NG 

2 

2 

3 

3 

4 

4 

1 2 

4 

1 

CN18 

3 

1 2 

4 

3 

DC FAN 

POWER 

2 

CN6 

3 


(F2 -Sht2) 

3 

3 

5 

4 - + 1 

2 

4 - + 1 

2 

5 


CN6 16 CKT 

N (-)1 

P (+)1 

N (-) 

P (+) 






8- INV_READY 


12- / OCR 


14- /TEMP_ERR 


LED4 

CHOPPER TEMP 






TEMP_C 

1 

CN17 

/ OVERTEMP < 

2 

GND_C 

3 

LED5 

ERROR

6 


(CHOPPER) 

For this 

version 

of the 

power supply 

Pilot 

Regulator 

is not used 

except to 

provide power 

and pass 

signals from 

HCT1, the 

pilot current 

sensor. 

Pilot 

Resistors, 

R1a-f, are 

used instead. 

6 

PILOT REG. 

(CHOPPER ) 

PCB2 

WK-5754 

1 

CN33 

P_ena 

P_ref 

Iref_G 

< /OVER_TEMP 

TEMP_C 

(C1, Sht 2) 

GND_C 

N2 P1 

BIAS 

POWER 

PILOT REG. 

(CHOPPER ) 

PCB1 

WK-5750 

CN3 1 

CN8 

2 

2 



2 

1 

3 

4 

CN5 

CN4 1 

CN4 2 

1 

2 

3 

4 

3 

2 

1 

CN7 

5 

4 

3 

5 

4 

3 

2 

1 

I_senseP 

GNDP 

7 


P_ena 

P_ref 

7 


Iref_G 

I_DET 

< 

I_SE 

I_senseP 

GNDP 

+15Vw 

-15Vw 

Isense_W 

GNDW 

HALL SENSOR 

+12V 

-12V 

SIGNAL 

COMMON 



C3 Capacitor 47 uf 400V (C1, Sht 2) 


10A, 690V, 3Ph 










D3 Diode Bridge 25A, 800V, 1Ph (C1, Sht 2) 




1 

CN3 

TB5 

CN2 1 

2 

3 


4 

CN2 1 

3 

2 

CN6 1 

2 

TB2 

3 

3 

2 

4 


TB4 

THS1 

SW_TEMP_NC 

CN9 

CN5 1 

1 

CN4 

1 

2 

2 

3 

4 

2 

TB1 

3 

4 

CN1 

CN1 

5 

2 

1 

1 

2 

3 

4 

+ - 

FAN3 

HCT1 

1 

2 

3 

4 


8 

8 

R1a-f 3.6 

(6 x 0.6 ohm in series) 

4 

3 

K2 

A2 

R6 

20K 

30W 

2 

1 

K1 

A1 

D2 

CN1 

1 

2 

3 

4 

MC2-A 

MC2-B 

MC2-C 

+15Vw 

-15Vw 

Isense_W 

GNDW 

9 

NEG ARC VOLTS 

(C7 & A9,Sht 2) 

TB2 TB3 

PCB 8 

WK-5687 

RC & 

RF CAPS 

CN2 1 

23 

HCT2 

HALL SENSOR 

1 

2 

3 

4 


(C7, Sht 2) 


" Contacts (A2, B2, Sht 1) D 




9 

TORCH (-) 

PILOT 

WORK (+) 

WORK 

(C7 & A9,Sht 2) 

Rev Revisions 

By Date 

AA ECO-B731 (REL) DAT 1-18-08 




603-298-5711 

PCB No: 

Assy No: 

Scale 


CN3 1 


14:32:11 

TB1 

Power Supply 

Rear Panel 

C2 

2 UF 

R9 

50 

Thermal 

Dynamics 

RAS 









NE2 Neon indicator, internal, 220VAC (C1, Sht 1) 

R1a-f Resistor, Pilot, 0.6, 300W, (B8, sht 1) 

(6 in series) 








Date: 





DAT 



PAK 200 Power Supply 600V 

1 of 2 

Size DWG No: 

10 

10 

WORK 

Art # A-08490 

Supersedes 

D 42X1313 

A 

B 

C 

E 

F

A 

B 

C 

D 

E 

F 

To T1 PRI - 0 

(F1 Sht 1) 

Art # A-08491 

To PCB7 TB3 

(F1 Sht 1) 

1 

1 

600 

220 

0___ 

D3 

AC AC 

- + 

To PCB7 CN2-1 

(F1 Sht 1) 

To PCB7 CN2-2 

(F1 Sht 1) 

C12 + 

T1 

APPENDIX 9: 

Power Supply Schematic, CSA 600V Cont. 

To PCB7 CN2-5 

(F2 Sht 1) 

To PCB7 CN2-4 

(F2 Sht 1) 

P1 

(A7, Sht 1) 

N2 


(C2, Sht 1) 

120. 

0___ 

24_ 

0__ 

24. 

0_ 

120. 

0... 

110 

0.. 


0. 

100 

0,, 

13 

0, 

C.P2 

C.P3 

C.P4 

C.P5 

R8 

1K 30W 

C.P7 

C.P6 

2 

AC24V-GCM 

(D9, A10) 


AC120V-GCM 

(D9, A10) 

0V-B (120V ret) 



sht 1 


2 


MC1 

MC3 

CN6 

AC120V @ 1A 

1 


AC13V @ 2A 

230 (not used) 

C.P8 

600 

CN9 

600_A 

1 

230_A 

2 

COM_A 

3 

3 

MC2 

PILOT 

CONTACTOR 

CN10 

1 

2 

3 

2 

3 

4 

CN3 

1 

2 

3 

1 

2 

CN11 

CN2 

TB3 

TB5 

COM 

600 

3 

2 

1 

CN9 

1 

2 

3 

4 

5 

TB4 

600 

230 

230 

COM 

PCB7 WK-5628 

RELAY PCB 

RY5 

TB1 

TB2 


1 

CN2 

+ 

RY1 

RY4 

RY4 

TO AC 

INDICATOR 

(on PCB6) 

CN12 1 

MC1 AUX 

MC3 AUX 

2 

RY2 

RY5 

+ 

RY3 

RY3 

3 

4 

2 

5 

3 

CN8 

1 

2 

3 

4 

CN7 

1 

2 

3 

4 

CN20 

1 

2 

3 

CN10 

1 

2 

3 

4 

5 

6 

CN12 

1 

2 

4 


1 

CN8 

+15V 

/PUMP 

/FAN 

/RAS 

4 

+15V 

AC120V-RAS 

0V-RAS 

1 1 

2 2 

3 3 

1 1 

2 2 

2 

3 

DC 15V 

DC 0V 

4 

(C9) 

CN1 1 

+15V 

2 

COOLANT TEMP 

(ON COOLANT 

RETURN) 

' PUMP . 

MOT1 

+ - 

FAN1 

CN13 1 

TH1 

t 

1 

2 

1 

2 

TP1 

TP2 

TP4 

TP11 

TP12 

TP13 

TP14 

TP7 

TP8 

2 

+V 

SIG 

GND 

5 

3 

3 

3 

R G B 

CCM MODULE 

I/O PCB 


29-41 VDC 

+15VDC 

+5VDC 

-15VDC 


NEG ARC VOLTS 


CUT DEM to PS 


+15VDC_ISO 

-15VDC_ISO 

+16 to +18VDC 

ISOLATED COMM 

5 

1 

CN14 

1 

2 


ISOLATED 

VOLTAGES 






CPU PCB 


2 

D1 GAS_ON 

D13 +5V 

LED1 

LEVEL 

LSW1-1 

FL1 

FLOW_TURBINE_PULSE SW_LIQUID_LEVEL_NC 

TP3 

TP5 

TP9 

TP6 

TP10 

1 

2 

D2 E-STOP_PS 

D4 OK_CNC 

D15 PSR 


D23 CNC_START 

D26 HOLD_START 

D11 INITIALIZING / PROGRAMMING

6 

CN10 26 CKT 

RIBBON CABLE 

TEST SOCKET 

J35 26 CKT 

6 

CN11 34 CKT 

RIBBON CABLE 

TEST SOCKET 

J36 34 CKT 




2-Cut Demand 


6-/ Start 

7-/ Start2 










TP11 

7 

NEG ARC VOLTS 

(A9 SHT1) 


(B9 SHT1) 

J6 

- ARC V 

7 

WORK 

(C9 SHT1) 



4- / Pilot On 









18- / PS ID "00*" 

19- / PS ID "0*0" 

20- / PS ID "*00" 

21- E-Stop 

22- E-Stop 

29,31,33 - 24 VAC Supply 

30,32,34 - 24 VAC Return TB1 

E-STOP - 1 


STOP 

E-STOP + 2 

3 

4 

START 

START / STOP - 5 

+ 6 

7 

1 

5 

TP12 

8 

8 

9 

TB2 

24VAC 

24 VAC RET 

+15V 

/ AC 

/ TEMP 


/ DC 

/ STATUS 




8 

9 

CN23 

1 

2 

3 

4 

5 

6 

10 

11 

12 

1 

2 

3 

4 

5 

6 

7 

10 

11 

12 

TP1 

J9 

1 

PSR 

2 

3 

K6 

1K 

- ARC V 

4 

5 

GAS ON 

E-STOP 

100K 


6 

K6-2 

100K3 

8 

CN24 

J5 

8 

PCB6 DISPLAY 

WK-5603 

PLASMA ENABLE 

1 

PLASMA ENABLE 

2 


3 

J8 

1 

2 

3 

4 

J4 

1 

3 

5 

7 

1 

2 

3 

4 

5 

J7 

4 

5 

6 

7 

8 

9 

1 

2 

3 

4 

5 

6 

J1 

1 

2 

3 

4 

5 

6 

7 

8 

9 

GREEN AC 

YELLOW TEMP 

GREEN1 

GREEN2 

RED 




GAS 

DC 

STATUS 

9 

DC 15V 

(F4) 

DC 0V 

9 

AC120V-RAS 


AC24V-GCM 

(E2) 


AC120V-GCM 

(E2) 

0V-B (120V ret) 


AC24V-GCM 

0V-B (120V ret) 

AC120V-GCM 

WORK 

(C9, sht 1) 

NEG ARC VOLTS 

(A9, sht 1) 

Rev Revisions 


By Date 

DAT 1-18-08 




603-298-5711 

PCB No: 

Assy No: 

Scale 

Last Modified: 

Friday, January 18, 2008 

(E4) 

14:32:11 

(E2) 


STRIP TB3 


POWER SUPPLY 

REAR PANEL 

Thermal 

Dynamics 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

J59-RAS 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

KEY PLUG 



Date: 




Drawn: 

DAT 

References 



PAK 200 Power Supply 600V 

2 of 2 

Size DWG No: 

10 

24 VAC @ 1A 

120 VAC @ 100ma. 




1 

2 

3 

4 

5 

6 

7 

J55-GCM 

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 

J15-CNC 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

JUMPER IN 

REMOTE 

HMI 

PLASMA ENABLE 

START / STOP 

Other CNC 

functions 

disabled for 

hand torch 

system 

10 

Art # A-08491 

Supersedes 

D 42X1313 

A 

B 

C 

D 

E 

F

Manual No. 0-5057 

Cover Date Rev Change(s) 

APPENDIX 10: 

PUBLICATION HISTORY 

June 9, 2008 AA First issue 

Oct. 8, 2008 AB Chapter 3 and 4: Up-date and/or add technical information (flow and pressure 

requirements). 

NOTE 

* Thermal Dynamics uses the date on the manual cover to indicate the most recent revision of the manual. 

Manual 0-5057 A-20 APPENDIX

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION 

Thermadyne USA 

2800 Airport Road 

Denton, Tx 76207 USA 

Telephone: (940) 566-2000 

800-426-1888 

Fax: 800-535-0557 

Thermadyne Canada 

2070 Wyecroft Road 

Oakville, Ontario 

Canada, L6L5V6 

Telephone: (905)-827-1111 

Fax: 905-827-3648 

Thermadyne Europe 

Europe Building 

Chorley North Industrial Park 

Chorley, Lancashire 

England, PR6 7Bx 

Telephone: 44-1257-261755 

Fax: 44-1257-224800 

Thermadyne, China 

RM 102A 

685 Ding Xi Rd 

Chang Ning District 

Shanghai, PR, 200052 

Telephone: 86-21-69171135 

Fax: 86-21-69171139 

Thermadyne Asia Sdn Bhd 

Lot 151, Jalan Industri 3/5A 

Rawang Integrated Industrial Park - Jln Batu Arang 

48000 Rawang Selangor Darul Ehsan 

West Malaysia 

Telephone: 603+ 6092 2988 

Fax : 603+ 6092 1085 

Cigweld, Australia 

71 Gower Street 

Preston, Victoria 

Australia, 3072 

Telephone: 61-3-9474-7400 

Fax: 61-3-9474-7510 

Thermadyne Italy 

OCIM, S.r.L. 

Via Benaco, 3 

20098 S. Giuliano 

Milan, Italy 

Tel: (39) 02-98 80320 

Fax: (39) 02-98 281773 

Thermadyne International 

2070 Wyecroft Road 

Oakville, Ontario 

Canada, L6L5V6 

Telephone: (905)-827-9777 

Fax: 905-827-9797

Corporate Headquarters 

16052 Swingley Ridge Road 

Suite 300 

St. Louis, MO 63017 

Telephone: 636-728-3000 

Email: TDCSales@Thermadyne.com 

www.thermadyne.com

PAK® OperatingManual 200 - Victor Technologies - Europe

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