Hypertherm PAC500 Water Injection Plasma Cutting System - Manual (Page 29)

PAC500 Instruction Manual 3-5
4
INSTALLATION
Torch
1. Mount the torch in a torch holder on the cutting machine. Torch must be held by the black insulator sleeve.
DO NOT hold torch by the stainless steel body. Improper mounting may cause internal arcing and destroy
torch body.
2. Feed the torch leads to a suitable support.
3. The water-cooled cables are marked with a red and a green tape.
The green is water in to the electrode.
The red is water out from the electrode.
4. Pass the water-cooled cables through the feedthru, figure 3, page 5-14, (shield adapter) and connect to the
cathode block being careful to maintain the proper flow direction as indicated by color code on the cathode
block fittings.
5. Attach the red hose to the WATER OUT fitting (figure 3, page 5-14). NOTE: Left hand thread.
6. Attach the green hose to the GAS fitting (figure 3, page 5-14).
7. The white pilot arc lead from the torch is passed through the shield adapter and the empty grommeted hole near
the cathode block and is connected to point 33 of the air core transformer (figure 6, Tank Coil-right hand stud).
Gas System
Attach a 3/8" dia. gas hose from the cutting gas supply to the GAS fitting on the rear panel of the console
(figure 2, page 5-13).
Operator's Panel
Interface connections are made to terminal strip 4TB located inside the operator's panel. Control power (120 VAC)
is connected to 4TB-1 and 4TB-2. (L1, L2).
The START/STOP pushbutton station (supplied as an optional accessory item) is connected to the terminal strip
4TB. The START normally open contacts are connected to the 4TB-5 and 4TB-6 and the STOP normally closed
contacts are connected to 4TB-6 and 4TB-7.
A provision for automatic start of the torch carriage ("Machine Start") is available through normally open contacts
between terminals 4TB-20 and 4TB-21. The normally open contacts will close when the arc transfers to the
workpiece. These contacts can be used to automatically start torch motion. (Consoles with serial numbers followed
by the letter “H” have normally closed contacts between terminals 4TB-20 and 4TB-21).
The 20 pin Amphenol plug (1PL) is connected to the Receptacle (1 RECP) on the console. The gas and water
hoses are connected to fittings provided on the console (see figure 2, page 5-13). These are color coded and care
must be taken to connect them correctly. The water hoses are black and color coded with tape: a green band is
water to the operator's panel; a red band is water from the operator's panel. The corresponding fitting is also color
coded. The gas hoses are green and color coded with tape: a green band is gas to the operator's panel; a red band
is gas from the operator's panel.