Hypertherm PAC500 Water Injection Plasma Cutting System - Manual (Page 30)

3-6 PAC500 Instruction Manual
4
INSTALLATION
A ground connection is made to the mounting stud on the torch connection side of the console; number 10 wire
should be used. Make sure a good clean connection is made. Run the ground cable to a high quality earth ground.
If the PAC500 is installed on an N/C cutting machine, the ground leads from the console, cutting machine, power
supply and cutting table should be connected to a common, high quality “star” ground. This will help reduce
electrical noise.
Argon-Hydrogen Manifold
1. Position the manifold on top of the control console. Make sure the torch hose connection can be easily reached
and that the flowmeter is conveniently located.
2. Drill four mounting holes and secure manifold with the four 8-32 x 3/8" screws provided.
3. Install a 1/2-in. cord grip to the rear panel of the control console. If possible, locate the cord grip on the left side
of the rear panel. This will simplify solenoid cable routing since connections are made to the terminal strip 3TB
located in the plumbing compartment (figure 7, page 5-17). If space is not available, install the cord grip on the
right side of the rear panel and route the cable through the grommeted opening at the top of the center partition.
4. The pressure switch, 2PS, is electrically connected in parallel with the existing pressure switch, 1PS, to provide
protection from loss of plasma gas. These leads are numbered and are connected to 3TB-10 and 3TB-25. The
Argon-Hydrogen solenoid, 3 SOL, is paralleled with the water solenoid, 1 Sol. These leads are also numbered
and are connected to 3TB-2 and 3TB-9.
5. Connect the gas supply hose to the fitting located at the rear of the manifold. Connect the green torch gas hose
to the fitting located on the front of the manifold.
System Check-Out
1. Turn power supply disconnect switch OFF.
2. Verify proper consumables installed in torch. (Electrode, .032 Swirl Ring, .166 Nozzle)
3. Turn the nitrogen supply on; adjust the pressure to 150 psi.
4. Turn the operator's panel switches to OFF and TEST.
5. Open the water supply valve if a valve is used. Turn the disconnect switch for the water pump ON.
6. Turn the disconnect switch for the power supplies ON.
7. Adjust the power supply to an intermediate setting.
8. Check the pump output pressure; it should read 175 psig. This pressure can be adjusted by removing the
large acorn nut cap on the relief valve and by turning the adjustment screw clockwise to increase pressure,
counterclockwise to decrease pressure. Also check the water discharge from the torch cooling return line;
1.6 gal./min. is required.
9. Check to be sure the mode switch is in TEST. Push the START button.
10. Adjust the gas flow and water flow: for the .166 nozzle, set the gas flowmeter at 45% and the water flowmeter
at 75%.