Thermal Dynamics Econo-Pak 50 User manual

Manual No. 0-2450
September 1, 1998
ECONO-PAK 50
Air Plasma Cutting Power Supply
Operating Manual
The System Includes:
• ECONO-PAK 50 Power Supply
• PCH-26 Torch with Leads
• Work Cable with Clamp

WARNING
WARNING
Read and understand this entire Operating Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Operating Manual
represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Econo-Pak 50 Air Plasma Cutting Power Supply
Operating Manual Number 0-2450
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1997 by
Thermal Dynamics 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 the Econo-Pak 50 Air Plasma Cutting Power Supply
Operating Manual, whether such error results from negligence,
accident, or any other cause.
Printed in the United States of America
September 1, 1998

Purchase Date
Power Supply
Torch
RECORD SERIAL NUMBERS FOR WARRANTY PURPOSES

TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION ..................................................................................... 1
1.01 Notes, Cautions andWarnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et Avertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 6
1.08 Statement ofWarranty ................................................................................... 7
SECTION 2: INTRODUCTION & DESCRIPTION........................................................................ 9
2.01 SYSTEM SPECIFICATIONS ......................................................................... 9
2.02 TORCH PARTS............................................................................................ 10
SECTION 3: INSTALLATION ..................................................................................................... 11
3.01 UNPACKING AND CHOOSING A LOCATION.............................................. 11
3.02 ELECTRICAL CONNECTIONS ................................................................... 11
3.03 GAS CONNECTIONS ................................................................................. 12
3.03 GAS CONNECTIONS (Continued).............................................................. 13
SECTION 4: OPERATION ......................................................................................................... 15
4.01 OPERATING CONTROLS ........................................................................... 15
4.02 GETTING STARTED ................................................................................... 16
4.03 OPERATING THE SYSTEM ........................................................................ 17
4.03 OPERATINGTHE SYSTEM (continued) ..................................................... 18
4.04 OPERATING WITH A HANDTORCH ........................................................... 19
4.05 RECOMMENDED CUTTING SPEEDS ....................................................... 20
SECTION 5: CUSTOMER/OPERATOR SERVICE..................................................................... 21
5.01TROUBLESHOOTING AND MAINTENANCE .............................................. 21
5.02 BASICTROUBLESHOOTING GUIDE .......................................................... 22
5.03 REPLACING CONSUMABLETORCH PARTS ............................................ 23
SECTION 6: PARTS LISTS........................................................................................................ 25
6.01 INTRODUCTION......................................................................................... 25
6.02 REPLACEMENT - COMPLETE SYSTEMS ................................................. 26
6.03 REPLACEMENTTORCH AND LEAD ASSEMBLIES .................................. 27
6.04 OPTIONS AND ACCESSORIES ................................................................. 28
6.05 REPLACEMENT HANDTORCH PARTS ..................................................... 29
This Page Left Blank ............................................................................................ 31
APPENDIX I: SYSTEM SCHEMATIC......................................................................................... 32

TABLE OF CONTENTS (continued)

1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
areused tohighlight importantinformation. Thesehigh-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful 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 oper-
ating area.
1.02 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structionsbefore usingtheequipment. 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.
• 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 met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
•Alwaysreadthe MaterialSafetyData Sheets(MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding thekind andamount offumes andgases
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 com-
bustibleor explosivegases or materials arelocated.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
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 op-
erator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
•Wear dryglovesand clothing. Insulateyourselffrom
the work piece or other parts of the welding cir-
cuit.
• 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, Publica-
tions.
•Disconnect powersourcebeforeperforming anyser-
vice or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.

GENERAL INFORMATION 2
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 mate-
rial in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
•Do notcut or weld on containers that mayhave held
combustibles.
• Providea firewatch whenworking inan area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water 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 dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noisecan causepermanent hearingloss. Plasma arcpro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
• To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the deci-
bels (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.
PLASMAARC RAYS
PlasmaArcRays caninjureyour eyesandburn yourskin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyesand burnyour skinifyou are notproperlyprotected.
• To protect your eyes, always wear a welding hel-
metor shield. Alsoalways wearsafety glasseswith
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro-
tect 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 recommended in Subsec-
tion 1.03, item 4.
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, Wash-
ington, 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 WELD-
INGAND GAS WELDING AND CUTTING, obtain-
able from the Superintendent of Documents, U.S.
GovernmentPrinting Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATIONAND EDUCATIONALEYEAND 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 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable fromAmerican National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable fromAmerican Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protec-
tion 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 Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA22202

3 GENERAL INFORMATION
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Ca-
nadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply
Association, 1900Arch Street, Philadelphia, PA19103
14. American Welding Society StandardAWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPA-
RATION FOR WELDING AND CUTTING OF CON-
TAINERS 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 RESPIRA-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
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
AVERTISSEMENT
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.
Il faut communiquer aux opérateurs et au person-
nel 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 respi-
ration. 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
revêtementsse trouvantsur lemétal etdesdifférents
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.

GENERAL INFORMATION 4
• 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
provenantdes solvantsetdes produitsde nettoyage
chlorés. Eliminez toute source de telle fumée.
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 deschocs graves,voiremortels, pourl’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 par-
ties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de tra-
vail 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 tra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
Lesincendies etlesexplosions peuventrésulterdes 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 com-
bustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable 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.
• Necoupez paset 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
vosyeux etbrûler votrepeau. Leprocédéàl’arcde plasma
produit une lumière infra-rouge et des rayons ultra-vio-
lets 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
ouun écrande soudeur. Porteztoujours deslunettes
de sécurité munies de parois latérales ou des lu-
nettes de protection ou une autre sorte de protec-
tion 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 protec-
tion 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.
• Respectez le teint de lentille recommandé dans le
article 4, page 5.
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 protégervotre ouïecontreles bruitsforts,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.

5 GENERAL INFORMATION
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
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 Docu-
ments, U.S. Government Printing Office, Washing-
ton, 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 ETAU GAZ, disponible auprès du Superin-
tendent 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’InstitutAméricain desNormesNationales (Ameri-
can National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURESPROTECTRICES, disponibleauprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (AWS), LE SOUDAGE ET LACOUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITSCOMBUSTIBLES, disponibleauprès de
laAmerican Welding Society, 550N.W. LeJeuneRd.,
Miami, FL 33126
8. Norme 51 de l’AssociationAméricaine pour la Pro-
tectioncontreles Incendies(NFPA), LESSYSTEMES
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 NA-
TIONAL,disponible auprèsde laNational Fire Pro-
tectionAssociation, BatterymarchPark, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, 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 CSAW117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan-
dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13.ivret NWSA,BIBLIOGRAPHIESUR LASÉCURITÉ
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,RECOMMANDATIONS DEPRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE
ETAUSOUDAGE DECONTENEURS ETTUYAUX
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 PROTEC-
TION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018

GENERAL INFORMATION 6
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc-
tive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National leg-
islation 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:
* CSA(Canadian StandardsAssociation) standard C22.2 number 60 forArc welding equipment.
* UL(Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment and associated accessories.
* 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: DavidAshworth
Vice President & Managing Director
ThermadyneEurope
Chorley England.

7 GENERAL INFORMATION
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 priceof the
goods upon which such liability is based.
THISWARRANTY BECOMES INVALID IF REPLACEMENTPARTSOR ACCESSORIES AREUSED WHICHMAY 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 Thermal products shall be as follows (with the exception of STAK PAK II and DRAG-GUN): 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 the further limitations on such two (2) year period (see chart below).
The limited warranty period for STAK PAK II shall be as follows: A maximum of four (4) years from date of sale to an
authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with
the further limitations on such three (3) year period (see chart below).
The limited warranty period for DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the
further limitations on such two (2) year period (see chart below).
PARTS PARTS PARTS
PAK UNITS, POWER SUPPLIES STAK PAK II DRAG-GUN All OTHERS LABOR
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
CONSOLES, CONTROL EQUIPMENT, HEAT1 Year 1 Year 1 Year
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS
Maximizer 300 Torch N/A 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
REPAIR/REPLACEMENTPARTS 90 Days 90 Days 90 Days None
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 19, 1998

GENERAL INFORMATION 8

Manual0-2450 9 INTRODUCTION & DESCRIPTION
SECTION 2: INTRODUCTION & DESCRIPTION
2.01 SYSTEM SPECIFICATIONS
Econo-pak 50
Air Plasma Cutting
System Includes:
Controls
Panel Indicators
Input Power
Output Power
OCV
Duty Cycle
Work Lead
Cut Capacity
Pilot Circuitry
Gas Connection
Gases
Pressure
Flow
Weight
Dimensions
• Econo-pak 50 - The power supply provides 35 amps maximum
output cutting current from a standard 208-230 volt, 60Hz AC
input service. All electrical, pilot, and gas control circuitry is
included.
• Hand Torch with Leads. Cut capacity is 1/2 inch (12.8 mm)
steel. Parts-In-Place (PIP) is an integral safety feature of this
torch to reduce the risk of electric shock.
• Spare Parts Kit.
• ON/OFF Switch
• RUN/SET Switch
• Output Current Control
• Pressure Regulator Control
LED Indicators: AC Power, READY
Pressure Gauge
208-230 VAC, 60 Hz, 25/30 Amp Single Phase
Continuously variable from 15 to 35 Amps maximum
330 VDC
40%
10 ft (3 m) with clamp
1/2 in (12.8 mm) Steel
Capacitor Discharge (CD), Pulsed DC
Rear panel entry 1/4 NPT
Compressed Air or Nitrogen (N2) Only
60 psi (4.2 BAR)
135 scfh (64 lpm)
70 lbs (32 kg) with 12.5' Torch Leads
20 3/4" (527 mm) High
9 3/4" (248 mm) Wide
25" (635 mm) Deep
SPECIFICATIONS

INTRODUCTION & DESCRIPTION 10 Manual0-2450
2.02 TORCH PARTS
Torch Parts Selection
The same torch parts are used for drag cutting and standoff cutting.
See Section 5.03, Replacing Consumable Torch Parts.
Order replacement parts by catalog number and description.
Standard Shield Cup
Catalog No. 9-6003
A-01745
Shield Cup
Attachment (Copper)
Catalog No. 9-6503
Drag Cutting Tip
(0.031 inch Orifice)
Catalog No. 9-6501
Electrode
Catalog No. 9-6506 Gas Distributor Catalog No. 9-6507

Manual 0-2450 11 INSTALLATION
What's Included with
the Power Supply
Unpacking Procedure
Choosing a Location
CAUTION
NOTE
Power Requirements
CAUTION
Included with each system is:
(1) Work Cable with Clamp (Attached)
(1) 230V Single-Phase, Three Wire Input Power Cable (Attached)
(1) Operating Manual
(1) Spare Parts Kit - Includes:
(5) Drag Cutting Tips..........................................Part No. 9-6501
(3) Electrodes .......................................................Part No. 9-6506
(1) Gas Distributor ..............................................Part No. 9-6507
1. Unpack each item and remove all packing material.
2. Inspect each item for possible shipping damage. If damage is
evident, contact your distributor and/or shipping company
before proceeding with system installation.
Select a clean, dry location with good ventilation and adequate
working space around all components.
The power supply is cooled by air flow through the front and
rear panels. Air flow must not be obstructed. Provide at least 12
inches (300 mm) clearance for both front and rear of system.
Operation without proper air flow will inhibit proper cooling and
reduce duty cycle.
Review Important Safety Precautions (page iii) to be sure that the
selected location meets all safety requirements.
The unit will operate on single phase 208-230 VAC, 60 Hz. The
service should be fused for 30 amps.
The primary power source, power cable, and plug must conform
to local electric code and recommended circuit protection and
wiring requirements.
SECTION 3: INSTALLATION
3.01 UNPACKING AND CHOOSING A LOCATION
3.02 ELECTRICAL CONNECTIONS

INSTALLATION 12 Manual 0-2450
Compressed Air or Nitrogen (N2), Only
60 psi (4.2 BAR)
135 scfh (64 lpm)
Maximum input gas pressure must not exceed 125 psi (8.6 BAR).
This cutting system must not be used with Oxygen (O2).
Air supply must be free of oil, moisture, and other contaminants.
Excessive oil and moisture may cause double-arcing, rapid tip
wear, or even complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear.
To test the quality of air, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moisture in the air will be
visible on the lens. Do not initiate an arc!
An air line filter, capable of filtering to at least 5 microns, is
required when using air from a compressor to insure that mois-
ture and debris from the supply hose does not enter the torch.
The rear panel of the power supply is equipped with a female
1/4 NPT gas input fitting.
To use air or nitrogen from a high pressure gas cylinder:
1. Examine the cylinder valves to be sure they are clean and free
of oil, grease or any foreign material. Momentarily open each
cylinder valve to blow out any dust which may be present.
2. Each cylinder must be equipped with an adjustable high-
pressure regulator capable of pressures up to 75 psi (5.3 BAR)
minimum and flows of up to 200 scfh (94 lpm).
3. Set the tank regulator to 75 psi (5.3 BAR). Use the regulator
on the front of the power supply to adjust the gas pressure to
the unit.
Refer to the manufacturer's specifications for installation and
maintenance procedures for high pressure gas regulators.
Do not use an air line filter with high pressure gas cylinders.
3.03 GAS CONNECTIONS
Gases
Pressure
Flow
CAUTION
WARNING
CAUTION
Checking Air Quality
Filtering
Gas Connections
Using High Pressure
Gas Cylinders
NOTE
Using Shop Air
CAUTION

Manual 0-2450 13 INSTALLATION
3.03 GAS CONNECTIONS (Continued)
To use shop air from a compressor, refer to Figure 3-A and:
Air supply must be free of oil, moisture, and other contaminants.
Excessive oil and moisture may cause double-arcing, rapid tip
wear, or even complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear.
1. Install an air filter assembly to the gas input fitting on the
front panel of the power supply. The air filter is supplied
with 1/4 NPT gas couplings. A quick disconnect fitting is
recommended on the filter body cap to allow easy connection
to the compressed air source.
2. Connect the air supply hose to the inlet fitting on the air filter
body cap.
When connecting a gas fitting to the filter cap, hold the cap flats
with a wrench. Over tightening the cap on the filter body can
damage the filter cartridge or cap gasket.
Air filter cartridge (Part No. 7-0252) should be replaced every 30
days, depending on the condition of the compressed air. If a
noticeable drop in air pressure occurs, the filter has become filled
with contaminants and must be replaced.
To replace cartridge, unscrew filter cap from body, slide out old
cartridge and insert new filter element. The filter cartridge fits
only one way. Filter cap must be hand tight only.
Supply hoses must be at least #4 hose (1/4 in or 6.4 mm mini-
mum inside diameter).
Figure 3-A Air Line Filter Gas Connections
CAUTION
Replacing Filter
Cartridge
NOTE
Using the System with Cylinder Air
Using the System with Shop Air
Connect to
Front Panel 1/4 NPT
Gas Fitting
Optional
Air Line Filter
Assembly Supply Hose
from Source
(1/4 NPT)
Supply Hose
from Regulator
(1/4 NPT)
Connect to
Front Panel 1/4 NPT
Gas Fitting
Filter Cap
AIR FLOW
A-00786

INSTALLATION 14 Manual 0-2450