Victor PAK 200i User manual

VictorThermalDynamics.com
480V
©
400V380V
200
Operating
Manual
Revision: AB Issue Date: July 1, 2015 Manual No.: 0-5335
PAK®200i
PLASMA CUTTING SYSTEM

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Victor 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 distribu-
tor or service agency call 1-800-752-7622, 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
Victor 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 Pre-
cautions. 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.
Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for
Victor Technologies.
We distinguish ourselves from our competition through market-leading, dependable products that
have stood the test of time. We pride ourselves on technical innovation, competitive prices, excel-
lent 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

Plasma Cutting Power Supply, Pak® 200i
Operating Manual No. 0-5335
Published by:
Thermal Dynamics Corporation.
2800 Airport Rd.
Denton, Texas 76207
www.thermal-dynamics.com
© Copyright 2013, 2014, 2015 by
Thermal Dynamics Coporation.
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.
Publication Date: July 1, 2014
Revision Date: July 1, 2015
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________
!
WARNING
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.

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding and cutting equipment,
we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install,
operate, or maintain this equipment. Do NOT attempt to install or operate this equip-
ment until you have read and fully understand these instructions. If you do not fully
understand these instructions, contact your supplier for further information. Be sure
to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that
are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement
become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty main-
tenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by
the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.
ATTENTION
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionnement
et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous
vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Wel-
ding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non
qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez
PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces
instructions. Si vous ne comprenez pas bien les instructions, communiquez avec
votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de
Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement
et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous
devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou
n’est pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédia-
tement. Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une
demande de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’uti-
lisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien
fautif, des dommages, une réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre
de service désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!

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TABLE OF CONTENTS
SECTION 1: SAFETY...............................................................................................................1-1
1.01 Safety Precautions - ENGLISH...................................................................1-1
1.02 Précautions de sécurité - FRENCH CANADIAN ........................................1-6
SECTION 2: SPECIFICATIONS ...............................................................................................2-1
2.01 General Description Of The System ...........................................................2-1
2.02 Plasma Power Supply.................................................................................2-1
2.03 Plasma Cutting Torch..................................................................................2-1
2.04 System Component Layout.........................................................................2-1
2.05 Power Supply Specifications & Electrical Requirements ............................2-2
2.06 Power Supply Dimensions ..........................................................................2-3
2.07 Power Supply Rear Panel Features............................................................2-4
2.08 Gas Requirements......................................................................................2-6
2.09 PCH/M 200 Torch Specifications ................................................................2-7
SECTION 3: INSTALLATION ....................................................................................................3-1
3.01 Installation Requirements ...........................................................................3-1
3.02 Cables and Leads Identification..................................................................3-2
3.03 Cables & Leads Identification .....................................................................3-2
3.04 Position the Power Supply ..........................................................................3-3
3.05 Primary Power Connections .......................................................................3-4
3.06 Connect Work Cable...................................................................................3-6
3.07 Connect Gas Supply Lines .........................................................................3-7
3.08 Auxiliary Connections .................................................................................3-8
3.09 Connect Torch Leads to the Arc Starter......................................................3-8
3.10 Torch Parts Selection................................................................................3-10
3:11 Fill Cooling System ...................................................................................3-12
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 System Operation .......................................................................................4-4
4.05 Gas Selection .............................................................................................4-6
4.06 Power Supply Status Codes .......................................................................4-7
4.07 Cut Quality ................................................................................................4-13
4.08 Recommended Cutting Speeds................................................................4-14
SECTION 5: MAINTENANCE...................................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Coolant Filter Cleaning Procedure..............................................................5-1
5.03 Coolant Replacement Procedure................................................................5-2
5.04 Arc Starter Service .....................................................................................5-3
5.05 Arc Starter Spark Gap Adjustment .............................................................5-4

TABLE OF CONTENTS
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS .........................................................6-1
6.01 Replacement Power Supply........................................................................6-1
6.02 Leads and Cables.......................................................................................6-2
6.03 Power Supply External Replacement Parts ...............................................6-3
6.04 Power Supply Replacement Parts - Lower Right Side................................6-4
6.05 Power Supply Replacement Parts - Upper Right Side................................6-5
6.06 Power Supply Replacement Parts - Lower Left Side .................................6-6
6.07 Power Supply Replacement Parts - Upper Left Side ..................................6-7
6.08 Power Supply Replacement Parts - Rear Panel .........................................6-8
6.09 Power Supply Replacement Parts - Front...................................................6-9
6.10 Recommended Gas Supply Hose ............................................................6-10
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
7.04 Inspection and Replacement Consumable Torch Parts ..............................7-3
7.05 Troubleshooting Guide................................................................................7-5
7.06 Servicing Hand Torch Components ............................................................7-7
7.07 Servicing Machine Torch Components .......................................................7-9
7.08 Torch And Leads Troubleshooting.............................................................7-10
APPENDIX 1: CONTROL MODULE....................................................................................... A-1
Control PCB Connections........................................................................................ A-1
Remote Functions ................................................................................................... A-2
Remote Connections ............................................................................................... A-3
APPENDIX 2: CCM CPU PCB LAYOUT................................................................................. A-4
APPENDIX 3: CCM I/O PCB LAYOUT ................................................................................... A-6
APPENDIX 4: PILOT PCB LAYOUT ....................................................................................... A-8
APPENDIX 5: RELAY AND INTERFACE PCB LAYOUT ...................................................... A-10
APPENDIX 6: DISPLAY PCB LAYOUT................................................................................. A-12
APPENDIX 7: SYSTEM BIAS PCB LAYOUT ....................................................................... A-14
APPENDIX 8: MAIN INVERTER BOTTOM PCB LAYOUT ................................................... A-16
APPENDIX 9: MAIN INVERTER TOP PCB LAYOUT ........................................................... A-18
APPENDIX 10: CONTROL AND FAULT PCB LAYOUT........................................................ A-20
APPENDIX 11: CAP BIAS BOTTOM PCB LAYOUT............................................................. A-22
APPENDIX 12: CAP BIAS TOP PCB LAYOUT..................................................................... A-23
APPENDIX 13: SUPPRESSOR PCB LAYOUT .................................................................... A-24

TABLE OF CONTENTS
APPENDIX 14: GAS BOX LAYOUT...................................................................................... A-25
APPENDIX 15: COOLING DIAGRAM .................................................................................. A-26
APPENDIX 16: SYSTEM SCHEMATICS ............................................................................ A-28
System Schematic 380V - 415VAC - pg1 .............................................................. A-28
System Schematic 380V - 415VAC - pg2 .............................................................. A-30
System Schematic 400V CE - pg1 ........................................................................ A-32
System Schematic 400V CE - pg2 ........................................................................ A-34
System Schematic 480V - pg1 .............................................................................. A-36
System Schematic 480V - pg2 .............................................................................. A-38
APPENDIX 17: ADVANCED TROUBLESHOOTING ............................................................ A-40
APPENDIX 18: PUBLICATION HISTORY ............................................................................ A-78
INTERNATIONAL CONTACT INFORMATION........................................................BACK COVER

TABLE OF CONTENTS
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