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1. LE 211149 99 79 Le LAS CAS SAS VAS Figure 6 2 1000 Plasma Gas Console MAX1000 380 415V CE Instruction Manual PARTS LIST MAX100D Plasma Gas Console Part Item Number Description Designator Qty 129163 MAX100D Gas Cont SA 1 1 001612 Gas Console Enclosure 1 029793 Manf SA MAX100D Gas Cont 1 2 004566 Manf MAX100D Plasma Gas 1 3 006093 Sol Valve 150 Manif Mnt 120V NC V1 1 4 006093 Sol Valve 150 Manif Mnt 120V NC V2 1 5 006093 Sol Valve 150 Manif Mnt 120V NC V3 1 6 006093 Sol Valve 150 Manif Mnt 120V NC V4 1 7 005093 Press Sw 0 90 psi 1 8 NPT PS1 1 8 005093 Press Sw 0 90 psi 1 8 NPT PS3 1 9 005093 Press Sw 0 90 psi 1 8 PS4 1 10 006002 Meter Valve 1 4 125 Orifice MV1 1 11 004117 Valve 4 12 022008 Pressure Gauge 100 Bar 2 5 1 8CBM PG1 1 13 005044 Sw SPDT Maint ON ON 10TGS 1 14 028559 Rept Assy MAX100D Qdisc 1 MAX1000 380 415V CE Instruction Manual 6 7 1 98 PARTS LIST 62 d hil A deris H EI Figure 6 3 MAX100 p Right Center Wall MAX1000 380 415V CE Instruction Manual PARTS LIST MAX100D Right Center Wall Part Item Number Description Designator Qty 1 003021 Relay 120VAC SPST NO CR1 1 2 007022 Shunt 100A 100 mv 1MSH 1 3 008317 Fuse 125A 250V Semicond F5 1 4 014021 Transformer 5000 20 T3 1 5
2. 3 8 Remote Start Stop SWITCH OLET 3 9 Machine Computer a 3 9 Power Supply Gas 3 10 Plasma GaS OPC COINS ese se ee 3 10 Shield Gas EIERE 3 11 TOC E 3 12 Torch er 3 12 MAX1000 380 415V CE Instruction Manual 3 1 SETUP Upon Receipt Verify that all components listed below are present Alert your distributor if any parts are missing All communica tions regarding this equipment must include the model number and serial number located on the back of the MAX100D PAC160 System Hand Torch Configuration e MAX100D power supply with 7 6 meter work cable ground and clamp PAC160 hand torch with torch lead assembly Consumable spare parts kit 028649 PAC160E System Extended Hand Torch Configuration e MAX100D power supply with 7 6 meter work cable ground and clamp PAC160E hand torch with torch lead assembly Consumable spare parts kit 028665 e Hand heat shield 020711 MAX100D System Machine Torch Configuration e MAX100D power supply with 7 6 meter work cable ground and clamp e MAX100D machine torch and torch lead assembly Consumable spare parts kit 028650 e Dual Gas Mixer optional 059123 THC 2 Torch Height Control optional 052002 Note For detailed part number information see the Parts List Section 6 Claims and Te
3. Dual Gas Mixer Operating Instructions Operating Tips Changing Consumable Parts Cutting with Hand Torch Piercing with Hand Torch Gouging with Hand Torch Common Cutting Faults pne a Cut Gouging Charts Cut Gouging Index Mild Steel Stainless Steel Cutting Aluminum Mild Steel Gougmng Stainless Steel Aluminum E MAX1000 380 415V CE Instruction Manual Section 4 OPERATION 4 1 Description of Controls and Indicators Plasma Gas Console Panel Figure 4 1 GOUGING CUTTING Application Switch Changes pilot arc current for gouging or cutting operations e PLASMA Gas Adjustment Valve Adjusts plasma gas pressure in TEST position PLASMA Gas Pressure Gauge Indicates dynamic flowing plasma gas pressure MAX100D Control Panel Figure 4 2 Green ON button Activates the power supply and its control circuits Red O OFF button Shuts the power supply down White POWER ON light Illuminates after the ON button is released to indicate that all control circuits are activated safety interlocks are satisfied and the system is ready for operation Green GAS PRESSURE light Illuminates after the ON button is releas
4. 3 6 OCDE Q 3 6 Power Supply Placement ee t 3 7 Power Supply Electrical GOMMECHONS 3 7 380 415V Linkboard el Tee 3 7 Power Cable Connection 3 8 Remot clan 3 9 Machine Computer Interface C OE 3 9 POWER OS ga 3 10 Plasma Gas 3 10 Shield GaS Ree e 3 11 CONNEC UNO ORCI 3 12 Torch Leads to Power Supply 3 12 Section 4 OPERATION 4 1 Description or Controls 1 S aucnn id Ee 4 2 se be on Dee 4 5 Se GIG E 4 10 Tm 4 20 8 OO e se E a E 4 21 II SOS Mtt 4 22 Stainless Steel CUMING EE 4 30 EE e E 4 39 OU ING 4 49 Stainless Steel Gouging E 4 51 A ON E 4 53 Section 5
5. 1 2 Follow Safety ee danses ss same nn ee ent 1 2 Ed can Cause Fire OF es 68 nd 1 2 uf 1 3 Cuting Can Froduce TOC UMR seance ______ ____ ______ 1 3 A Plasma Arc Can Cause Injury and Clg E 1 4 Are Rays Can Burn Eyes and Es 1 4 Grounding erii E E T 1 4 Compressed Gas Equipment Salely 1 5 Gas Cylinders Explode If un Ee dio uM 1 5 Noise Can Damage Hearing iiec io pas eese ___ __ ____________ ______ 1 5 Pacemaker Hearing Ald Operation EE 1 5 A Plasma Arc Can Damage Frozen Pip EE 1 5 Additional Safety Information ccccccccccecceeeseceeeeeeeeseeeeeeeeeaeeeceeeeeeaeeeeeeeeesseeseceeeeseesseeeeeesaeaeeeeeesseaaseeeeessaaaaeeeeeeeaas 1 5 Section 1a S CURIT ae ae ae a a a a mi ne 1 1 IdenimerlTes consignes de SE CUS cg 1 2 Suivre les instructions de s curit 2 1a 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Les chocs lectriques peuvent tre 1a 3 Le coupage peut produire des vapeurs nennen nennen lt 9 1a 3 L arc plasma peut provoquer des blessures ou des br lures Vs 1a 4 Mise la masse et 1 1a 4 Les rayons de l arc peuvent br ler les yeux et
6. 5 1 Idee an a g E 5 2 Routine 5 3 SEUS C OLEV ON 5 4 ee 5 10 TOU SOO 5 13 E 5 20 Disass mbly of Kei DEE 5 22 Disassembpiy of Machine Emm 5 24 IV MAX1000 380 415V CE Instruction Manual TABLE OF CONTENTS Section G PARTS LIST ee ee ee ee eee 6 1 6 2 100 Power Supply Front Panel Outside Front Panel Inside Control Panel 6 5 SAS nie EE E m 6 7 Vt nudi m 6 9 Base Tate COMORES 6 9 OC OO EN T 6 11 Rear Panel Outside Bear Panel ne TEE 6 13 MAX 100D Machine Torch ASSEmMDI E 6 15 100 International Machine Torch Assembly 6 15 Hand RE 6 17 Gouging gl 6 19 TV OOD Lead ASSeMDIES 6 20 MAX100p Ren E te En EE 6 21 Machine Torch Consumable E 6 21 PAC160 Hand Torch Consumable E 6 22 160 Gouging Torch Consumable Parts 6 23 RECA RE a 6 25 Hose Package for Dual Gas OT 6 25 Hocomimendedg Spare
7. 6 11 Rear Panel Outside Rear Panel Inside iii 6 13 MAX100p Machine Torch le EE 6 15 100 International Machine Torch 6 15 PAG TCO Hand MIO CARS ___________________ _ __ __ _ _4_ 6 17 PACTOOE Gouging Torch ASSemibly ___________ ______________ ie 6 19 MAX100p Lead Assemblies EE 6 20 MAX100p Consumable Parts ISI EE 6 21 Machine Torch Consumable Parts rri remanere n rh PER e e a aee d ENNEN ec e A 6 21 PAC160 Hand Torch Consumable GT 6 22 PAC160E Gouging alles cannes sites sens 6 23 SS EE 6 25 Hose ie cce uedBu ic ccqupcg t 6 25 Recommended Spare ________________ _____________ 6 26 MAX1000 380 415V Instruction Manual 6 1 PARTS LIST Introduction In this section is a parts list breakdown with accompanying drawings for the MAX100p plasma torch system The format to list and call out Hypertherm parts is as follows Part Item Number Description Designator Qty 129153 Cont Pnl SA 1000 1 1 001611 Pnl 1000 Cont 1 12 005092 PB Sw Grn NO Full Gd PB1 1 14 008328 Knob 930 Dia 1 4 SFT Blk Nat Item Refers to item call out on opposing page Number Ex 1 refers to numbered call out 1 on opposing page Part Number Refers to Hypertherm part numbers Bold part numbers Ex 129153 signify par
8. 6 26 Section 7 WIRING DIAGRAMS 7 1 MAX OOD LACT ae and ane en en et et net ae ab ec da a 7 2 FETES ss heen eee noe ene nee __ __ _ _ ________ a 1 Appendix IEC SYMBOLS USED eebe 0 1 Appendix AERATION MANIFOLD FOR PLASMA CUTTING 1 MAX1000 380 415V CE Instruction Manual Section 1 SAFETY In this section PREC OO ley MOR E de D 1 2 Folow TIS ere 1 2 Cutting Can Cause Fire or E e E 1 2 Electi SOCK CR nd ae aan e 1 3 Coin Can Produce ToxiC FUMES S AE 1 3 A Plasma Arc Can Cause Injury and BULTIS 1 4 AIC Rays Can Burn Eyes Er E 1 4 EI el Eine ere E EE 1 4 Compressed Gas Equipment Safety 1 5 Gas Cylinders Can Explode IT Damaged E 1 5 NOISE Can Damage 1 5 Pacemaker Hearing Aid Operation 1 5 Plasma Are Can Damage Fro en le 1 5 Additonal Salety OUR a 1 5 Hypertherm Plasma Systems 1 1 SAFETY A RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine
9. 5 y 8112 PCB2 Power Distribution THC 2 Option Only B P N 041007 1 E Ee GC 39 Negative VDC LEGEND 21 56 10 9 1413 1817 2221 7 1112 1920 15 16 23 24 amm 42 Positive VDC pc d 70 25 1 Neg VDC PB1 POWER ON SWITCH L PL2 HEN E E 33 RED 33 Plasma Start PB2 POWER OFF SWITCH Spare 34 R B DEE PS1 PLASMA GAS PRESSURE SWITCH Ol alo aao A WHT 34 PS2 SHIELD GAS PRESSURE SWITCH OA amp ea 0 3 elel cec gas ela elt ele 37 24 VAC Neutral PS3 LINE CHARGE AT TRANSFER Qm 4 ol pep erg RE 38 24 VAC Hot PRESSURE SWITCH VAC Hot 54 LINE CHARGE AT START id nam E 4 2 120 Neut PRESSURE SWITCH PB1 PB2 V6 M1 M2 le V B 35 Machine MOTION PS5 CAP SENSOR PRESSURE SWITCH IK 36 Machine MOTION TS1 T2 TRANSFORMER TEMPERATURE J 3 SWITCH CR3 5 gt 9 LT1 POWER ON READY LIGHT LT2 DC POWER LIGHT 9 M1 1FAN 2 2 FAN SW1 CONTINUOUS PILOT SWITCH SW2 RUN TEST SELECTION SWITCH BIS ooa 712 6 e 10765 CUT GOUGE SELECTION SWITCH 5 gt Kl
10. 100D 380 415V CE Plasma Arc Cutting System Instruction Manual 802750 Revision 0 Hesse TT p The world leader plasma cutting technology 4 50199 50192 1000 380 4 15V Instruction Manual IM 275 P N 802750 Revision 0 December 1996 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 1996 Hypertherm Inc All Rights Reserved Hypertherm and MAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email Hypertherm Automation LLC 5 Technology Drive Suite 300 West Lebanon NH 03755 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm 5 Pte No 19 Kaki Bukit Road 2 Warehouse Complex Singapore 417847 Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 Technical Service Hypertherm UK Ltd 9
11. 120V NC Cable Ground Z4 W Clamp 25 MAX1000 380 415V CE Instruction Manual Designator R2 R1 PS2 PS5 V5 PARTS LIST sesch sch sesch wesch sesch zech I zech sech wesch D PARTS LIST 6 14 Figure 6 7 Machine Torch Assembly MAX1000 380 415V CE Instruction Manual MAX100D Machine Torch Assembly Ite Number 059115 059116 059117 028596 120433 020334 020846 020705 020706 020713 058019 020243 028555 028910 002190 028556 028910 002190 028557 028910 002190 Description MAX100D Machine Torch Assy 25 MAX100D Machine Torch Assy 50 MAX100D Machine Torch Assy 75 MAX100D Machine Torch Assy Electrode PAC130 160 MAX100 D Air Shield MAX80 100 C D 100A Shield Cap PAC160 100D 100A Cutting Nozzle PAC160 MAX100D 100A Cut Swirl Ring PAC160 MAX100D Cut MAX100D Machine Torch Main Body O Ring Viton 801 x 070 Torch Pos Sleeve MAX100 Leads MAX100D Machine Torch 25 Plug Assy PAC160 Mach Qdisc Boot 80A 100A QDisc PL Leads MAX100D Machine Torch 50 Plug Assy PAC160 Mach Qdisc Boot 80A 100A QDisc PL Leads MAX100D Machine Torch 75 Plug Assy PAC160 Mach Qdisc Boot 80A 100A QDisc PL MAX100D International Machine Torch Assembly Ite NN OO BR ND e 11 9 10 11 No rack with 020245 sleeve Pa
12. 1000 Machine PAC160 Hand Torch Mild Steel Cutting Plasma Gas Air Shield Gas Air Current Setting 60 Amp This gas combination gives good cut speed low dross levels and is very economical Some surface nitriding can occur 020756 120336 020706 120433 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 3 4 5 21 4 1 5 60 120 100 7620 0 5 6 91 6 9 1 3 120 7620 0 5 1 5 125 7620 0 5 2 130 6096 0 5 2 5 130 5080 0 5 3 130 4445 0 5 3 5 130 4318 0 6 6 135 1397 0 8 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa 4 26 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Mild Steel Cutting Plasma Gas Shield Gas Air Current Setting 60 Amp This gas combination is used when cut edge quality and surface nitriding are less important Electrode life is extended when this combination is used 020756 120336 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen
13. 5 20 Disassembly of Hand MTS TEE 5 22 OO ers msec m E E E E E E 5 22 mise MR E E DIU UU 5 22 Disassembly of Machine OMC t 5 24 E 5 24 mises ____ 5 24 MAX1000 380 4 15 1 CE Instruction Manual 5 1 MAINTENANCE Introduction The MAX100D and all Hypertherm plasma systems undergo rigorous testing prior to shipment and should require little maintenance if proper setup and operation procedures as outlined in Sections 3 and 4 are followed If a problem does arise this section will familiarize qualified service personnel with the proper operation of the MAX100D system and will provide guides to troubleshoot problems that may occur during operation The intent of this section is to isolate problems at a modular level PC board component level troubleshooting is not addressed This section begins with a detailed sequence of events flowchart an initial checks procedure a troubleshooting guide test procedures and instructions to remove and replace the torch and torch leads The service personnel performing the troubleshooting testing must be high level electronic service technicians that have worked with high voltage electro mechanical systems Knowledge of final isolation troubleshooting techniques is assumed In addition to being technically qualified service personnel must perform all testing with safety in mind Refer to the Safety section for operating
14. Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Inlet Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 3 4 5 21 4 1 5 60 125 100 7620 0 5 6 9 6 9 1 5 125 7620 0 5 2 130 6096 0 5 2 5 130 4572 0 5 140 3810 1 0 145 1651 1 0 150 1143 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 35 1000 Machine PAC160 Hand Torch Stainless Steel Cutting Plasma Gas shield Gas CO Current Setting 60 Amp This gas combination is used when surface nitriding and surface oxidation of alloying elements is less important Electrode life is extended when using this gas combination 020756 120336 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas CO Torch to work Current Voltage Duty Delay Inlet CO Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 1 3 4 5 21 4 1 5 60 125 100 9144 0 5 6 91
15. This gas combination is used when cut edge quality is less important Electrode life is extended when this combination is used 020756 120336 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 3 3 4 5 91 4 1 5 60 125 100 6096 0 5 6 91 6 9 1 5 125 4572 0 5 2 135 4064 0 5 2 5 140 3302 0 5 3 145 2159 0 8 6 155 1016 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 2 6 895 KPa 4 46 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas shield Gas CO Current Setting 60 Amp This gas combination is used when cut edge quality is less important Electrode life is extended when this combination is used 020756 120336 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Torch to work Current Voltage Duty Delay Inlet CO Inlet Thickness TEST RUN Pressure Distance Sett
16. Contactor MAX100 60A 3P 24VAC Cont MAX100 NO Aux Transformer 40 100 220 380 415V PC Bd Assy Power Dist MAX100 CE LVD Relay 24 7A Mini Relay 115VAC 7A DPDT Mini Fuse 2A 250V 6 3mmX32mm Cover MAX100 CE LVD Side MAX1000 380 415V CE Instruction Manual Designator CR3 Ti PCB2 CR1 CR2 CR3 CR4 F3 F4 PARTS LIST g ND QD a a Sa sch a PARTS LIST LOO 49 Figure 6 6 MAX100 p Rear Panel Outside Rear Panel Inside 6 12 MAX1000 380 415V CE Instruction Manual MAX100D Rear Panel Outside Rear Panel Inside Part Number 001182 001577 029772 004264 011025 011027 015532 024162 028559 008415 008944 008070 001549 001556 129024 009625 009625 029771 005093 006014 005093 006014 023209 Description Handle MAX80 MAX100 Panel MAX100 CE LVD Rear Air Regulator SA MAX100D Bracket 80 100 200 Air Regulator Filter Regulator 0 120 psi 1 4NPT Air Gauge 0 120 psig for 011025 Street Elbow 1 4 90 Hose Assy 6 x 19 1 2 Air Reg Rept Assy MAX100D Qdisc Strain Relief 3 4 NPT x 310 560 Strain Relief 3 4 NPT 530 X 750 Strain Relief 1 2 NPT x 312 375 Enclosure MAX100 CE Filter Cover MAX100 CE Filter Enclosure Line Filter SA MAX100 CE Resistor 2 0 ohm 395W Resistor 2 0 ohm 395W Gas Sply SA MAX100D Press Sw 0 90 PSI 1 8 NPT Sol Valve 90 1 4 120V NC Press Sw 0 90 PSI 1 8 NPT Sol Valve 90 1 4
17. Figure 6 1 6 4 100 Front Panel Outside Front Panel Inside and Control Panel MAX1000 380 415V CE Instruction Manual MAX100D Front Panel Outside Front Panel Inside and Control Panel 5 3 O1 Part Number 129153 001611 005105 005041 005088 005089 005168 009177 005197 006002 022008 005121 005122 009483 008328 027079 027080 041313 129118 005199 129075 008997 001574 Description Cont Pnl SA MAX100b CE LVD Pnl MAX100D CE LVD Cont Tgl Sw 3PDT Tgl Sw DP Maint ON ON Lamp Hldr Use T3 1 4 LTBULB Lens Wht For 005088 Lightbulb 28VDC 40ma T3 1 4 Lens Green for 005088 Lens Amber for 005088 Meter Valve 1 4 FPT 125 Orf Gauge Press 2 1 2 Dia 1 100 PB Sw Grn NO Full Gd PB Sw Red NC Pot 1K Ohm 1W 10 Knob 930 Dia 1 4 SFT BIk Nat Fan 450 550 CFM 120VAC 50 60 Hz Fan 225 CFM 120VAC 50 60 Hz PC BD Assy Ctrl 1000 CH130 CE LVD Chopper SA Temperature Switch 82 Linkboard SA 100 D CE LVD 380 415 Fuse 2A 500V 10mmx38mm Slo Panel MAX100 CE LVD Front MAX1000 380 415V CE Instruction Manual Designator SW2 SW1 LT1 LT2 LT3 PB1 PB2 R6 M1 PCB4 TS2 F1 F2 PARTS LIST g mn sch oa om oa sch sch sm om 4 4 sch PARTS LIST HYPERTHERM 2 RE APPLICATION MADE IN U S A GOUGING CUTTING
18. 3 4 2 When using air as the plasma gas connect hose from SOURCE SUPPLY to the connector located on the left of the regulator on the rear of the power supply Fig 3 6 Remove TEE PLUG on right side of regulator and connect 0 5 m hose 024373 from the tee to the PLASMA GAS inlet on the plasma gas console Fig 3 6 3 4 3 If you are not cutting with an H35 N mixture skip this step 3 When using a nitrogen and argon hydrogen mixture as the plasma gas the optional Dual Gas Mixer must be used The mixer is secured to the rear and top of the Plasma Gas Console with four 8 32 screws 015230 Attach the left handed adapter 015230 included in the Dual Gas Mixer hose package 028721 to the argon hydrogen H35 tank Find the red 7 6 meter left hand threaded hose 024384 from the package and connect the hose from the argon hydrogen tank to INLET1 of the Dual Gas Mixer MAR e Attach the right handed adapter 015009 included in the Dual Gas Mixer hose package 028721 to the nitrogen tank Find the blue 7 6 meter right hand threaded hose 024205 from the package and connect the hose from the nitrogen tank to INLET2 of the Dual Gas Mixer 015230 remove from hose Find the 610 mm red hose 024374 from the hose package and remove the left hand connector 015230 Attach this connector to the PLASMA GAS inlet on the rear of the Gas Console Connect the hose from the Dual Gas Mixer OUTLET to the PLASMA GAS inlet
19. C7 Always replace the capacitors in pairs MAX1000 380 415V CE Instruction Manual MAINTENANCE Problem Possible Causes and Solutions 7 5 7 6 8 There is high frequency but 8 1 there is no pilot arc 8 2 8 3 8 4 8 5 8 6 MAX1000 380 415V CE Instruction Manual There is no high frequency at the torch Check for a shorted torch a damaged pilot arc lead or loose lead connections Replace the torch or pilot arc lead or tighten the lead connections Pilot arc relay CRI is not functioning or not getting 120VAC from the Control Board PCBA See if the CR1 relay contacts close after the START command is given If CR1 does not close check to see if CR1 is getting 120VAC from PCBA If it is replace CR1 If there is no 120VAC from replace Control Board PCBA Torch parts are worn Check consumable parts and replace if necessary See Changing Consumable Parts in Section 4 Torch leads are loose or worn Replace torch leads as required Pilot arc relay CH1 not functioning See solution 7 6 Main contactor CON2 or PCB4 is defective Check to see if CON2 is getting 24VAC after START command is given If there is no 24VAC check pins connections and associated wiring from CON2 to PCB4 If wiring is O K replace 4 If there is 24VAC at CON2 after START command is given measure for 200 VAC between terminals A B and C of main transformer T2 If there is no voltage between these point
20. autoris es sur la machine peuvent engendrer des probl mes de s curit et raccourcir la dur e d utilisation de l quipement DANGER AVERTISSEMENT PR CAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSEMENT sont situ es sur la machine pour signaler certains dangers sp cifiques Les messages d AVERTISSEMENT pr c dent les instructions d utilisation expliqu es dans ce manuel et signalent les risques de blessures ou de mort au cas ces instructions ne seraient pas suivies correctement Les messages de PR CAUTION pr c dent les instructions d utilisation contenues dans ce manuel et signalent que le mat riel risque d tre endommag si les instructions ne sont pas suivies correctement LE COUPAGE PEUT PROVOQUER UN INCENDIE Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur proximit Eloigner toute mati re inflammable une distance d au moins 10 m du poste de coupage Tremper le m tal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des mat riaux combustibles Ne jamais couper des r cipients pouvant contenir des mati res inflammables avant de les avoir vid s et nettoy s correctement A rer toute atmosph re potentiellement inflammable avant d ut
21. understand the potential for personal injury and follow the related instructions to avoid the hazard FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety labels on your machine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the controls properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION A signal word DANGER or WARNING 15 used with a safety symbol DANGER identifies the most serious hazards e DANGER and WARNING safety labels are located on your machine near specific hazards e WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly e CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly CUTTING CAN CAUSE FIRE OR EXPLOSION Fire Prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they m
22. 029190 Hi Freq IO Panel SA MAX100 PCB3 1 009350 Spark Gap Assy 40 20 2000 HD SG1 1 6 004061 Electrd Spk Gap 1 8 x 1 6 3 7 004140 Base 40 80 100 200 HD Spk Gap 1 8 009280 022uF 15kV C6 C7 2 9 009371 Coil Assy 80 100A HF T4 1 10 041120 BD Assy UO MAX100 1 11 029202 Current Sensor SA MAX100 CS1 1 12 129164 Capacitor SA MAX100 D CE LVD Filter 1 001578 Cover MAX100 CE LVD Side 1 001575 Cover MAX100 CE LVD Top 1 MAX100D Base Plate Components Part Item Number Description Designator Qty 1 014043 Inductor 4mh 100ADC MAX100 L1 2 014065 Transformer 15kW 220 380 415 3 50 T2 d 8 2 LJ LL Figure 6 4 MAX100p Base Plate Components MAX1000 380 415V CE Instruction Manual 6 9 PARTS LIST See Figure 6 2 for detail of Plasma Gas Console Figure 6 5 100 Left Center Wall 6 10 MAX1000 380 415V CE Instruction Manual MAX100D Left Center Wall 5 3 Jo O1 P ND Part Number 003021 004261 001601 001602 008079 009015 009296 009622 003153 003154 014028 041530 003173 003174 108000 001578 Description Relay 120VAC SPST NO Lifting Eye 80 100 Pwr Unit Plate MAX100 CE LVD Lifting Eye Gasket MAX100 CE LVD Lifting Eye Term Bd 12 Term Res 10K ohm 10W 5 VIT Cap 100uF 350WV 50 10 Res 10 ohm 50W 5 W L Brk
23. 3 135 3048 0 8 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa 4 28 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Mild Steel Cutting Unshielded Parts Plasma Gas Air Shield Gas Air Current Setting 60 Amp This gas combination gives good cut speed low dross levels and is very economical Some surface nitriding can occur 020333 020756 020922 020706 120433 Deflector Retaining Cap Nozzle Ring Electrode Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 2 8 5 51 4 3 60 110 100 10160 0 2 6 9 6 9 1 3 115 8636 0 2 1 5 120 7620 0 2 2 120 6096 0 5 2 5 125 5080 0 5 3 125 3810 0 8 3 4 125 3556 1 0 6 130 1651 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 29 OPERATION 1000 Machine PAC160 Hand Torch Stainless Steel Cutting Plasma Gas Shield Gas Air Current Setting 100 Amp This gas combination is used when cut edge quality surface nitriding and surface oxidation of alloying elements are less important Electrode life is ex
24. Appendix AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM Aeration Manifold for Plasma Cutting Aluminum Introduction When plasma arc cutting aluminum at the water table surface or below water free hydrogen gas may be generated by the cutting process The high temperature of the plasma process causes disassociation of oxygen and hydrogen from the water in the water table The hot aluminum which has a high affinity for oxygen then combines with the oxygen leaving free hydrogen An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the floor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Figure c 1 Make an Aeration Manifold with two inch 50 mm PVC tubing with one inch 25 mm Distribution Lines connected to it Drill 1 8 inch 8 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distribution lines and install the lines so that oxygen is delivered to all parts of the cutting area Connect the manifold to a shop air line Set a pressure regulator to obtain a steady stream of bubbles Aeration Manifold Distribution Lines Regulated air in Figure c 1 Aeration Manifold MAX1000 380 415V CE Instruction Manual 1
25. Gouging Charts in Section 4 Torch consumable parts are worn Check consumables and replace if necessary See Changing Consumable Parts in Section 4 The PLATE switch is in the EXPANDED position When cutting most metals place the PLATE switch in the NORMAL position Switch to EXPANDED position only when cutting metal grate see Description of Controls and Operating Instructions in Section 4 MAX1000 380 415V CE Instruction Manual Problem Plate overrun Problem 11 Machine motion continues machine torch only 12 Gas continues to flow after 10 seconds 13 No post flow of gas 14 Short torch consumables life MAX1000 380 415V CE Instruction Manual MAINTENANCE Possible Causes and Solutions 10 5 10 6 or The power supply has overheated Shut down system and wait for unit to cool down If unit will not restart see interlock troubleshooting guide earlier in this section 3 2 Chopper defective or not functioning See Chopper Module Test Procedure later in this section STOP pressed machine torch START button released hand torch Possible Causes and Solutions 11 1 11 2 12 1 13 1 13 2 14 1 14 2 Defective or miswired machine START switch Check switch and wiring diagrams for correct hookup of PLASMA START and MACHINE START Arc transfer signal not changing Check to see if D8 on Control Board PCB4 remains illuminated after torch moves away from plate S
26. Pressure mm bar bar bar mm amps volts mm min sec bar bar 6 3 4 5 91 4 3 100 145 80 2413 1 0 6 91 6 9 9 150 1778 1 0 12 155 1397 1 5 15 155 1143 1 5 19 160 889 25 165 559 32 175 279 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa 4 40 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas shield Gas CO Current Setting 100 Amp This gas combination is used when cut edge quality is less important Electrode life is extended when this combination is used 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Torch to work Current Voltage Duty Delay Inlet CO Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 6 3 4 5 91 4 3 100 145 80 2413 0 8 6 9 6 9 9 145 1778 1 0 12 150 1397 1 2 15 155 1143 1 5 19 160 889 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 41 OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cut
27. at the rear of the plasma gas console 8 32 screw holes Figure 3 4 Plasma Gas Console Connections and Torch Connection 3 10 MAX1000 380 415V CE Instruction Manual SETUP Outlet Inlet1 Inlet2 Figure 3 5 Dual Gas Mixer Connections Shield Gas Connections 1 When using air nitrogen or carbon dioxide as the shield gas connect hose from SOURCE SUPPLY to the connector on the left of the regulator on the rear of the power supply Fig 3 6 Source supply Figure 3 6 Shield Gas Power Supply Connections and Air Plasma Gas Connection MAX1000 380 415V CE Instruction Manual 3 11 SETUP Connecting the Torch Torch Leads to Power Supply 1 Align the TORCH CONNECTOR Key Plug with the 2X1 RECEPTACLE Key Slot on the plasma gas console and push in until the pins seat Figure 3 7 2 Turn the connector Securing Ring 1 4 turn counterclockwise to ensure that the securing ring threads and the receptacle threads are aligned prior to tightening Caution The connector securing ring and 2X1 receptacle are fine threaded Thread damage could occur if cross threaded 3 Turn the connector securing ring clockwise to tighten TORCH CONNECTOR 2X1 RECEPTACLE Key Plug Key Slot Securing Ring Figure 3 7 Quick Disconnect Alignment 3 12 MAX1000 380 415V CE Instruction Manual In this section Description of Controls and Indicators Plasma Gas Console Panel MAX100D Control
28. edge quality surface nitriding and surface oxidation of alloying elements are less important 020333 020756 020921 020950 020951 Deflector Retaining Cap Nozzle Ring Electrode Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 0 5 2 8 41 4 0 5 30 65 75 100 6350 0 6 91 6 9 0 6 30 5842 0 0 7 30 5588 0 0 9 30 5080 0 1 2 40 3810 0 1 1 5 40 3048 0 1 Some stainless steel plate comes with a plastic film attached to it Because of the close torch to work distance required for 30 40 amp cutting this film must be removed before cutting begins Turn AMPS knob totally counterclockwise for 30 Amp setting To maintain the 0 5 mm Torch to work Distance as the electrode wears increase arc voltage in this range to avoid having the torch dive into the plate T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa 4 38 MAX1000 380 415V CE Instruction Manual 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas Air Shield Gas Air Current Setting 100 Amp OPERATION This gas combination gives good cut speed low dross levels and is very economical 020335 Hand S
29. emm D emm emm emm emm emm D emm emm als d 182 129118 a 28 m 7 110VC C7 TT mU C 12 3 1 2 3 4 5 6 Re F1 f 2 K di We PL8 1 215 4 4 3 g des ee L TI eae 22 A Ti TS1 TEMP Ge LT1 2 POWER 115 24 VAC PPL gt TOMAS ag g zn d pam 2 6 4 5 Lu 2 un ep Kai 24VAC__ Olmo 512 EIS ze Wm PLI PL3 1 T m Gi 87 1112 1615 1920 2423 22 21 1817 1413 10 9 65 ERR 10165 E E BED NA CLOSED FOR GOUGING RED BLK GRN BLK OPEN FOR CUTTING 16 LEE PS1 WHT 15 380V UNITS ONLY RED28 28 ps3 R B 2 2 WHT 8LK 66 Id SW2 27 9 5 S RED 7 20 54 RED Kai RED WHT d R B 19 DRERK RED BLK BLU BLK vi BLK BLK GND a T gt TORCH LEAD RED DEEE RED BLK EES A TORCH START 1 2 one Ke So GAS CONSOLE 20 Un Q 25 1 Volt Divider O RECP1 E r I m get S ESCH i cR2 5 cm i F3 Y 9 9 EAS CR3 el a CR2 CRI 9 5 12 12 EN Move 14 13 13 13 9
30. la peau nennen 1a 4 S curit des bouteilles de gaz 1a 5 Les bouteilles de gaz comprim peuvent exploser en cas de dommages 1a 5 Le bruit peut provoquer des probl mes SITE 1a 5 Pacemakers et proth ses 1a 5 Secuon2 SPECIFICATIONS eors E e r Eai aa aE E E r 2 1 EE EE 2 2 I 077 11 070 2 3 EE SUDDIY a ee E PNEU io 2 3 OR OO DMC AO E 2 4 PACE Ee 2 4 Kent gn AINO 2 4 WIG RENE 2 5 THAO cCO 2 5 MAX1000 380 415V CE Instruction Manual lil TABLE CONTENTS Sections SETUP 3 1 3 Ser e EE 3 2 Clams amp Technical 3 2 MEO UCONN 3 3 Gas SOON 3 4 Cylinder Compressed WE 3 4 Shop Compressed AI TEE 3 4 Plasma and Shield ___ 3 5 Grounding Pii a 3 5 Bet P T 3 6 Ei
31. mr 0 79 kg WARNING The voltage between the tip of the torch and the workpiece will exceed 113 VDC if shielded consumable parts are not installed in the hand torches The hand torches must be operated with shielded parts to maintain the 5 mark and CE low voltage compliance for hand held applications This requirement does not apply to machine torch applications PAC160 Hand Torch Maximum cutting thickness range 32 mm Maximum current at 80 duty cycle 100 Amps Maximum temperature at torch head 149 C GaS FO 208 l min at 4 1 bar with 100 amp consumables MV CINE EE 0 68 kg PAC160E Hand Torch Maximum cutting thickness range 32 mm Maximum current at 80 duty cycle 100 Amps Maximum temperature at torch head 1499 C Maximum temperature at torch handle 60 C with hand heat shield Gouging capability metal removal rate H35 as plasma e 6 8 kg hour Air as plasma Bet 3 6 kg hour E 208 l min at 4 1 bar with 100 amp consumables el at 1 14 kg with hand heat shield 2 4 MAX1000 380 415V CE Instruction Manual 3 99 SPECIFICATIONS Dual Gas Mixer Optional The MAX100 gas mixer is used to provide an H35 Nitrogen gas mixture for high quality stainless steel cutting See Cut G
32. oil free and air must be delivered at the pressure and flow rate specified for each plasma system If the air supply contains moisture oil or dirt particles cut quality will be lowered and consumable parts life will be shortened which increase production costs To optimize both consumables life and cut quality Hypertherm recommends a three stage filtering process for compressor air for removing contaminants from the air supply 1 The first stage of filtering should remove at least 99 of all particles and liquids 5 microns and larger in size 2 The second stage should be a coalescing type filter to remove oil This filter should remove 99 99 of particles 0 025 micron and larger in size 3 The third and final stage of filtration should be an activated carbon adsorbent filter that removes 99 999 of oil or hydrocarbons that have not been trapped by the previous stages MAX1000 380 415V CE Instruction Manual a 1 Appendix IEC SYMBOLS USED IEC Symbols Used Direct Current DC Alternating current AC Plasma cutting torch AC input power connection The terminal for the external protective earthed conductor A chopper based power source Anode work clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle The power is on The power is off Volt amp curve MAX1000 380 415V CE Instruction Manual b 1
33. other damage Power Supply Inspect the power supply on a regular basis Check the exterior for any damage that might affect safe operation of the power supply e Remove the power supply cover and inspect the interior Check wiring harnesses and connections for wear or damage Check for loose connections and areas of discoloration which may indicate overheating Clean the power supply periodically use compressed air to blow dust and dirt that have accumulated inside the unit In an excessively dirty environment do this weekly MAX1000 380 415V CE Instruction Manual 5 3 MAINTENANCE Sequence of Events On the following pages is a detailed flow chart outlining the sequence of events during proper MAX100D operation with a hand or machine torch Shaded boxes represent action taken by the operator The following symbols used in the flowchart are ANSI standard flowcharting symbols Their names and definitions are as follows Terminus Task Process Box aum SS lt gt Diamond C 2 V Preparation Off page Connector The terminus is used to indicate the beginning or ending point of a flowchart The process or task box is used to indicate any process or task other than an input output operation or a decision The decision diamond is used to indicate a decision or branching point The preparation symbol is used to indicate an instruction modification The off page connector is used to indicate exit or ent
34. precautions and warning formats For service questions or problems contact the nearest Hypertherm Technical Service Department listed at the front of this manual WARNING SHOCK HAZARD The large electrolytic capacitor s blue cased cylinder s store large amounts of energy in the form of electric voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the chopper and the diode heatsinks Never discharge the capacitor s with a screwdriver or other implement explosion property damage and or personal injury will result Wait at least five minutes after turning the power supply off before touching the chopper or the capacitor s 5 2 MAX1000 380 415V CE Instruction Manual MAINTENANCE Routine Maintenance Hypertherm systems are designed to require little regular maintenance under normal use and conditions The routine maintenance suggestions this section will allow the operator to keep the system in peak operating condition Torch and Torch Leads Inspect the torch and torch leads on a regular basis Always inspect the torch s consumable parts and main body before cutting Worn or damaged parts cause gas leaks which can cause cut quality to deteriorate Inspect consumables for indications of arcing overheating or pitting and replace any parts that appear worn or damaged See Changing Consumable Parts in Section 4 The torch leads should be checked occasionally for cracking or
35. s curit LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES N Le coupage peut produire des vapeurs et des gaz toxiques qui r duisent le niveau d oxyg ne dans l air et peuvent provoquer des blessures voire la mort Conserver le poste de coupage bien a r ou utiliser un masque respiratoire homologu Ne pas proc der au coupage pr s d endroits s effectuent le d graissage le nettoyage ou la vapori sation Certains solvants chlor s se d composent sous l effet des rayons ultraviolets et forment du phosgene Ne pas couper des m taux peints ou contenant des mati res toxiques comme le zinc galvanis le plomb le cadmium ou le b ryllium moins que la zone de travail Hypertherm Systemes plasma soit tr s bien ventil e et que l op rateur porte un masque respiratoire Les rev tements et m taux contenant ces mati res peuvent produire des vapeurs toxiques lors du coupage Ne jamais couper de r cipients pouvant contenir des mati res inflammables avant de les avoir vid s et nettoy s correctement Quand on utilise ce produit pour le soudage ou le coupage il d gage des fum es et des gaz qui contiennent des produits chimiques qui selon l tat de Californie provoquent des anomalies cong nitales et dans certains cas le cancer 1a 3 2 12 01 SECURITE L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES Torches a allumage instantane plasma s allume imm diatement apres que
36. 0 Stainless 100 Amp 100 GOUGING Aluminum 100 Amp 100 Amp Dual Gas Mixer required Extended Consumables Cut Chart T Unshielded Consumable Parts MAX1000 380 415V CE Instruction Manual 4 21 OPERATION 1000 Machine PAC160 Hand Torch Mild Steel Cutting Plasma Gas Air Shield Gas Air Current Setting 100 Amp This gas combination gives good cut speed low dross levels and is very economical Some surface nitriding can occur 020846 020705 020706 120433 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 72 Machine Shield Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 6 3 4 4 81 4 3 100 135 80 3048 0 8 6 9 6 9 10 140 2032 1 0 12 145 1143 1 2 15 150 762 1 5 19 155 432 25 165 279 32 170 152 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa 4 22 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Mild Steel Cutting Plasma Gas shield Gas Air Current Setting 100 Amp This gas combination is used when cut edge quality and surface nitriding are less
37. 0 Hand Torch Consumable Parts 028649 5 3 O1 ND 6 22 Number 120433 020193 020335 020846 020756 020705 120336 020706 058019 027055 027322 001067 Description Electrode PAC130 160 MAX100 D Air Electrode PAC130 160 MAX100 D N2 H35 Shield PAC130 160 100A Shield Cap PAC160 100D 100A Cutting Shield Cap PAC160 MAX100D 60A Nozzle PAC160 MAX100D 100A Cut Nozzle MAX100D 60A Shield Swirl Ring PAC160 MAX100D Cut O Ring Viton 801 x 070 Lubricant Silicon 1 4 Oz Tube Wrench 3 8 Hex Electrode Box Gray Plastic Figure 6 11 g O 5 2 1 1 5 5 2 2 1 1 1 PAC160 Hand Torch Consumable Parts MAX1000 380 415V CE Instruction Manual MAX100D Consumable Parts Kits cont PAC160E Gouging Torch Consumable Parts 028665 PARTS LIST Part Item Number Description Qty 1 020744 Electrode PAC160E Air Gouge 10 2 020703 Electrode PAC160E H35 Gouge 5 3 020712 Shield PAC160E Gouge 2 4 020699 Shield Cap PAC160 100D 100A Gouging 1 5 020745 Nozzle 160 Air Gouge 5 6 020704 Nozzle 160 H35 Gouge 5 7 020750 Swirl Ring 160 Gouge 2 8 058019 O Ring Viton 801 x 070 2 027055 Lubricant Silicon 1 4 Oz Tube 1 027322 Wrench 3 8 Hex Electrode 1 001067 Box Gray Plastic 1 Figure 6 12 160 Gouging Torch Consumable Parts MAX1000 380 415V CE Instruction Manual 6 23 PARTS LIST HYPERTHERM Figure 6
38. 008997 005102 014021 027079 027080 041313 129118 041530 020761 020693 020713 6 26 Description Gauge 0 100 psig Filter Regulator 0 120 psi 1 4NPT Air Replacement filter LTBULB 28VDC 40ma T3 1 4 PB Sw Grn NO Full Gd PB Sw Red NC Press Sw 0 90 psi 1 8 NPT Sol Valve 150 Sol Valve 90 Relay 120VAC SPST NO Contactor MAX100 60A Sw MAX40 100 HT40C Aux Contactor Fuse 2 500V 10mmX38mm Slo Thermostat 75 C Transformer 5000VAC 20ma Fan 450 550 CFM 120VAC 50 60 Hz Fan 225 CFM 120VAC 50 60 Hz PC BD Assy Ctrl MAX100D CH130 Chopper Module PC Bd Assy Power Dist MAX100 PAC160 Torch Main Body PAC160E Torch Main Body 100 Machine Torch Main Body Designator PG1 2 LT1 LT2 LT3 PB1 PB2 PS1 2 3 4 5 V1 2 3 4 V5 6 CR1 CR2 CON2 F1 F2 TS Page Number Showing 6 4 6 6 6 12 6 4 6 4 6 4 6 6 6 12 6 6 6 12 6 8 6 10 6 10 6 10 6 4 6 8 6 4 6 4 6 4 6 4 6 10 6 16 6 18 6 14 MAX1000 380 415V CE Instruction Manual In this section MAXTOOD Wiring Diagram NEE MAX1000 380 415V CE Instruction Manual Section 7 WIRING DIAGRAMS 7 1 380 415 3PH 50HZ SHOWN WIRED FOR 415 gt amp I O 77 D L2 L1 _ c ca 1 6 P i D E f A MAX100 34 110VB D B CH130 CHOPPER SA AMAT SR gt zt emm emm emm emm emm emm
39. 100D torch See Cut Gouging Charts later in this section for correct consumables 4 Turn on the facility gas supply Adjust incoming plasma and shield gas pressures to a minimum of 5 4 bar 5 Apply 3 phase power to the MAX100D 6 Press the green I ON button to power up the system Hold it down until the white POWER ON light and the green GAS PRESSURE light both illuminate a O POWER ON D Ol HOr gt t lt PRESSURE p O OVER TEMPERATURE 7 Place the GAS TEST RUN switch in the TEST position Gases will flow through the system av O POWER ON pos 5 PRESSUHE Q OVER TEMPERATURE MAX1000 380 415V CE Instruction Manual 4 5 ff 30 40A mm mm mm EM EXPANDED 30 100A NORMAL MADE IN U S A 30 40A mE mE EM EXPANDED 30 100A NORMAL MADE IN U S A OPERATION 8 If you are not cutting with an H35 N mixture skip this step 8 8 1 At the Plasma Gas Console Panel choose CUTTING 8 2 Fully open PLASMA Gas Adjustment Valve on the Plasma Gas S Console Panel 8 3 Be certain that incoming flowing dynamic pressures to the Dual Gas Mixer are equal 8 4 Adjust the H35 GAS1 GAS2 mixture at the Dual Gas Mixer by referring to Plasma Gas Mix H35 GAS1 and Gas2 in the Cut Gouging Charts pg 4 32 for 100 amp cutting Note When adjusting the H35 N mixture at the Dual Gas Mixer be careful not to let the mixer OUTLET p
40. 13 Dual Gas Mixer MAX1000 380 415V CE Instruction Manual Dual Gas Mixer 5 3 O O1 D Part Number 059123 001408 001410 006062 011051 015001 015570 015608 015609 015610 015611 015612 015613 022020 046077 006074 015551 015230 015009 001409 Description MAX100D Dual Gas Mixer Encl Dual Gas Mixer Panel Dual Gas Mixer Front Motor Valve 1 8 FPT 062 Orf Flowmeter 27SCFH NO Valve Adapter Bulkhead 1 4 NPTF Reducer Bushing 1 4 x 1 8 Sleeve Delrin 1 4 Insert Brass 1 4 OD Connector Female 1 4 Connector Male 1 4 Tube x 1 8 Elbow Male 1 4 Tube x 1 8 NPT Male Running Tee Gauge Pressure 160 PSI BAR Tubing 1 4 OD x 040 Blu Check Valve 1 4 NPT Coupling 1 4 Brass Adapter 1 4NPT X LH B Brass Adapter 1 4NPT X RH B Male Brass Panel Dual Gas Mixer Rear Hose Package for Dual Gas Mixer Part Number 028721 015230 015009 024205 024373 024374 024384 Description Hose Package 100 Dual Gas Mixer Adapter 1 4NPT x LH B Adapter 1 4NPT x RH B Hose Assy 3 8 Blue RH 25 ft Hose Assy 3 8 Blue RH 1 5 ft Hose Assy 3 8 Red LH 2 ft Hose Assy 3 8 Red LH 25 ft MAX1000 380 415V CE Instruction Manual Designation E PARTS LIST g O L D D D 6 25 PARTS LIST Recommended Spare Parts Part Number 022008 011025 011031 005168 005121 005122 005093 006093 006014 003021 003066 003054
41. 30 80 4445 0 2 6 9 6 9 2 130 4064 0 2 2 5 130 3683 0 5 3 130 3683 0 5 3 135 3429 0 5 4 135 3175 0 8 6 135 2921 0 8 9 140 2286 1 0 12 140 1524 1 2 15 145 1143 1 5 19 145 762 25 155 508 32 160 304 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa 4 44 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas Air Shield Gas Air Current Setting 60 Amp This gas combination gives good cut speed low dross levels and is very economical 020756 120336 020706 120433 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 72 Machine Shield Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 1 9 3 4 5 51 4 1 5 60 120 100 7620 0 5 6 91 6 9 1 5 125 6096 0 5 2 125 5080 0 5 2 5 130 4064 0 5 3 130 3048 0 8 6 135 2286 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 45 OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas Shield Gas Air Current Setting 60 Amp
42. 35 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma H35 Shield Arc Arc Motion Gas Shield Gas Material Gas Torch to work Current Voltage Duty Delay H35 Inlet N Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 6 3 4 5 51 4 3 100 130 80 2413 0 8 6 91 6 9 9 135 1778 1 0 12 135 1397 1 2 15 140 1143 1 5 19 145 889 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 2 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 43 OPERATION 100 Machine Torch Extended Consumables Aluminum Cutting Plasma Gas Air Shield Gas Air Current Setting 100 Amp This gas combination gives good cut speed low dross levels and is very economical The extended consumables allow the user greater accessibility for some cutting applications 020333 020846 020754 020706 120444 Deflector Retaining Cap Nozzle Swirl Ring Electrode Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 5 3 4 5 51 4 3 100 1
43. 4 proceed as follows Ensure that high frequency is still disabled see step 1 e Disconnect PL7 from S3 on PCBA Place voltmeter across output of chopper and press the START command e f the voltmeter reads 280 VDC then there is a problem with PCB4 e f the voltmeter reads 0 volts then replace chopper module Bridge LED1 JP9 JP6 Figure 5 3 Chopper Module Front View 5 22 MAX1000 380 415V CE Instruction Manual 4 00 MAINTENANCE Disassembly of Hand Torch To remove and replace the hand torch main body from the lead perform the following procedure and see Figure 5 4 Removal 1 Remove the 5 screws and separate the two handle halves 2 Remove the torch switch from the handle switch holder and allow it to hang freely 3 For the shield gas lead use a 3 8 open end wrench to hold the torch main body fitting and a 1 2 open end wrench to loosen the torch lead fitting 4 For the plasma gas lead use a 5 16 open end wrench to hold
44. 6 9 1 5 125 9144 0 5 2 130 6096 0 5 2 5 130 3810 0 8 3 135 3048 1 0 4 140 1397 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa 4 36 MAX1000 380 415V CE Instruction Manual OPERATION 100 Machine Torch Stainless Steel Cutting Unshielded Parts Plasma Gas Shield Gas Air Current Setting 60 Amp This gas combination is used when cut edge quality surface nitriding and surface oxidation of alloying elements are less important Electrode life is extended when this combination is used 020333 020756 020922 020706 020193 Deflector Retaining Cap Nozzle Ring Electrode Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Inlet Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm volts mm min sec bar bar 1 3 2 8 5 51 4 3 60 120 100 9144 0 2 6 91 6 9 1 5 120 7620 0 2 2 125 6096 0 5 2 5 125 4572 0 5 135 3556 1 0 140 1524 1 0 145 1016 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 37 OPERATION 100 Machine Torch Stainless Steel Cutting Plasma Gas Air Shield Gas Air Current Setting 30 40 Amp This gas combination is used when cut
45. Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax France 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S r l Via Torino 2 20123 Milano ltalia 39 02 725 46 312 Tel 39 02 725 46 400 Fax 39 02 725 46 314 Technical Service Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel ETSO Technical Service 00 800 49 73 7843 Tel ETSO Technical Service toll free in Europe Japan 1952 14 Yata Natsumegi Mishima City Shizuoka Pref 411 0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax Hypertherm Brasil Ltda Rua Visconde de Santa Isabel 20 Sala 611 Vila Isabel RJ Brasil CEP 20560 120 55 21 2278 6162 Tel 5 23 03 55 21 2578 0947 Fax ELECTROMAGNETIC COMPATIBILITY EMC EMC INTRODUCTION Hypertherm s CE marked equipment is built in compliance with standard EN50199 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 may not be adequate to completely eliminate interfer ence when the affected equipment is in close proximity or has a high degree of sensitivity In such cases it may be neces sary to use other measures to further reduce interference This plasma equipment is designed for use only in an industr
46. EXPANDED NORMAL switch in the NORMAL position Note If you are cutting metal grate place the PLATE EXPANDED NORMAL switch in the EXPANDED position o u O POWER ON KEE mm mm EXPANDED N PRESSURE 30 100 p Q OVER TEMPERATURE 14 If you are using a torch height control system adjust the Arc Voltage Setting on the torch height control according to the specifications in the Cut Gouging Charts later in this section MADE IN USA PLATE 30 40 m mm EH NM EXPANDED 30 100A NORMAL MADE IN U S A MADE IN USA MAX1000 380 415V CE Instruction Manual 4 7 15 Adjust the work clamp to the work table or workpiece Do not attach the work clamp to the portion of the workpiece that will fall away See Figure 4 4 16 Position the torch the appropriate distance from the workpiece Refer to the Torch to work Distance in the Cut Gouging Charts later in this section 17 Set the machine travel speed Refer to Travel Speed in the Cut Gouging Charts later in this section Figure 4 4 Proper Work Clamp Connection 18 Hand Torch Press the torch start button and hold it down Machine Torch Press the START button After a two second delay the pilot arc will activate and transfer will occur if the Torch to work Distance is set properly Notes Hand Torch The arc will extinguish if the torch
47. PAC160 Torch Assy 25 PAC160 Torch Assy 50 PAC160 Torch Assy 75 Handle PAC130 PAC140 Tch Boot PAC130 Tch PB Switch Tch Electrode PAC130 160 MAX100 D Air Shield MAX80 100 C D 100A Shield Cap PAC160 100D 100A Cutting Nozzle PAC160 MAX100D 100A Cut Swirl Ring PAC160 MAX100D Cut Leads PAC160 160E Torch 25 PL Assy PAC160 100D QDisc Leads PAC160 160E Torch 50 PL Assy PAC160 100D QDisc Leads PAC160 160E Torch 75 PL Assy PAC160 100D QDisc PAC160 Tch Main Body P S 6 x 3 4 PH Rnd S B MAX1000 380 415V CE Instruction Manual PARTS LIST ch 6 17 PARTS LIST 4 Figure 6 9 160 Hand Torch Assembly 6 18 MAX1000 380 415V CE Instruction Manual PAC160E Gouging Torch Assembly 5 3 O O1 gt ch CO O Part Number 059112 059113 059114 001214 001217 005094 020703 020712 020699 020704 020750 029730 028558 029731 028558 029732 028558 020693 075365 020711 Description PAC160E Torch Assy 25 PAC160E Torch Assy 50 PAC160E Torch Assy 75 Handle PAC130 PAC140 Tch Boot PAC130 Tch PB Switch Tch Electrode PAC160E H35 Gouge Shield PAC160E Gouge Shield Cap PAC160 100D 100A Gouging Nozzle PAC160E H35 Gouge Swirl Ring PAC160 MAX100D Cut Leads PAC160 160E Torch 25 PL Assy PAC160 100D QDisc Leads PAC160 160E Torch 50 PL Assy PAC160 100D QDisc Leads PAC160 160E T
48. Plasma Gas Console 7 Plasma Gas To Torch In PS1 Plasma NO set to 1 Connection close 20 PSI Wee ee VIT VK uM MAX100D Power Supply PS2 NO set to close 60 PSI PG2 Shield Gas E To Torch In p V5 MV2 Shield Connection x ET 7 NO set to close 60 PSI To Torch V6 Cap Sensor et enc xxr Figure 5 6 MAX100D System Plasma and Shield Gas Flow Schematic MAX1000 380 415V CE Instruction Manual 5 25 MAINTENANCE D6 Start Command O D8 Arc Transfer 5 12 VDC D e Mach Motion PIN 1 D17 Current shunt Figure 5 7 PCB4 Control Board 5 26 MAX1000 380 415V CE Instruction Manual Section 6 PARTS LIST In this section MOUCHO ect ges ee ee ence 6 2 100 Power Supply Front Panel Outside Front Panel Inside Control Panel 6 5 BE CRIE BE aces 7 6 7 OO __ 6 9 Base Plate Components E 6 9 Lett Center A M
49. Repair and or replace defective component s if necessary 5 If voltage from above step is 280 VDC and is not blown check output of chopper by putting the positive lead of the voltmeter at point WORK and placing the negative lead on point TORCH See Fig 5 3 6 Turn the system on and press the START command After the START command has been given check the voltage If the output from the chopper at these points is 280 VDC chopper is OK 7 f the chopper does not output 280 VDC check to see if LED1 logic power light is illuminated If LED1 is not illuminated check if 120V is going to JP6 If there is no 120V at JP6 check wiring back to power distribution board Repair or replace defective component s if necessary Also check to see if LED3 is turning green when enabled normal condition If LED1 is illuminated and LEDS is red when enabled fault condition then make sure that JP9 is seated properly MAX1000 380 415V CE Instruction Manual 5 21 MAINTENANCE Test Procedures cont 8 If chopper still does not output 280V after completing step 7 there may be a problem with the control signal or the chopper module The chopper drive signal comes from the control board PCB4 as an analog level from 0 to 12 VDC which varies the duty cycle and subsequent output current of the chopper This analog signal is on pins 10 amp 11 of S3 on PCBA To determine if there is a problem with the chopper module or with control board PCB
50. Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Inlet Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 3 4 5 21 4 1 5 60 125 100 7620 0 5 6 9 6 9 1 3 125 7620 0 5 15 125 7620 0 5 2 130 5334 0 5 2 5 130 3556 0 5 3 135 3048 0 5 3 5 135 2159 0 6 6 145 762 0 8 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 27 1000 Machine PAC160 Hand Torch Mild Steel Cutting Plasma Gas shield Gas CO Current Setting 60 Amp This gas combination is used when cut edge quality and surface nitriding are less important Electrode life is extended when this combination is used 020756 120336 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas CO Torch to work Current Voltage Duty Delay Inlet CO Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 1 3 4 5 21 4 1 5 60 125 100 7620 0 5 6 91 6 9 1 3 125 7620 0 5 1 5 125 7620 0 5 2 130 5334 0 5 2 5 130 4064 0 5
51. ___ 2 3 TOOD Power SUDDIY 2 3 WAKTOOD MAC MING EE 2 4 g 2 4 Hand TG 0 2 PE 2 4 2 5 EE 2 5 MAX1000 380 415V CE Instruction Manual 2 1 SPECIFICATIONS General Hypertherm s MAX100D is a dual gas system designed for cutting most metals from gauge to 32 mm thick In addition to hand cutting it can be used with a machine torch and a THC 2 Torch Height Control system for high speed mechanized cutting The MAX100D provides continuously variable current output from 30 to 100 Amps for optimum performance on all thicknesses of metal up to 32 mm thick This allows the operator wide variations in cutting speeds on the same thickness of metal Two nozzle sizes 60 Amp and 100 Amp provide high quality cuts throughout its range of cut thicknesses The system can also provide a continuous pilot arc which allows high quality cutting of perforated or expanded metal without any appreciable deterioration in parts life This feature is only available for use with the 60 Amp nozzle The unique MAX100D power supply design uses transistor technology to produce a very smooth constant current DC output Air can be used as the primary plasma gas providing low operating costs combined with high speed performance Cylinder air or shop air is acceptable as lo
52. a Gas Inlet Pressure 1 bar 6 895 KPa 4 50 MAX1000 380 415V CE Instruction Manual 1000 Machine PAC160E Hand Torch Stainless Steel Gouging Plasma Gas H35 Shield Gas Air Current Setting 100 Amp OPERATION Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas This gas combination is highly efficient and yields long consumable life 020712 Shield 020669 Retaining Cap 020704 Nozzle 020750 020703 Swirl Ring Electrode Plasma Gas Pressure H35 Torch to work Shield Arc Approx Angle of Gas Air Torch to work Current Duty Motion inclination TEST RUN Pressure Distance Setting Cycle Travel Speed Delay Time Degrees bar bar bar mm amps 96 mm min sec 40 3 4 3 71 4 3 100 80 508 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual Plasma Gas Shield Gas H35 Inlet Air Inlet Pressure Pressure bar bar 6 91 6 9 4 51 OPERATION 1000 Machine PAC160E Hand Torch Stainless Steel Gouging Plasma Gas H35 shield Gas Current Setting 100 Amp Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas This gas combination is highly efficient yields long consumable life and leaves a superior work surface 020712 020669 020704 020750 020703 Shield Retaining Cap Nozzle Swirl Ring Electrode Plasma Gas Pressure H35 To
53. accordance with appropriate national or local electrical codes 1 4 5 6 02 ISO 4850 No 11 12 Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and Slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare e Warn others not to watch the arc Use placards signs Input Power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply be sure to connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating Hypertherm Plasma Systems COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and fittings designed for the s
54. and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 Hypertherm Plasma Systems 9 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 10 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 11 98 Section 1 SECURITE Dans cette section Identifier les Consignes de _ ____ __ _______ _ 1 2 ouivre les instructions d n ieren _ ___ 1 2 Danger Avertissement Pr caution 1 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Pr vention des incendies Pr vention des 1a 2 Risque d explosion argon hydrog ne m ihane 1a 2 D tonation de l hydrog ne lors du coupage de l aluminium 1a 2 Les chocs lectriques peuvent tre cem pU 1a 3 Pr vention des chocs lectriques 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 Larc plasma peut provoquer des blessures ou des br lures 4 1a 4 Torches a dll mage T 1 4 Les rayons l arc peuvent br ler les yeux et lapeau 1a 4 Protection des yeux Pro
55. chnical Questions Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier When requested Hypertherm will furnish you with a copy of the bill of lading Claims for defective merchandise units shipped from Hypertherm undergo rigorous quality control testing However if your unit does not function correctly 1 Read Troubleshooting in the Maintenance section Section 5 of this manual You may find the problem is quite easy to fix such a loose connection 2 f you are unable to solve the problem call your distributor He will be able to help you or refer you to an authorized Hypertherm repair facility 3 If you need additional assistance contact the nearest Hypertherm Technical Service Department listed at the front of this manual 3 2 MAX1000 380 415V CE Instruction Manual SETUP Introduction The following requirements must be fulfilled prior to the installation of the MAX100D plasma cutting system Please read these requirements carefully Their purpose is to aid you in the installation of your plasma cutting system and to allow maximum performance Installation and service of the electrical and plumbing systems must conform to national or local electrical and plumbing codes This work should be performed only by qualified licensed personnel For installation operation or service questions or problems contact the nearest Hypertherm Technical Service Depart
56. ck switch The ON switch is normally open 1 2 The red O OFF PB2 pushbutton is defective Check switch The OFF switch is normally closed 1 3 Associated wiring not making good contact Check wiring and repair or replace if necessary 2 1 CH4 on the Power Distribution Board is defective Check that CR4 switches when ON pushbutton is pressed See Figure 5 2 for location of CR4 If CR4 is defective replace PCB2 2 2 lerminals to fans are not seated together securely and or not getting 120VAC from Power Distribution Board Check terminals and associated wiring for good continuity Check for 120VAC at terminals 2 3 PL2 and 2 on Power Distribution Board see Figure 5 2 for location of RECP2 are not seated well Check pins connectors and associated wiring for good continuity Repair or replace if necessary MAINTENANCE Problem 3 The fans are operating but the POWER ON indicator does not illuminate Note Indicator On Indicator Off u O POWER ON O O os PRESSURE OVER TEMPERATURE POWER O O PRESSURE OVER TEMPERATURE U abe PRESSURE ESL eem TEMPERATURE Possible Causes and Solutions 3 1 3 2 1 3 2 2 3 2 3 3 3 3 4 The ON 1 pushbutton was not held down for a long enough time Press and hold the ON button for a minimum of 5 seconds If the POWER ON indicator wi
57. ct line power by turning main disconnect switch off 2 Using a Phillips head screwdriver remove top plate two side plates front plate and rear plate 3 Inspect interior of unit for discoloration on pc boards or other apparent damage If a component or module is obviously defective upon visual inspection remove and replace it before doing any testing Refer to the Parts List section 6 to identify parts and part numbers 4 f no damage is apparent apply power by turning on the main disconnect switch 5 Measure the voltage between the V and W terminals on the EMI filter located on the rear of the 100 power supply Refer to Figure 5 1 The voltage between any two of the three terminals should be equal to the supply voltage 380 or 415 VAC If there is a problem at this point disconnect main power and check connections power cable and fuses at line disconnect switch Repair and or replace defective component s if necessary continued on page 5 12 5 10 MAX1000 380 415V CE Instruction Manual MAINTENANCE MAX100D Figure 5 1 Primary Power Measurement Location 5 11 MAX1000 380 415V CE Instruction Manual MAINTENANCE Figure 5 2 Power Distribution Board PCB2 6 Measure voltage at power distribution board PCB2 See Figure 5 2 for detail of PCB2 Look on the board for fuses F3 and F4 Measurements between each fuse and chassis ground are as follows F3 115 VAC F4 24 VAC If voltages are not prese
58. d Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible 5 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 6 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 2 ANSI Standard 249 2 Fire Prevention in the Use of Cutting and 1235 Jefferson Davis Highway Arlington VA 22202 Welding Processes American National Standards Institute 7 CSA Standard W117 2 Code for Safety in Welding and Cutting 1430 Broadway New York NY 10018 Canadian Standards Association Standard Sales 3 ANSI Standard Z87 1 Safe Practices for Occupation and 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada Educational Eye and Face Protection American National 8 NFPA standard 51B Cutting and Welding Processes National Standards Institute 1430 Broadway New York NY 10018 Fire Protection Association 4 AWS F4 1 Recommended Safe Practices for the Preparation for 470 Atlantic Avenue Boston MA 02210 Welding and Cutting of Containers
59. e U4 x Input Current l4 POSITI 380 415V CE LVD 3PH 50 60 Hz 28 26 Amps Dimensions and Weight lile 673 mm acie 1092 BI 806 E 205 kg Gas Requirements Plasma Gas Air Nitrogen N5 Argon Hydrogen H35 35 hydrogen and 65 argon Argon Hydrogen Nitrogen mixture Shield Gas Air Carbon Dioxide Nitrogen Gas Quality Clean dry oil free Plasma Gas 58 l min Shield Gas FO 208 Plasma Gas Inlet Pressure 5 4 bar to 8 5 bar dynamic flowing pressure Shield Gas Inlet Pressure 5 4 bar to 8 5 bar dynamic flowing pressure Plasma Gas and Shield Gas Pressures in Test and Operate modes See Cut Gouging Chart data in Section 4 MAX1000 380 415V CE Instruction Manual 2 3 3 99 SPECIFICATIONS 1000 Machine Torch Maximum mechanized cutting 16 mm Maximum current at 80 duty cycle 100 Amps Maximum temperature at torch head 149 C Gouging capability metal removal rate 199 as plasma EE 6 8 kg hour Air as plasma gas 3 6 kg hour Gas 208 l min at 4 1 bar with 100 amp consumables
60. e jamais utiliser une bouteille qui n est pas plac e la verticale et bien assujettie Le capuchon de protection doit tre plac sur le robinet sauf si la bouteille est en cours d utilisation ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des cl s ou d autres outils pour d bloquer le robinet des bouteilles 9 PACEMAKERS ET PROTHESES AUDITIVES K Les champs magn tiques produits par les courants haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un m decin avant s approcher d un lieu o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques e Garder loin de soi et du m me c t du corps le cable de retour et le faisceau de la torche Faire passer le faisceau de la torche le plus pr s possible du c ble de retour Ne pas s enrouler le faisceau de la torche ou le cable de retour autour du corps Se tenir le plus loin possible de la source de courant 1a 5 2 12 01 Section 2 SPECIFICATIONS In this section v 2 2 Product SD CINCANOTS _ ___ _ _____
61. e of the torch and the workpiece The pilot arc is made between the torch electrode and the torch nozzle and precedes transfer in normal operation When transfer is made it is sensed by a Hall effect device CS1 on the I O board and the signal is sent to the Control Board To check for proper functioning of the arc transfer sensing system perform the following procedure 1 Observe D8 on PCB4 see Figure 5 6 and see if it illuminates after main contactor closes see sequence flowchart earlier in this section If it does not illuminate continue to next step If it does illuminate return to Troubleshooting section 2 Disconnect connector from CS1 see Figure 6 3 for location of CS1 and check for 12VDC If there is 12VDC go to step 5 3 If there is no 12VDC power down and check connectors pins and associated wiring between PL4 and PL6 connected to S2 on Control Board PCB4 Repair and or replace defective component s if necessary 4 If wiring is OK replace Control Board PCB4 5 If there is 12VDC at CS1 reconnect PL4 and take voltage between pins 13 amp 14 of PL6 on Control Board 4 after arc is established This should read O volts If there is no 0 volts replace 51 5 20 MAX1000 380 415V CE Instruction Manual MAINTENANCE Test Procedures cont Chopper Module Test Procedure Note Take voltages with a digital multimeter capable of storing min and max readings WARNING SHOCK HAZARD Use extre
62. ed to indicate that the gas pressure is adequate If power supply shuts down and light is not illuminated when the ON button is pushed then the gas pressure is inadequate Yellow OVER TEMPERATURE light Normally not illuminated If power supply shuts down and light is illuminated when the ON button is pushed then the power transformer and or the chopper has overheated AMPS output adjustment knob Adjusts output current between 30 and 100 amps Increase the amperage to cut thicker material PLATE EXPANDED NORMAL switch In EXPANDED up position a continuous pilot arc remains on This setting is recommended for cutting expanded plate Never exceed 40 amps while in this position Use in NORMAL down position when cutting normal plate MAX1000 380 415V CE Instruction Manual OPERATION Description of Controls and Indicators cont GAS TEST RUN switch In TEST position gases flow so that adjustments to both shield and plasma gas pressures can be made RUN position is used after gases have been set in TEST position and cut is about to be made SHIELD Gas Adjustment Valve Adjusts shield gas pressure in TEST position SHIELD Gas Pressure Gauge Indicates dynamic flowing plasma gas pressure PLASMA Gas Adjustment Valve APPLICATION y PLASMA GA HYPERTHERM 2 lt d EH D lt MADE IN U S A GOUGING CUTTING PLASMA Gas Pressure Gauge Figure 4 1 Plasma Gas Console Panel SHIELD Gas Adjus
63. ee Figure 5 7 for location of D8 e f D8 remains illuminated check to see if CS1 is sending a 0 volt signal to PCB4 If there is 0 volts at PCBA replace sensor CS1 If voltage at PCB4 is greater than 0 volts replace Control Board PCB4 f D8 is extinguished replace Control Board PCB4 Gas TEST RUN switch is in the TEST position Be certain that Gas switch is in the RUN position when cutting Defective Control Board PCB4 See step 4 3 If valves are working in TEST mode but not in post flow mode replace Control Board PCBA Defective valves See solution 4 4 Plate is in the Expanded position See solution 10 4 Pilot arc relay CH1 not opening after transfer of arc Check to see if contacts on relay CH1 are stuck shut Replace if necessary If relay is OK check to see if CR1 is receiving 120VAC fromthe Control Board PCBA after transfer of arc If Control Board PCB4 continues to send 120VAC to CH1 after arc transfer replace Control Board PCBA 5 19 MAINTENANCE Test Procedures WARNING SHOCK HAZARD Always use caution when servicing a power supply when the covers are removed Dangerous voltages exist within the power supply which could cause injury or death If questions or problems arise during servicing contact the nearest Hypertherm Technical Service Department listed at the front of this manual Arc Transfer Test Procedure The transfer of arc refers to the arc being made between the electrod
64. emature wear Multiple passes or weaving may be necessary to gouge wider and deeper sections See Fig 4 10 4 16 MAX1000 380 415V CE Instruction Manual Direction of Travel Figure 4 10 Gouging MAX1000 380 415V CE Instruction Manual OPERATION Common Cutting Faults The workpiece is not totally penetrated Causes can be The current is too low The cut speed is too high The torch parts are worn The metal being cut is too thick Dross forms on the bottom of the cut Causes can be The cutting speed is too slow The torch parts are worn Duty Cycle The duty cycle or the amount of time the pilot or plasma arc can remain on in minutes within a 10 minute period is affected by many factors When the current is set at 100 amps the MAX100D has an 809 duty cycle During normal operation the plasma arc can remain on 8 minutes out of every 10 minutes without causing the temperature sensors to disable the unit The duty cycle increases to 10096 when the current is set at or below 80 amps The duty cycle is reduced if he input line voltage is less than nominal due to a long power cord poor utility supply etc You are cutting material greater than 25 mm thick he work clamp is not making a good electrical contact with the workpiece due to paint rust etc Gas Pressure The plasma gas compressed air or nitrogen must be available at a flow rate of 208 liters m
65. en cut edge quality surface nitriding and surface oxidation of alloying elements are less important Electrode life is increased when this combination is used The extended consumables allow the user greater accessibility for some cutting applications 020333 020846 020754 020706 020887 Deflector Retaining Cap Nozzle Ring Electrode Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm volts mm min sec bar bar 2 5 3 4 5 51 4 3 100 130 80 4445 0 5 6 9 6 9 3 130 4064 0 5 4 135 2032 0 8 6 135 1524 0 8 9 140 1016 1 0 12 145 889 1 2 15 150 457 1 5 19 155 381 25 160 254 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa 4 34 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Stainless Steel Cutting Plasma Gas Shield Gas Air Current Setting 60 Amp This gas combination is used when cut edge quality surface nitriding and surface oxidation of alloying elements are less important Electrode life is extended when this combination is used 020756 120336 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334
66. ent is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out Hypertherm Plasma Systems The size of the surrounding area to be considered will depend on the structure of the building and other activities that are tak ing place The surrounding area may extend beyond the boundaries of the premises METHODS OF REDUCING EMISSIONS Mains Supply Cutting equipment must be connected to the mains supply according to the manufactur ers recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of per manently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connect ed to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation The cutting equipment should not be modified in any way except for those changes and adjust ments covered in the manufacturer s instructions In particular the spark gaps
67. ent or subassemblies that contain additional items Normal style part numbers Ex 001611 signify items under parent or subassembly Description Describes the item Bold descriptions not indented Ex Cont SA 100 signify parent assemblies that contain additional items Normal style part numbers that are indented Ex Pnl 100 CE LVD Cont signify items under parent or subassembly Normal style part numbers that are not indented Ex Knob 930 Dia 1 4 SFT Blk Nat represent subassemblies that are not under the parent assembly Designator Represents a cross reference to wiring diagrams or pneumatic diagrams Ex PB1 refers to pushbutton PB1 shown in wiring diagrams Qty Refers to the number of items in the parent or subassembly 6 2 MAX1000 380 415V CE Instruction Manual PARTS LIST
68. ers with potentially toxic materials inside they must be emptied and properly cleaned first 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 1 3 3 99 SAFETY A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant On Torches Plasma arc comes on immediately when the torch switch is activated The plasma arc will cut quickly through gloves and Skin e Keep away from the torch tip Do not hold metal near the cutting path e Never point the torch toward yourself or others ARC RAYS CAN BURN EYES AND SKIN Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields and a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays Lens Shade d AWS USA No 8 No 10 Arc Current Up to 100A 100 200 A 200 400 A Over 400 A No 11 No 13 No 14 No 14 GROUNDING SAFETY Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to an earth ground in
69. gt gt P kel fe V1 PLASMA MAIN FLOW SOL VALVE L a Jj EUREN E EE _ Mop AI V2 PLASMA STEP FLOW SOL VALVE V3 LINE CHARGE AT TRANSFER SOL VALVE 16 15 11 1 14 13 12 4 15 16 13 14 7 4 1 2 1211 4 1 11 15 1 2 1 EE p V4 LINE CHARGE START SOL VALVE E _ a V5 SHIELD SOL VALVE V6 CAP SENSOR SOL VALVE MWW 10 15 96 P WA gt v 5 gt E Hypertherm Incorporated 3 e 75 E c 5 5010 03755 5010 603 643 3441 n ec 2 ve Di t 5 a E g gt 5 DESCRIPTION y za gt 2 5 8 2 5 0 amp 29 5 DIMENSIONS AREIN INCHES MAX100D CE LVD SYSTEM SCH 5 gt us M T d c p t 5 THIS DRAWING AND ALL INFORMATION TOLERANCES ON 8 S 8 3 I 9 v 8 8 x p 9 36 5 2 GEES 1 ERT So Control d 9 a 22 Z EM Im NM Ls e Ra SE E aan a 2 os J FOR MANUFACTURING OR FABRICATION FRACTIONS 1 64 N A 013 4 305 013305D PURPOSES WITHOUT PERMISSION BREAK SHARP CORNERS WITH SCALE MODEL SHEET UT P UJ Appendix AIR FILTERS Air Filters Gas purity is critical for maximizing consumable parts life as well as for producing the highest quality cutting which Hypertherm plasma equipment can achieve Plasma air must be clean dry and
70. hield 020334 Machine Shield Plasma Gas Pressure Air Shield Material Gas Air Thickness TEST RUN Pressure mm bar bar bar 6 3 4 5 21 4 9 12 15 19 25 32 020846 Retaining Torch to work Current Voltage Setting Setting Cycle Travel Speed Distance mm 3 020705 Nozzle Swirl Ring Electrode Arc amps 100 Arc volts 140 140 145 150 155 160 170 020706 Duty 80 120433 mm min 2413 1778 1397 1143 838 559 279 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual Approx Motion Delay Time sec 0 8 1 0 1 2 1 5 Plasma Gas Shield Gas Air Inlet Air Inlet Pressure Pressure bar bar 6 91 6 9 4 39 OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas Shield Gas Air Current Setting 100 Amp This gas combination is used when cut edge quality is less important Electrode life is extended when this combination is used 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure
71. ial environment INSTALLATION AND USE The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electro magnetic disturbances are detected then it shall be the responsibility of the user to re solve the situation with the technical assis tance of the manufacturer In some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of Workpiece In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome ASSESSMENT OF AREA Before installing the equipment the user shall make an assessment of potential elec tromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equip ment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hear ing aids f Equipment used for calibration or mea surement g Immunity of other equipment in the en vironment User shall ensure that other equipment being used in the environm
72. iliser un syst me plasma Lors de l utilisation d oxyg ne comme gaz plasma un syst me de ventilation par aspiration est n cessaire Pr vention des explosions Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s Ne pas couper de r cipients contenant des mati res combustibles 1a 2 2 12 01 OU UNE EXPLOSION AVERTISSEMENT Risque d explosion argon hydrog ne et methane L hydrog ne et le methane sont des gaz inflammables et potentiellement explosifs Conserver l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de m thane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasma d argon hydrogene ou de m thane AVERTISSEMENT D tonation de l hydrog ne lors du coupage de l aluminium Lors du coupage de l aluminium sous l eau ou si l eau touche la partie inf rieure de la pi ce d aluminium de l hydrog ne libre peut s accumuler sous la piece couper et d tonner lors du coupage plasma Installer un collecteur d a ration au fond de la table eau afin d liminer les risques de d tonation de l hydrog ne oe r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration Hypertherm Systemes plasma e A Toucher une pi ce lectrique sous tension peut provoquer un choc lectrique fatal
73. important Electrode life is extended when this combination is used 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Approx Plasma Plasma Gas Pressure Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Inlet Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bari bar mm amps volts mm min sec bar bar 6 3 4 5 51 4 3 100 140 80 1651 1 0 6 91 6 9 9 145 1270 1 0 12 150 1016 1 5 15 155 508 1 5 19 165 254 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 23 1000 Machine PAC160 Hand Torch Mild Steel Cutting Plasma Gas shield Gas CO Current Setting 100 Amp This gas combination is used when cut edge quality and surface nitriding are less important Electrode life is extended when this combination is used 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas CO Torch to work Current Voltage Duty Delay Inlet CO Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel S
74. ing Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 9 3 4 5 91 4 1 5 60 125 100 6096 0 5 6 9 6 9 1 5 125 4572 0 5 2 135 4064 0 5 2 5 140 3302 0 5 3 145 2159 0 8 6 155 1016 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 47 OPERATION 1000 Machine Torch Aluminum Cutting Unshielded Parts Plasma Gas Air Shield Gas Air Current Setting 60 Amp This gas combination gives good cut speed low dross levels and is very economical 020333 020756 020922 020706 120433 Deflector Retaining Cap Nozzle Swirl Ring Electrode Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 1 3 2 8 5 51 4 3 60 115 100 7620 0 2 6 91 6 9 1 5 120 6096 0 2 2 120 5080 0 5 2 5 125 4064 0 5 3 125 3048 0 8 6 130 2286 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 2 6 895 KPa 4 48 MAX1000 380 415V CE Instruction Manual 1000 Machine PAC160E Hand Torch Mild Steel Gouging Plasma Gas Air Shield Gas Air Current Setting 100 Amp This combina
75. inute and a minimum pressure of 5 4 bar If the pressure is below 4 1 bar the torch will extinguish 4 18 MAX1000 380 415V CE Instruction Manual Cut Gouging Charts The cut and gouging chart information on the following pages will enable you to successfully cut or gouge using the MAX100D system Caution Before cutting check all settings and adjustments Also check for damaged torch parts and worn consumable parts Note the metal thickness that you are cutting is not listed in the cut charts make appropriate interpolation for Arc Voltage Travel Speed and Approx Motion Delay Time WARNING The voltage between the tip of the torch and the workpiece may exceed 113 VDC if shielded consumable parts are not installed in the torch Cut charts that specify non shielded consumables are for machine torch applications only The PAC160 hand torch must be operated with shielded parts to maintain the S mark and CE low voltage compliance 4 20 MAX1000 380 415V CE Instruction Manual OPERATION Cut Gouging Index CUT GOUGING INDEX Metal Current Plasma Gas Shield Gas Page Mild Steel 100 Amp 100 Amp 100 Amp 100 60 Amp 60 Amp 60 Amp 60 Ampt Stainless 100 Amp 100 Amp 100 Amp 100 Amp CUTTING 100 Amp 60 Amp 60 Amp 60 Ampt 30 40 Amp Aluminum 100 Amp 100 Amp 100 Amp 100 Amp 100 Amp 100 60 Amp 60 Amp 60 Amp 60 Ampt Mild Steel 100 Amp E 10
76. ith respect to the torch and leads within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise damaged Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall be returned with Hypertherm s prior authorization which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty Distributors OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be bi
77. ivery to the system Exceeding this pressure will cause shortened torch parts life Note Whether you use a compressed air cylinder or shop compressed air Use an inert gas hose to connect the gas supply to the input connection on the air regulator mounted at the rear of the power supply Use a filter to maintain a high air purity level All moisture oil and other contaminants must be removed 3 4 MAX1000 380 415V CE Instruction Manual SETUP Plasma and Shield Gases When nitrogen argon hydrogen or an argon hydrogen nitrogen mixture is used as the plasma gas and nitrogen or carbon dioxide is used as the shield gas they must be supplied to the MAX100D at 99 995 purity The source can be compressed gas cylinders or liquid containers The gas supply source must be capable of delivering a minimum of 208 liters minute at a delivery pressure of 5 4 bar Refer to the Cut Gouging Charts in Section 4 for detailed information Hoses To obtain the proper plasma and shield gas flow rates and pressures use hose that meets the following specifications I D 9 5 mm minimum Length 30 m maximum Purity If the purity level of the plasma gas is too low cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Note These conditions also occur if there are leaks in the gas supply hoses or connections Grounding Requirements The plasma system must be properly grounded t
78. l SETUP Power Cable Connection Continued Power Cable from MAX100D Power Supply to Power Source 1 Be certain that the line disconnect switch is in the OFF position 2 Connect the power cord leads to the line disconnect switch Follow applicable national or local electrical codes 3 Be certain that the line disconnect switch remains in the OFF position during the rest of the setup of the MAX100D system Remote Start Stop Switch Optional To connect the remote start stop switch 1 Pass the remote start stop switch cable assembly through the strain relief at the rear of the MAX100D 2 Connect wires 33 and 34 to TB1 5 and TB1 6 for machine start See Figure 6 5 for location of TB1 and Figure 3 3 for detail of TB1 3 Connect wires 37 and 38 to TB1 7 and TB1 8 for auxiliary 24 volt AC input 2 39 42 34 33 37 38 55 36 ei Figure 3 3 Remote Start Stop Switch Connections Machine Computer Interface Optional The customer must supply 2 pair twisted 22 AWG American Wire Gauge cable or equivalent Refer to TB1 on page 7 2 in the Wiring Diagrams for machine interface connections MAX1000 380 415V CE Instruction Manual 3 9 SETUP Power Supply Gas Connections Plasma Gas Connections 1 When using nitrogen or argon hydrogen as the plasma gas connect hose from source to the connector on the rear of the plasma gas console located on the top of the power supply labeled PLASMA GAS Fig
79. la torche soit mise en marche L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de metal pres de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes LES RAYONS DE L ARC PEUVENT BRULER LES YEUX ET LA PEAU Protection des yeux Les rayons de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d crans lat raux et encore masque de soudure avec des verres teint s appropri s pour prot ger les yeux des rayons ultraviolets et infrarouges de l arc Protection de la peau Porter des v tements de s curit pour se prot ger contre les br lures que peuvent causer les rayons ultraviolets les tincelles et le m tal br lant Puissance des verres teint s AWS U 1504850 N 8 NO 11 NO 10 NO 11 12 NO 12 NO 13 NO 14 NO 14 Courant de l arc Jusqu 100A 100 200 A 200 400 A Plus de 400 A MISE LA MASSE ET LA TERRE C ble de retour Bien fixer le c ble de retour ou de masse la pi ce couper ou la table de travail de fa on assurer un bon contact m tal m tal Ne pas fixer le c ble de retour la partie de la pi ce qui doit se d tacher Table de t
80. ll not illuminate after holding down the ON button for 5 seconds check the safety interlock indicators while holding down the ON button Refer to the control panel indicator conditions and possible causes and solutions listed opposite Gas is not on or is set too low Control panel indicator GAS PRESSURE will not illuminate if the pressure to the 100 is set too low Be certain that the plasma supply gas is on and is set toa minimum of 6 2 bar There is a gas leak somewhere in the system Be certain that there is no hissing sound coming from the torch or anywhere between the torch and the gas supply Pressure switch PS1 not functioning 51 is normally open and closes when gas pressure of 2 7 bar or greater is sensed It is powered by 24VAC from the Power Distribution Board After PS1 is closed 24VAC illuminates the GAS PRESSURE indicator Use wiring diagram in Section 7 to troubleshoot Main Transformer T2 and or chopper has overheated Temperature switch TS1 will open when the transformer overheats Temperature switch TS2 will open when the chopper overheats If transformer T2 or chopper are excessively hot leave the 100 off with fans running for 1 hour to cool down If transformer and chopper are not hot take TS1 connector apart and check for continuity 51 and TS2 are normally closed Also check TS2 for continuity Check pins connectors and associated wiring from TS1 and TS2 to PL3 of power dis
81. ller et mettre la terre l quipement selon les instructions du pr sent manuel et conform ment aux codes lectriques locaux et nationaux Inspecter fr quemment le cordon d alimentation primaire pour s assurer qu il n est ni endommag ni fendu Remplacer imm diatement un cordon endommag Un c ble d nud peut tuer Inspecter et remplacer les c bles de la torche qui sont us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du coupage Laisser la pi ce couper en place ou sur la table de travail le c ble de retour connect lors du coupage Avant de v rifier de nettoyer ou de remplacer les pi ces de la torche couper l alimentation ou d brancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de s curit Avant d enlever le capot du syst me ou de la source de courant couper l alimentation lectrique Attendre ensuite 5 minutes pour que les condensateurs se d chargent Ne jamais faire fonctionner le syst me plasma sans que les capots de la source de courant ne soient en place Les raccords expos s de la source de courant sont extr mement dangereux Lors de l installation des connexions attacher tout d abord la prise de terre appropri e Chaque syst me plasma Hypertherm est concu pour tre utilis uniquement avec des torches Hypertherm sp cifiques Ne pas utiliser des torches inappropri es qui pourraient surchauffer et pr senter des risques pour la
82. ly on the metal or just off the metal Holding the torch firmly to the workpiece causes the nozzle to stick and makes smooth cutting difficult The arc transfers once the torch 15 within 3 mmof the workpiece To cut circles use a template or a radius cutter attachment Fig 4 7 Pull the torch through the cut Pulling it is easier than pushing it Hold the torch nozzle tip at a vertical position and watch the arc as it cuts along the line Fig 4 8 By lightly dragging the nozzle on the workpiece you can maintain a steady cut For straight line cuts use a Straight edge as a guide MAX1000 380 415V CE Instruction Manual OPERATION Figure 4 6 Starting a Cut Figure 4 7 Cutting a Circle MAX1000 380 415V CE Instruction Manual 4 13 OPERATION 4 14 SE EA oe Figure 4 8 Dragging the Torch MAX1000 380 415V CE Instruction Manual OPERATION Piercing with Hand Torch Note Consumable life will be shortened when piercing metal greater than 15 mm thick Hold the torch so that the nozzle is approximately 1 5 mm away from the workpiece before pressing the start button This method maximizes the life of the nozzle Hold the torch at an angle to the workpiece away from yourself then slowly roll it to a vertical position This is particularly important when cutting thicker material Make sure that the torch is pointed away from you and the people around you to avoid any danger from sparks and hot metal e Start
83. me care when working near the chopper modules The large electrolytic capacitor s blue cased cylinder s store large amounts of energy in the form of electric voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the chopper and the diode heatsinks Never discharge the capacitor s with a screwdriver or other implement explosion property damage and or personal injury will result Wait at least five minutes after turning the power supply off before touching the chopper or the capacitor s 1 Turn all power to the 100 OFF Disconnect terminals labeled 21 amp 22 from their mating receptacles to disable the high frequency transformer Terminals 21 22 are located near the high voltage transformer T3 See Fig 6 2 for location of T3 2 Remove large fuse F5 Check to see if fuse is open See Fig 6 3 for location of F5 3 Place the positive lead to the side of the bridge and the negative lead to the side of the bridge See Fig 5 3 Note that actual connection points are hidden by cap support bracket in Fig 5 3 4 Turn power to the MAX100 ON and start system up After the START command has been given check voltage The input to the chopper at these points should be about 280 VDC If the input is OK and F5 was blown replace the chopper module If there is no 280 VDC input check input to bridge for shorts Also check contactor CON2 connections and associated wiring to the contactor
84. ment listed at the front of this manual MAX1000 380 415V CE Instruction Manual 3 3 SETUP Gas Supply Requirements Two different sources of air can be used to supply the MAX1000 The setting should be flowing dynamic Cylinder Compressed Air The cylinder air supply must be clean dry and oil free The cylinder regulator must be used only for compressed air and must be capable of delivering at least 208 liters minute of air at 5 4 bar to 8 5 bar output pressure Caution Do not exceed 8 5 bar delivery pressure to the system Exceeding this pressure will cause shortened torch parts life Pressures in excess of 8 5 bar can also damage the pressure gauge that is located on top of the MAX100 filter If delivery pressure is greater than 8 5 bar turn regulator on top of the MAX100p filter counterclockwise to decrease the pressure to the system Shop Compressed Air Shop compressed air must be clean dry and oil free if used to supply the MAX100b Poor quality air reduces cut speeds produces poor cut quality and reduces parts life Shop air must be available at a minimum dynamic pressure of 5 4 bar and must be routed through the regulator and filter supplied with the system The regulator and filter are mounted at the top rear of the MAX100D power supply If the shop air is not clean refer to Appendix A for recommended filter specifications These filters are available from any industrial supplier Caution Do not exceed 8 5 bar del
85. minum Gouging Plasma Gas H35 shield Gas Current Setting 100 Amp Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas This gas combination is highly efficient yields long consumable life and leaves a superior work surface 020712 020669 020704 020750 020703 Shield Retaining Cap Nozzle Swirl Ring Electrode Plasma Gas Pressure H35 Torch to work Shield Arc Approx Plasma Gas Shield Gas Angle of Gas Torch to work Current Duty Motion H35 Inlet N Inlet inclination TEST RUN Pressure Distance Setting Cycle Travel Speed Delay Time Pressure Pressure Degrees bar bar bar mm amps 96 mm min sec bar bar 40 3 4 3 71 4 3 100 80 508 1 0 6 91 6 9 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa 4 54 MAX1000 380 415V CE Instruction Manual Section 5 MAINTENANCE In this section PAM e e ere ns _____ _ ____ ____________ __ 5 2 Routine d Eau 5 3 Torch and Torem Leads m 5 3 POW tele EE 5 3 CUENCO E ONIS 5 4 SC Ss geo 5 10 E ele 0 5 13 H 5 20 Chopper Module Test Procedure
86. mixture dross may form on the bottom of the cut if the N flow rate is too low When the Dual Gas Mixer is properly set the plasma gas pressure gauge on the gas console should read approximately 3 8 bar Align flowmeter scale with middle of flowmeter float ball when setting mix ratios Full scale 100 Flow rate at full scale 100 of the flow meter is about 35 4 liters minute 1 bar 2 6 895 KPa 4 32 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Stainless Steel Cutting Plasma Gas H35 Shield Gas Current Setting 100 Amp 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma H35 Shield Arc Arc Motion Gas Shield Gas Material Gas Torch to work Current Voltage Duty Delay H35 Inlet Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 9 3 4 5 21 4 3 100 155 80 1016 1 5 6 91 6 9 12 155 762 1 5 15 160 762 2 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 33 OPERATION 1000 Machine PAC160 Hand Torch Extended Consumables Stainless Steel Cutting Plasma Gas Shield Gas Air Current Setting 100 Amp This gas combination is used wh
87. national or local codes See also Mains Supply on page i in the front part of this manual for further power supply cable shielding recommendations To connect power cable to power supply see Power Cable Connection later in this section 3 6 MAX1000 380 415V CE Instruction Manual SETUP Power Supply Placement Place the power supply in an area that is free of excessive moisture is relatively clean and has proper ventilation so that air flow is not blocked in any way Cooling air is drawn in through the front panel grating and is exhausted through the rear of the unit by a cooling fan e Do not place any filter device over the air intake locations This reduces cooling efficiency and VOIDS THE WARRANTY Power Supply Electrical Connections 380 415V Linkboard Configurations The 380 415 volt power supply is shipped from the factory linked for 380 volt operation The links must be moved for 415 volt operation See Figure 3 1 WARNING Danger High Voltage Line voltage may be present on this linkboard Disconnect input power before servicing 1 Remove the left side cover of the power supply and locate the linkboard on the inside front wall 2 Ensure that the linkboard is configured for the proper line voltage 280 VOLTS 415 VOLTS o lo o E2 415 E E2 445 CONTROL 4 CONTROL u
88. nding upon Hypertherm PATENT INDEMNITY Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other product not supplied by 9 01 Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement and Hypertherm s obligation to indemnify shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim LIMITATION OF LIABILITY In no event shall Hypertherm be liable to any person or entity for any incidental consequential indirect or punitive damages including but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise and even if advised of the possibility of such damages LIABILITY CAP In no event shall Hypertherm s liability whether such liability is based on breach of contract to
89. ng as it is free of moisture oil and particulate matter contamination For better cut quality on metals such as stainless steel aluminum and other non ferrous materials use either nitrogen argon hydrogen Hypertherm recommends a mixture of 35 hydrogen and 65 argon or a mixture of argon hydrogen and nitrogen as the plasma gas Air nitrogen and carbon dioxide are the shield gases that can be used In addition to cutting the MAX100D can be used for plasma arc gouging Both mechanized and hand gouging capabilities are provided Air and H35 are the plasma gases for the gouging application When H35 is used as the plasma gas high gouging efficiency is achieved Air gouging has lower efficiency but is economical on gas consumption 2 2 MAX1000 380 415V CE Instruction Manual SPECIFICATIONS Product Specifications MAX100 Power Supply 100 is a constant current secondary converter chopper power supply providing continuously variable amperage from 30 Amps to 100 Amps It conforms to the following specifications Maximum OCV Up rm 280 VDC EEGEN 30 100 A Output Voltage U5 sm 90 150 VDC Duty Cycle Rating X 800 15 KW 40 104 Ambient Temperatures Duty Power supplies will operate between 14 and 104 F 10 and 440 C Power supplies operated an ambient temperature above 86 F 30 C may show some decrease in duty cycle Input Power Input Voltag
90. nt or incorrect at one or more of these points disconnect power and troubleshoot PCB2 fuses and associated pins connectors and wiring between power distribution board connector 1 and transformer secondary 1 See Figure 6 5 for location of 1 Also check main power fuses F1 and F2 located in Figure 6 1 and associated wiring and connections between T1 and L1 and L2 Repair and or replace defective component s if necessary 5 12 MAX1000 380 415V CE Instruction Manual Troubleshooting MAINTENANCE The troubleshooting section is presented by following normal operational sequence Shaded boxes with operator action correspond to action outlined in Sequence of Events Before troubleshooting for specific problems be sure that unit passes Initial Checks as outlined earlier in this section WARNING SHOCK HAZARD Always use caution when servicing a power supply when the covers are removed Dangerous voltages exist within the power supply which could cause injury or death If questions or problems arise during servicing call the nearest Hypertherm Technical Services Department listed at the front of this manual Push ON button PB1 Problem 1 The fans are not operating and the POWER ON indicator does not illuminate 2 POWER ON indicator illuminates but the fans are not operating MAX1000 380 415V CE Instruction Manual Possible Causes and Solutions 1 1 green ON PB1 pushbutton is defective Che
91. o ensure personal safety and to reduce emission of radio frequency interference e Connect the work table to a high quality earth ground within 6 m of the table A suitable ground consists of a solid copper rod of at least 13 mm diameter driven to a depth of at least 2 5 m into the earth below the permanent moisture level For more information refer to applicable national and local electrical codes MAX1000 380 415V CE Instruction Manual 3 5 SETUP Power Requirements Line Disconnect Switch Use a primary line disconnect switch for each power supply This disconnect switch allows you to turn the power supply off quickly in an emergency situation The switch should be located on a wall near the power supply and be easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses The line disconnect fuses should be sized according to the table below Time Lag Recommended Power Cord Gauge Size mm Input Rated Input type gG Voltage Current Fuse Size to 25 m 25 50 m 50 75 m 75 100 m 380 VAC 28 40 415 VAC 26 40 A Power Cables Power cables are supplied by the customer Cable sizes vary based on the distance of the receptacle from the main box see table above In Europe use a 4 conductor Harmonized type cord Final specification and installation of the power cord should be made by a licensed electrician and according to applicable
92. of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Cutting Cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered However metallic compo nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equip ment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reason
93. orch 75 PL Assy PAC160 100D QDisc PAC160E Ext Tch Main Body P S 6 x 3 4 PH Rnd S B Hand Heat Shield MAX1000 380 415V CE Instruction Manual PARTS LIST sch sch ech ech sch ech sch c c c sch sch sch sch sch 6 19 PARTS LIST MAX100D Lead Assemblies MAX100D Machine Torch Lead Assemblies 028555 Leads MAX100D Machine Torch 25 028556 Leads MAX100D Machine Torch 50 028557 Leads MAX100D Machine Torch 75 PAC160 160E Hand Torch Lead Assemblies 029730 Leads PAC160 160E Torch 25 029731 Leads PAC160 160E Torch 50 029732 Leads PAC160 160E Torch 75 6 20 MAX1000 380 415V CE Instruction Manual MAX100D Consumable Parts Kits Machine Torch Consumable Parts 028650 5 3 O O1 ND Number 120433 020193 020334 020846 020756 020705 120336 020706 058019 027055 027322 001067 Description Electrode PAC130 160 MAX100 D Air Electrode PAC130 160 MAX100 D N2 H35 Shield MAX80 100 C D 100A Shield Cap PAC160 100D 100A Cutting Shield Cap PAC160 MAX100D 60A Nozzle PAC160 MAX100D 100A Cut Nozzle MAX100D 60A Shield Swirl Ring PAC160 MAX100D Cut O Ring Viton 801 x 070 Lubricant Silicon 1 4 Oz Tube Wrench 3 8 Hex Electrode Box Gray Plastic Figure 6 10 Machine Torch Consumable Parts MAX1000 380 415V CE Instruction Manual PARTS LIST 5 e D OO A 6 21 PARTS LIST MAX100D Consumable Parts Kits cont PAC16
94. ore checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard CUTTING CAN PRODUCE TOXIC FUMES Cutting can produce toxic fumes and gases deplete oxygen and cause injury or death Keep the cutting area well ventilated or use approved air supplied respirator Do not cut in locations near degreasing cleaning or spraying operations The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation Do not cut metal coated or containing toxic materi als such as zinc galvanized lead cadmium or Hypertherm Plasma Systems beryllium unless the area is well ventilated and the operator wears an air supplied respirator The coatings and any metals containing these elements can produce toxic fumes when cut Never cut contain
95. ou des br lures graves La mise en fonctionnement du syst me plasma ferme un circuit lectrique entre la torche et la piece a couper La piece a couper et tout autre element en contact avec cette piece font partie du circuit electrique Ne jamais toucher le corps de la torche la piece a couper ou l eau de la table eau pendant le fonctionnement du syst me plasma Pr vention des chocs lectriques Tous les syst mes plasma Hypertherm utilisent des hautes tensions pour le coupage souvent de 200 400 V On doit prendre les pr cautions suivantes quand on utilise le syst me plasma Porter des bottes et des gants isolants et garder le corps et les v tements au sec Ne pas se tenir s asseoir ou se coucher sur une surface mouill e ni la toucher quand on utilise le syst me plasma o isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol o il s av re n cessaire de travailler dans ou pr s d un endroit humide proc der avec une extr me prudence Installer un sectionneur avec fusibles appropri s proximit de la source de courant Ce dispositif permet l op rateur d arr ter rapidement la source de courant en cas d urgence En cas d utilisation d une table eau s assurer que cette derni re est correctement mise la terre S CURIT LES CHOCS LECTRIQUES PEUVENT TRE FATALS Insta
96. ouging Chart data in Section 4 Plasma inlet pressure dynamic 6 8 bar Plasma outlet pressure dynamic 4 1 bar Percentage of mixture 0 to 100 Plasma flow 39 l min Dimensions and Weight Valle E 292 mm 3 1 mm 102 Weight 7 3 kg THC 2 Optional See 20 800200 for details and instructions for the THC 2 Torch Height Control system MAX1000 380 415V CE Instruction Manual 2 5 3 99 Section 3 SETUP In this section 3 2 Claims amp Technical e 3 2 E ed 3 3 Gas Supply Requirements E 3 4 6 Compressed EE 3 4 Compressed sd OE mU 3 4 Plasma Shield GAS ______ __ ___ ___ _ 6 _ _ _ _ _ 3 5 ad E Emm 3 5 EU 3 6 INE Disconnect 3 6 3 6 Power Supply PAC DO D OTRA 3 7 Power Supply Elecirical Connections E 3 7 380 415V Linkboard R Late tel 3 7 Power Cable CONA CION
97. pecific application Maintain all compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes NOISE CAN DAMAGE HEARING SAFETY d GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders accordance with applicable national or local codes Never use a cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve PACEMAKER AND HEARING AID OPERATION E Pacemaker and hearing aid operation can be affected Prolonged exposure to noise from cutting or gouging can damage hearing Use approved ear protection when using plasma by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a system e Warn others nearby about the noise hazard A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch ADDITIONAL SAFETY INFORMATION 1 ANSI Standard 4249 1 Safety in Welding an
98. peed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 6 3 4 5 91 4 3 100 140 80 2159 1 0 6 91 6 9 9 145 1270 1 0 12 145 1016 1 2 15 150 762 1 5 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 2 6 895 KPa 4 24 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Extended Consumables Mild Steel Cutting Plasma Gas Air Shield Gas Air Current Setting 100 Amp This gas combination gives good cut speed low dross levels and is very economical Some surface nitriding can occur The extended consumables allow the user greater accessibility for some cutting applications 020333 020846 020754 020706 120444 Deflector Retaining Cap Nozzle SwirlRing Electrode Plasma Gas Pressure Approx Plasma Air Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay Air Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 3 3 4 5 51 4 3 100 120 80 4572 0 5 6 9 6 9 6 120 3175 0 8 10 125 2286 1 0 12 135 1270 1 2 15 135 889 1 5 19 145 559 25 150 356 32 150 254 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 25 OPERATION
99. ravail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s 1a 4 5 6 02 Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Pr parer la zone de coupage afin de r duire la r verb ration et la transmission de la lumiere ultraviolette Peindre les murs et autres surfaces de couleur sombre pour r duire la r flexion de la lumi re Utiliser des crans et autres dispositifs de protection afin de prot ger les autres personnes de la lumi re et de la r verb ration Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux Alimentation S assurer que le fil de terre du cordon d alimentation est connect la terre dans le coffret du sectionneur S il est n cessaire de brancher le cordon d alimentation a la source de courant lors de l installation du syst me s assurer que le fil de terre est correctement branch Placer tout d abord le fil de terre du cordon d alimentation sur le plot de mise la terre puis placer les autres fils de terre par dessus Bien serrer l crou de retenue e S assurer que toutes les connexions
100. rch to work Shield Arc Approx Plasma Gas Shield Gas Angle of Gas Torch to work Current Duty Motion H35 Inlet N Inlet inclination TEST RUN Pressure Distance Setting Cycle Travel Speed Delay Time Pressure Pressure Degrees bar bar bar mm amps 96 mm min sec bar bar 40 3 4 3 71 4 3 100 80 508 1 0 6 91 6 9 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 2 6 895 KPa 4 52 MAX1000 380 415V CE Instruction Manual 1000 Machine PAC160E Hand Torch Aluminum Gouging Plasma Gas H35 Shield Gas Air Current Setting 100 Amp OPERATION Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas This gas combination is highly efficient and yields long consumable life 020712 Shield 020669 Retaining Cap 020704 Nozzle 020750 020703 Swirl Ring Electrode Plasma Gas Pressure H35 Torch to work Shield Arc Approx Angle of Gas Air Torch to work Current Duty Motion inclination TEST RUN Pressure Distance Setting Cycle Travel Speed Delay Time Degrees bar bar bar mm amps 96 mm min sec 40 3 4 3 71 4 3 100 80 508 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual Plasma Gas Shield Gas H35 Inlet Air Inlet Pressure Pressure bar bar 6 91 6 9 4 53 OPERATION 1000 Machine PAC160E Hand Torch Alu
101. rcing activity 4 Unscrew the shield Inspect the gas holes from the inside The holes should be clear of metal or other debris If the gas holes are blocked by debris try to open them by pushing a pin through each one from the outside of the shield to the inside If the shield is still good screw it back on to the retaining cap If it is damaged replace it with a new one 5 Inspect the O rings on the torch They should be lubricated and undamaged If they are dry lubricate them with a thin film of the lubricant provided in the spare parts kit If they are damaged replace them 6 Inspect the nozzle for damage or signs of wear The inside of the nozzle should be clean and bright with no deposits from the electrode You can clean the inside of the nozzle with steel wool but be sure to remove any remnants of the steel wool afterward The hole in the nozzle should not be worn or oval shaped If the nozzle is damaged replace it with a new one 7 Inspect the swirl ring It should be clean and the holes along the side should not be plugged If the swirl ring is damaged replace it with a new one 8 Remove the electrode with the wrench supplied in the spare parts kit Inspect it If the center of the electrode has a pit more than 1 mm deep replace it If the electrode is still good inspect its O ring it should be lubricated and undamaged If the O ring is dry lubricate it with a thin film of the lubricant supplied in the consumable parts ki
102. ressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar 1 5 3 4 5 91 4 3 100 125 80 5588 0 2 6 9 6 9 2 5 140 4318 0 5 4 145 1778 1 0 6 150 1397 1 0 9 150 1016 1 0 12 155 762 1 5 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual 4 31 OPERATION 1000 Machine PAC160 Hand Torch Stainless Steel Cutting Plasma Gas H35 N shield Gas Current Setting 100 Amp Dual Gas Mixer 059123 required This gas combination is used when good surface quality and long consumable life are desired 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Approx Dual Gas Gas Mix Shield Arc Arc Motion Mixer Shield Gas Material Gas Torch to work Current Voltage Duty Delay 5 amp Inlet N Inlet Thickness H35 Pressure Distance Setting Setting Cycle Travel Speed Time Pressures Pressure mm GAS1 GAS1 bar mm amps volts mm min sec bar bar 3 10 90 4 3 100 150 80 3429 0 5 6 9 6 9 4 20 80 150 2540 0 5 6 60 40 150 1651 1 0 9 80 20 155 1016 1 5 12 90 10 155 762 1 5 15 90 10 160 762 2 0 Note To get good cut quality dynamic flowing input pressure to Dual Gas Mixer should be equal 6 9 bar e When cutting stainless steel with the H35 N
103. ressure go below 20 psi 1 4 bar A pressure switch inside the power supply will shut down the system if the incoming pressure drops below 20 psi 1 4 bar 8 5 Go to step 10 9 At the Plasma Gas Console Panel choose CUTTING or GOUGING application and then with the PLASMA Gas Adjustment Valve set the plasma gas pressure for the particular metal you are cutting Refer to the Plasma Gas Pressure in TEST position in the Cut Gouging Charts later in this section Note Plasma gas pressure in RUN position is always higher than the set TEST pressure No adjustment is necessary for RUN position pt E MADE IN U S A 10 Using the SHIELD Gas Adjustment Valve on the MAX100D Control Panel set the shield gas pressure according to the Shield Gas Pressure in the Cut Gouging Charts later in this section av POWER et gt lt PRESSURE 30 100A OVER TEMPERATURE NORMAL MADE IN U S A 4 6 MAX1000 380 415V CE Instruction Manual OPERATION 11 After gases have been set switch to the RUN position Gases will stop flowing through the system C POWER ON gt lt PRESSURE 30 100A Q OVER TEMPERATURE SOEUR 12 Adjust the AMPS potentiometer to the desired current Refer to the Arc Current Setting in the Cut Gouging Charts later in this section av O POWER ON pos gt lt PRESSURE p O OVER TEMPERATURE 13 Place the PLATE
104. rkpiece are part of the electrical circuit Never touch the torch body workpiece or the water in a water table when the plasma system is operating Electric Shock Prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and boots and keep your body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process Bef
105. rt Number 059163 059164 059165 028752 120433 020334 020846 020705 020706 020713 058019 020245 028555 028910 002190 028556 028910 002190 028557 028910 002190 Description Designator MAX100D Intl Machine Torch Assy 25 MAX100D Intl Machine Torch Assy 50 MAX100D Intl Machine Torch Assy 75 MAX100D Intl Machine Torch Assy Electrode PAC130 160 MAX100 D Air Shield MAX80 100 C D 100A Shield Cap PAC160 100D 100A Cutting Nozzle PAC160 MAX100D 100A Cut Swirl Ring PAC160 MAX100D Cut MAX100D Machine Torch Main Body O Ring Viton 801 x 070 Torch Mntg Sleeve MAX100 Intl Leads MAX100D Machine Torch 25 Plug Assy PAC160 Mach Qdisc Boot 80A 100A QDisc PL Leads MAX100D Machine Torch 50 Plug Assy PAC160 Mach Qdisc Boot 80A 100A QDisc PL Leads MAX100D Machine Torch 75 Plug Assy PAC160 Mach Qdisc Boot 80 100 QDisc PL MAX1000 380 415V CE Instruction Manual PARTS LIST esch zech Il sesch esch ll sesch sesch PARTS LIST 6 16 Figure 6 8 PAC160 Hand Torch Assembly MAX1000 380 415V CE Instruction Manual 160 Hand Torch Assembly 5 3 O O1 ND gt CO O Part Number 059124 059125 059126 001214 001217 005094 120433 020335 020846 020705 020706 029730 028558 029731 028558 029732 028558 020761 075365 Description
106. rt strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim INSURANCE At all times you will have and maintain insurance in such quantities and types and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products NATIONAL AND LOCAL CODES National and Local codes governing plumbing and electrical installation shall take precedent over instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices TRANSFER OF RIGHTS You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a Successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Hypertherm Plasma Systems TABLE OF CONTENTS Electromagnetic Compatibility EMC grum ii Section l 1 1 Recognize Safety
107. ry from another page to the flowchart MAX1000 380 415V CE Instruction Manual MAINTENANCE Push ON button 1PB 120V relay CHA on PCB2 SC SS All interlocks Control Panel lights not Fans on satisfied illuminated LEDs on PCB4 not illuminated V6 activated Yes CR1 and CR2 on PCB2 close 24VAC relay CR3 on PCB2 closes POWER ON LT1 and GAS PRESSURE LT2 illuminate 120V to PCBA D5 on PCBA illuminates 12VDC activates CS1 on PCB3 Switch to TEST SW2 opens 1 120 volts activates V1 gas start V2 gas step and V5 pre flow post flow gas 2 Gases flow through system 5 6 MAX1000 380 415V CE Instruction Manual 5 5 MAINTENANCE Adjust flow rates THC 2 Set machine delay set voltage installed Switch to RUN SW2 closes 1 V1 V2 and V5 deactivated 2 Gases stop flowing Plate switch to NORMAL SW1 closes To CR1 opens pilot arc off page 5 7 5 6 MAX1000 380 415V CE Instruction Manual MAINTENANCE Adjust current R6 Press START button D6 on PCBA illuminates V1 V5 activated V4 momentarily Gases flow Chopper output activated 2 seconds of gas preflow MAX1000 380 415V CE Instruction Manual 5 7 MAINTENANCE Main Contactor CON2 closes power to 2 Pilot arc relay CR1 closes Power to high voltage transformer T3 High frequency sparking and pilo
108. s me 4 4 415 380 415 380 n N o O A2 A4 1 A2 A4 Al 415 580 N 415 580 AN ke B2 B4 B1 B2 B4 1 415 580 415 580 4 FM Aa o 02 C4 C1 C2 C4 C1 Q Q Q Q Figure 3 1 Dual Voltage 380 415 Volt Linkboard MAX1000 380 415V CE Instruction Manual 3 7 SETUP Power Cable Connection Power Cable to MAX100D Power Supply 1 Locate the EMI filter box on the rear of the power supply 2 Unscrew the filter cover screws and remove the cover for access to the input voltage connections 3 Insert the power cable through the strain relief 4 Connect leads L1 to U L2 to V and L3 to W terminals of the filter see Fig 3 2 Ensure that all connections are tight to avoid excessive heating 5 Connect the ground lead to rear terminal of filter marked GND Strain Relief Wis Power Cable L1 EMI Filter Box L2 L3 Figure 3 2 MAX100D Primary Power Connections There is line voltage at the filter even if the ON pushbutton on the 1000 power supply has not been pressed As a common safety practice ALWAYS verify that the line disconnect switch is in the OFF position before installing disconnecting or servicing in this area In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures 3 8 MAX1000 380 415V CE Instruction Manua
109. s replace CON2 Surge injection circuit is defective Check capacitor C3 and resistor R3 Replace as required Chopper defective or not functioning See Chopper Module Test Procedure later in this section to troubleshoot MAINTENANCE close to plate Problem 9 Arc not transferring to workpiece 10 The unit stops cutting during cut or cuts poorly Possible Causes and Solutions 9 1 9 2 9 3 9 4 9 5 10 1 10 2 10 3 10 4 The work clamp is not connected or it is broken Connect or repair the work clamp The PLATE switch is in the EXPANDED position Verify that PLATE is in the NORMAL position Torch Height Control receiving incorrect voltage for correct standoff distance for machine torches with THC Check the arc voltage setting for the type and thickness of metal you are cutting from the Cut Gouging Charts in Section 4 Transfer of arc not sensed by MAX100b See Arc Transfer Test Procedure later in this section Chopper defective or not functioning See Chopper Module Test Procedure later in this section There is insufficient gas pressure Check gas inlet pressure specifications under Cut Gouging Charts in Section 4 Check plasma and shield gas pressures in TEST and RUN positions as specified under Cut Gouging Charts in Section 4 Torch is getting insufficient current Check the arc current setting for the type and thickness of metal you are cutting from the Cut
110. s Changing the earthing arrangements should only be au thorized by a person who is competent to assess whether the changes will increase the risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC TC26 sec 94 and IEC TC26 108A CD Arc Welding Equipment Installation and Use Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications WARRANTY WARNING Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty WARNING You are responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment GENERAL Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship if Hypertherm is notified of a defect i with respect to the power supply within a period of two 2 years from the date of its delivery to you with the exception of G3 Series power supplies which shall be within a period of three 3 years from the date of delivery to you and ii w
111. sont bien serr es pour viter la surchauffe Hypertherm Systemes plasma SECURITE DES BOUTEILLES DE GAZ COMPRIME Ne jamais lubrifier les robinets des bouteilles ou les r gulateurs avec de l huile ou de la graisse Utiliser uniquement les bouteilles r gulateurs tuyaux et accessoires appropri s et concus pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz contenu dans chaque tuyau Se r f rer aux codes locaux ou nationaux en vigueur LE BRUIT PEUT PROVOQUER DES PROBLEMES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs Utiliser un casque de protection homologu lors de l utilisation du syst me plasma Pr venir les personnes aux alentours des risques encourus en cas d exposition au bruit UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELES Les tuyaux gel s peuvent tre endommag s ou clater si l on essaie de les d geler avec une torche plasma Hypertherm Systemes plasma S CURIT LES BOUTEILLES DE GAZ COMPRIME PEUVENT EXPLOSER EN CAS DE DOMMAGES Les bouteilles de gaz contiennent du gaz haute pression Si une bouteille est endommag e elle peut exploser Manipuler et utiliser les bouteilles de gaz comprim conform ment aux codes locaux ou nationaux N
112. switch is released or if no material remains under the arc Machine Torch The arc will extinguish if the STOP button is pressed or if no material remains under the arc Postflow of gas will continue for ten seconds after arc is extinguished 4 8 MAX1000 380 415V CE Instruction Manual OPERATION Operating Tips Changing Consumable Parts A WARNING Always unplug the power supply before inspecting or changing the torch parts The consumable parts in the torch need to be inspected periodically for signs of wear A good rule of thumb is to check the parts after every 100 starts pierces edge starts parts cut etc To remove the consumables Fig 4 5 1 Machine torch Bring the torch to the edge of the machine with the lifter raised to its highest point Hold your hand under the retaining cap the nozzle and swirl ring may fall when you remove the retaining cap Unscrew and remove the retaining cap If the nozzle and swirl ring remain inside the cap take them out and set them aside Hand torch Unscrew and remove the retaining cap The nozzle and swirl ring will come out set them aside 2 Inspect the retaining cap It should be undamaged 3 Check the shield for external signs of wear The shield should be clean and clear of metal debris Debris will cause arcing The gas holes along the edge of the shield should not be blocked with debris The center hole should not have any nicks or gouges and should show no signs of a
113. t If it is damaged replace it 4 10 MAX1000 380 415V CE Instruction Manual OPERATION 9 Inspect the inside of the torch body It should be clean and undamaged 10 Replace the electrode and tighten it with the wrench Do not overtighten it 11 Install the swirl ring on the electrode with the word front facing away from the torch body it won t fit in properly if it is installed in the wrong direction Place the nozzle on top of the swirl ring Be certain that the nozzle is inserted far enough into the torch so that the O ring is not visible and is not pinched 12 Replace the retaining cap and shield Make sure that it is tightened snugly if it is loose it can affect the cut or gouge quality Shield Retaining Cap Nozzle Swirl Electrode Torch Ring Figure 4 5 Consumable Parts MAX100n 380 415V CE Instruction Manual 4 11 Cutting with Hand Torch Set APPLICATION switch to CUTTING Do not fire the pilot arc into the air needlessly doing so causes a drastic reduction of the nozzle and electrode life Start cutting from the edge of the workpiece Fig 4 6 unless you must pierce For tips on piercing see Piercing later in this section When cutting make sure that the sparks are coming out of the bottom of the workpiece If they are spraying on top of the workpiece you are moving the torch too fast or you do not have sufficient power to fully penetrate the workpiece Hold the torch light
114. t arc initiated Move torch closer to plate Transfer of arc Yes Arc transfer sensed by CS1 D8 Xfer on PCBA illuminates D17 on PCBA illuminates Pilot arc relay CR1 opens pilot arc off Power off to high voltage transformer T3 high frequency off V3 on momentarily 7 V2 activated step gas on Machine motion delay THC installed Yes 1 D4 on PCB4 illuminates 2 Machine motion starts machine torch only 3 Cutting begins MAX1000 380 415V CE Instruction Manual MAINTENANCE From page 5 8 UP DOWN lights THC 2 installed Yes active on THC 2 No STOP pressed machine torch START button released hand torch Machine motion stops machine torch only Main contactor CON2 opens Chopper output deactivated D4 D6 D8 D17 on PCB4 off V1 V2 deactivated 10 seconds of gas post flow 1 V5 deactivated 2 Gases stop flowing 3 Cut sequence complete MAX1000 380 415V CE Instruction Manual 5 9 MAINTENANCE Initial Checks Before tracking down specific problems it is good practice to do a visual check and verify proper voltages are present at the power source transformer and power distribution board WARNING SHOCK HAZARD Always use caution when servicing a power supply when plugged in and the covers are removed Dangerous voltages exist within the power supply which could cause injury or death 1 Disconne
115. tection de la peau Zone de coupage ss 1a 4 Mise la masse EE 1a 4 Cable de retour Table de travail mI Imm mmm nnne rre rennes 1a 4 S curit des bouteilles de gaz COMMING TE LS 1a 5 Les bouteilles de gaz comprim peuvent exploser cas de dommages neee 1a 5 Le bruit peut provoquer des probl mes TC 1a 5 Pacemakers et proth ses 1a 5 Un arc plasma peut endommager les tuyaux 9 1a 5 Hypertherm Syst mes plasma 1a 1 2 12 01 SECURITE IDENTIFIER LES CONSIGNES A DE SECURITE Les symboles indiqu s dans cette section sont utilis s pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce soit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE SECURITE Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non
116. tended when this combination is used 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay inlet Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts mm min sec bar bar L 3 4 5 51 4 3 100 130 80 5588 0 2 6 9 6 9 2 5 140 4191 0 5 4 145 1778 0 8 6 150 1397 0 8 9 150 1016 1 0 12 155 762 1 2 15 155 559 19 155 559 25 165 279 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 6 895 KPa 4 30 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Stainless Steel Cutting Plasma Gas shield Gas CO Current Setting 100 Amp This gas combination is used when surface nitriding and surface oxidation of alloying elements is less important Electrode life is extended when using this gas combination 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma Nitrogen Shield Arc Arc Motion Gas Shield Gas Material Gas Torch to work Current Voltage Duty Delay Inlet CO Inlet Thickness TEST RUN P
117. the cut at an angle rather than in an upright position This method permits the hot metal to escape to one side rather than splashing back against the nozzle protecting the operator from the sparks and extending the torch nozzle life Fig 4 9 When the pierce is complete proceed with the cut 2 Rotate the torch to an upright position Figure 4 9 Piercing MAX1000 380 415V CE Instruction Manual 4 15 Gouging with Hand Torch The MAX100D can be used for gouging mild steel stainless steel or aluminum by using the gouging consumables See Cut Gouging Charts later in this section Use the following guidelines to assist you with the gouging process set APPLICATION switch to GOUGING When gouging it is absolutely necessary to wear full protection a welding helmet with at least a 6 glass welding gloves and a welding jacket The arc is fully exposed and will cause serious burns if skin is not covered An optional hand heat shield 020711 is available and should be used for hand gouging The hand heat shield guards the hand and the plastic torch handle from excessive heat Install the gouging consumables just as you would install the standard cutting consumables Adjust the gas pressures according to Cut Gouging Chart data Tilt the torch approximately 40 45 from the surface to be gouged and feed into the gouge Try not to allow the shield to come in contact with the plate since this can cause pr
118. the torch main body fitting and a 7 16 open end wrench to loosen the torch lead fitting 5 For the cap on gas lead use a 5 16 open end wrench to hold the torch main body fitting and a 3 8 open end wrench to loosen the torch lead fitting 6 Remove the torch main body Replacement Reverse the above steps to replace the new torch body onto the torch leads Handle Switch Holder Figure 5 4 PAC160 or PAC160E Hand Torch Assembly MAX1000 380 415V CE Instruction Manual 5 23 MAINTENANCE Disassembly of Machine Torch Refer to Figure 5 5 and follow the instructions below Removal 1 2 5 Unscrew the torch sleeve from the torch main body and slide it over the torch leads For the shield gas lead use a 3 8 open end wrench to hold the torch main body fitting and a 1 2 open end wrench to loosen the torch lead fitting For the plasma gas lead use a 5 16 open end wrench to hold the torch main body fitting and a 7 16 open end wrench to loosen the torch lead fitting For the cap on gas lead use 5 16 open end wrench to hold the torch main body fitting and a 3 8 open end wrench to loosen the torch lead fitting Remove the torch main body Replacement Reverse the above steps to replace the new torch body onto the torch leads Sleeve Leads Shield Shield Main Body Cap On Cap On Figure 5 5 Machine Torch Assembly 5 24 MAX1000 380 415V CE Instruction Manual MAINTENANCE
119. ting Plasma Gas H35 Shield Gas Air Current Setting 100 Amp This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives maximum thickness cutting capability good cut quality and weldability Electrode life is extended when this combination is used 020846 020705 020706 020193 020335 Retaining Cap Nozzle Swirl Ring Electrode Hand Shield 020334 Machine Shield Plasma Gas Pressure Approx Plasma H35 Shield Arc Arc Motion Gas Shield Gas Material Gas Air Torch to work Current Voltage Duty Delay H35 Inlet Air Inlet Thickness TEST RUN Pressure Distance Setting Setting Cycle Travel Speed Time Pressure Pressure mm bar bar bar mm amps volts 96 mm min sec bar bar 6 3 4 5 51 4 3 100 130 80 2413 0 8 6 91 6 9 9 130 1778 1 0 12 135 1397 1 2 15 135 1143 1 5 19 140 889 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure Piercing not recommended 1 bar 2 6 895 KPa 4 42 MAX1000 380 415V CE Instruction Manual OPERATION 1000 Machine PAC160 Hand Torch Aluminum Cutting Plasma Gas H35 Shield Gas Current Setting 100 Amp This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives maximum thickness cutting capability excellent cut quality and excellent weldability Electrode life is extended when this combination is used 020846 020705 020706 020193 0203
120. tion is very economical on gas 020712 020669 020745 020750 020744 Shield Retaining Cap Nozzle Swirl Ring Electrode Plasma Gas Pressure Torch to work ir Shield Arc Approx Angle of Gas Air Torch to work Current Duty Motion inclination TEST RUN Pressure Distance Setting Cycle Travel Speed Delay Time Degrees bar bar bar mm amps 96 mm min sec 40 3 4 3 71 4 1 5 100 80 381 1 0 T If RUN pressure is higher than recommended lower Plasma Gas Inlet Pressure 1 bar 6 895 KPa MAX1000 380 415V CE Instruction Manual OPERATION Plasma Gas Shield Gas Air Inlet Air Inlet Pressure Pressure bar bar 6 91 6 9 4 49 OPERATION 1000 Machine PAC160E Hand Torch Mild Steel Gouging Plasma Gas H35 Shield Gas Air Current Setting 100 Amp Hypertherm recommends a plasma gas mixture of 35 hydrogen and 65 argon This gas combination is highly efficient and yields long consumable life 020712 020669 020704 020750 020703 Shield Retaining Cap Nozzle Swirl Ring Electrode Plasma Gas Pressure Torch to work H35 Shield Arc Approx Plasma Gas Shield Gas Angle of Gas Air Torch to work Current Duty Motion H35 Inlet Air Inlet inclination TEST RUN Pressure Distance Setting Cycle Travel Speed Delay Time Pressure Pressure Degrees bar bar bar mm amps 96 mm min sec bar bar 40 3 4 3 71 4 3 100 80 508 1 0 6 91 6 9 T If RUN pressure is higher than recommended lower Plasm
121. tment Valve a C POWER ON EXPANDED GAS gt lt PRESSURE OVER TEMPERATURE 30 100A NORMAL MADE IN U S A SHIELD Gas Pressure Gauge Figure 4 2 1000 Control Panel MAX1000 380 415V CE Instruction Manual 4 3 Description of Controls and Indicators cont Dual Gas Mixer Figure 4 3 Note If you are not cutting with an H35 N mixture skip this page GAS1 Adjustment Valve Adjusts plasma flow for gas component 1 that is plugged into INLET1 GAS1 Flowmeter Indicates flow rate of gas component 1 that is sent to the Plasma Gas Console GAS1 Pressure Gauge Indicates plasma GAS inlet pressure GAS2 Adjustment Valve Adjusts plasma flow for gas component 2 that is plugged into INLET2 GAS2 Flowmeter Indicates flow rate of gas component 2 that is sent to the Plasma Gas Console GAS2 Pressure Gauge Indicates plasma GAS2 inlet pressure OUTLET Pressure Gauge Indicates plasma gas mixture outlet pressure Dual Gas Mixer Figure 4 3 Gas Mixer MAX1000 380 415V CE Instruction Manual OPERATION Operating Instructions WARNING Before operating this system you must read the Safety section of this manual thoroughly 1 Ensure that the work environment and your clothing meet the safety requirements outlined in the Safety section 2 Follow the system installation instructions in the Setup section Be sure that the correct consumable parts are in the MAX
122. tribution board PCB2 There are problems with the gas pressure and the transformer or chopper See 3 2 to 3 3 above MAX1000 380 415V CE Instruction Manual MAINTENANCE Switch to TEST Problem Possible Causes and Solutions 4 Gas flow is weak or not 4 1 TEST RUN switch no functioning flowing SW2 is open in the TEST position Make a continuity check 4 2 Plasma Gas or Shield Gas adjustment valves are closed Open plasma gas valve on plasma gas console and shield gas valve on front control panel 4 3 Valves V5 or V2 not getting 120VAC from Control Board PCBA Check for 120VAC at V5 and V2 after switch is in TEST position If V5 and or V2 are not getting 120VAC from PCBA check to see if PCBA is functioning Repair and or replace defective componeni s 4 4 Gas line s from valves to adjustment valves to torch are blocked or leaking Check hoses and repair or replace if necessary Adjust flow rates Problem Possible Causes and Solutions 5 Flow rates cannot be adjusted 5 1 Source gas pressures not on or set too low to specifications suggested in Cut Gouging charts 5 2 MAX1000 380 415V CE Instruction Manual Set incoming pressure to a minimum of 6 2 bar at 59 liters minute for plasma gas and 6 2 bar at 208 liters minute for shield gas Gas line s from valves to adjustment valves to torch are blocked or leaking Check hoses and repair or replace if necessary MAINTENANCE Problem 6 Gas continues to flo
123. ust be emptied and properly cleaned first Ventilate potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosion Prevention Do not use the plasma system if explosive dust or vapors may be present Do not cut pressurized cylinders pipes or any closed container Do not cut containers that have held combustible materials WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma e When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations e Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation Refer to the Appendix section of this manual for aeration manifold details WARNING Hydrogen Detonation with Aluminum Cutting Hypertherm Plasma Systems SAFETY ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause a fatal shock or severe burn e Operating the plasma system completes electrical circuit between the torch and the workpiece The workpiece and anything touching the wo
124. w Problem 7 There is no high frequency and no pilot arc Possible Causes and Solutions 6 1 6 2 6 3 TEST RUN switch not functioning SW2 is closed in RUN position Make a continuity check Solenoid valves V2 and V5 not getting OVAC from Control Board PCB4 Disconnect terminals to V2 and V5 and check for OVAC from Control Board PCB4 after SW2 is in the RUN position If there is 120VAC replace Control Board PCB4 Solenoid valves V2 and V5 not functioning If valves are getting OVAC from verify that valves are opening correctly If not replace them Press START button Possible Causes and Solutions 7 15 7 2 7 7 4 There is spark between the spark gap electrodes Clean with emery cloth align and or regap 5 mm per gap the electrodes if necessary Ensure that the electrode surfaces between the gaps are flat If surfaces are rounded replace and regap High voltage transformer T3 is overheating Check T3 for leaking or overheating Replace if necessary High voltage transformer T3 not getting 120VAC from Control Board PCB4 Check pins connectors and associated wiring from T3 to PCBA T3 or capacitor pair C6 C7 in spark gap assembly defective Shut down system and remove capacitors C6 and C7 Hestart system and see if a faint spark is now observed across the gaps If a spark is not observed at the gaps replace T3 If there is a spark replace capacitor pair C6

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