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MAX200 Service Manual - Rapid Welding and Industrial Supplies Ltd

1. SHEET SHEET G 4 D3 U 2 D2 SHEET A 2 B4 H SHEET LS1 Ps2 PS1 TS2 FS1 PS3 LTI 4 B3 x OX f ON je SHEET z z 4 005 2 J S Al 9 N 24 NL rl p v dd 4b 4 gt gt CA 24vVAC O Le alt alt 4 at at aj at at E E I i T I I I I El I MBVAC 54 1 5 Es Paz Es Es uds ds ds ds uds ds Es Es 240 VAC 2 x e al ew ol ely a 2 w hae al o o to D wo to
2. SHEET P 4 wo w o aja E F SHEET alz 2 B1 SHEET N e 4 B3 N h K ojo 3 B1 aja NO d 52 M T SHEET 5 2 NI 8 S 5 SHEET lol lel els ojo 5 B4 e WHT g Flo Ela a E x ds lt lt 1 Sic sla EX EIE 67 RED aa ala x u S 68 RED BLK 3 2aia alea anna u 69 RED o Lun wo ati E aL Z r gt gt gt gt gt a gt gt gt gt gt S gt ms 70 RED BLK 71 BLU r s n d I IST alice T ol Totale ps ELIT T TRE 1 72 ET a le a e 73 BLU RIL RL Si Si S Gy BiB S SS S SS SI Bye m DID S 8121921 21546100101 181891091819 184 E 1 Li Li Li LI Li LI Lil b 1 Li m 4 3 x 4 4 4 External zu T T E 1 1 e xpi I I Interlock Machine Motion a l Machine L uf a 1 ADVVANCED DELAY START 24 VAC AUX STOF HIGH VOLTAGE _ _ _ _ _ 5 I I L laa Machine L _ _ _ _ Auxilliary Trandformer I I STOP 120 7 es Machine ___
3. CO1 vi gt PS1 60psi N PLASMA V5 GAS 25 D e e z v9 w CO3 Q PG1 N 26psi SHIELD V2 PSA V5 GAS e SHIELD PG2 PS3 GAS 4psi V4 PLASMA MT GAS TORCH vi HZ PS2 TOpsi v2 CAP CAP NOZZLE GAS FLOW DIAGRAM va k MAX200 TIMING CHART va MAIN CONTACTOR vi PLASMA PRE POST FLOW SOLENOID VALVE v2 SHIELD GAS SOLENOID v3 PLASMA STEP GAS SOLENOID VALVE PBI START PS3 PS4 STOP v4 CAP ON SENSE SOLENOID VALVE v9 PLASMA CHARGING VALVE PBI POWER ON SWITCH TIMING CHART MAX200 PB2 POWER OFF SWITCH PS3 PLASMA GAS OUTLET PRESSURE SWITCH N O SWITCH THAT CLOSES WHEN THE PLASMA GAS PRESSURE EXCEEDS 3 psi PS4 QUICK CHARGE PRESSURE SWITCH N C SWITCH THAT OPENS WHEN PLASMA GAS REACHES 26 psi START PLASMA START SIGNAL FROM CNC STOP PLASMA STOP SIGNAL FROM CNC XFER ARC TRANSFER POST FLOW 1 SECOND GAS FLOW AT END OF CYCLE NOTES 1 IN TEST MODE V1 V2 AND V3 ARE THE ONLY VALVES THAT ARE A ACTIVE MATERIAL DRAWN BY DATE 2 WHEN V1 BECOMES ACTIVE AFTER START 10 TO 15 psi WILL BE ee U Jano es e mos REGISTERED AT PON peu tmenin 3 THE HV TRANSFORMER IS ACTIVATED 2 SECONDS AFTER THE PLASMA oe Box 5010 Hanover NH 03755 5010 603 643 3441 START SIGNAL IT WILL STAY ACTIVE FOR 5 SECONDS OR UNTIL THE U
4. TORCH gue m m JP9 WORK CHOPPER 01 JP6 3 32 MAX200 Service Manual 3 00 MAINTENANCE Test Procedures Cont Voltage Divider Test Procedure Machine Torch Systems The voltage between the electrode and the workpiece during arc transfer is divided down by 100 in the MAX200 and sent to the THC board PCB9 Adjustments to the torch height are made by the THC board so that consistent distance can be maintained between the torch and the workpiece In order to see if the voltage dividing is being done properly perform the following procedure 1 Press the OFF button on the MAX200 Power Supply 2 Place a DC voltmeter between the positive and negative terminals on the I O PC board 5 See Figure 4 12 for location of PCB5 The positive and negative terminals have cables marked 45 and 42 attached to them 3 Press the ON button of the MAX200 4 After all STATUS indicators light press START 5 When the arc transfers record the voltage off of the meter 6 Remove voltmeter from the positive and negative terminals 7 Place voltmeter across pins 3 amp 4 of REC5 on PCBY See Figure 3 15 for location of REC5 on 8 Depress the START button again to start a second cut 9 When the arc is transferred
5. 4 29 Recommended Spare 4 30 MAX200 Rev 1 Hand Torch Consumables 4 33 Hand Torch Consumable Parts Kit usines 4 33 MAX200 Rev 1 Hand Torch Assemblies iii 4 35 Hand Torch Lead Assembly 4 36 Hand Torch Lead Extensions indt u Lu Mads 4 37 MAX200 Machine Torch Const mabl6eS 5 UI ertt ern eret eh o x tenant d ege au 4 39 Machine Torch Consumable Parts Kits uci ertet ERIS saa Qk RE dad 4 40 MAX200 Machine Torch Assembly e ieee 4 41 Machine Torchibead ducenti ote am 4 44 Switch Remote SR CONTON unas eei crac 4 51 Digital Remote DR Control 4 53 Programmable Remote PR Control iii 4 55 Inductive IHS Control Module 4 57 MAX200 Power Supply Internal 1 iii 4 58 Machine and Remote nsn a 4 59 to 4 63 Inductive IHS Torch Mounting nennen nnns nennen nen 4 64 interconnecting Leads for Inductive IHS sienne 4 67 IMS Fittings 4 69 Hold Ca
6. gq GIS UOWWWOD uBISH UOWWOD HI UOWWOD Hes euBis dis euis 1uBi H oiny eubis pes euise d nig NOILONN4 40709 Ajddns samog 12 941800 502800 9ZIS 2 22 602800 5 681800 Ajddns ZXL 6 cc 2480 90170 pus 8JON 2227 OVAOcCL 10H OVAOCL 98 XNY OWA 10H XnV p dis C e eyeq dos eubis 1uBieH UOWLUOD 5 UOWWOD pes leUBIS ISA pug pueba7 10 1 193205 981800 9215 91 21 945 161800 5 261800 ys 4 61 MAX200 Service Manual PARTS LIST 9 A reuBia Aiddns lqeO 2 98 ui 916 00 818620 sured 958 4 SZZ S ZO 9 092 18850 19 Y 002 156620 091 055520 L 8 y ser 671550 OV w 001 655550 OV ui gz u 9 875550 HA d PIOUS OV 155550 dos OV 97 y sz 975550 HIS PSH PISIUS 5 dos 3Ig u45 pjerus EN Kay
7. 20101010 L1 O PE L2 L3 GND Figurea 3 Power Cable Connections to TB1 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 Line Disconnect Switch Connecting the power cable to the line disconnect switch must conform to national or local electrical codes This work should be performed only by qualified licensed personnel See Power Requirements and Line Disconnect Switch on page 3 6 in IM 87 and page 3 8 in IM 98 b 4 MAX200 Service Manual APPENDIX B ELECTROMAGNETIC COMPABILITY EMC EMI Filter Parts List Part Item Number Description Qty 001557 Cover 200 2000 CE Electronic Filter Enclosure 1 1 001558 Enclosure 200 2000 CE Electronic Filter 1 2 001559 Cover 200 2000 CE Top 1 3 008489 Bushing 1 97 ID X 2 5 Hole Black Snap 1 4 008610 Strain Relief 1 1 2NPT 1 5ID 2 Screw 1 5 029316 1 Input Power SA 200 2000 4X00 HD 1 6 109036 Filter 0A 440VAC 3PH 2 Stage Electronic 1 7 109040 Filter Mounting Bracket for 109036 1 Nounv souxauv Vy i n Y wounvo V Figure a 4 MAX200 EMI Filter Parts MAX200 Service Manual b 5 APPENDIX B ELECTROMAGNETIC COMPABILITY EMC b 6 MAX200 Service Manual Appendix C DIAGRAMS In this section
8. 200 Service Manual PAC200E Gouging Torch Assembly Part 5 3 073188 002244 001440 001217 020908 020913 044027 027254 075365 029865 020933 020607 020934 020882 020891 Y O Number Description PAC200E Gouging Torch Assembly Safety Trigger PAC120 200T E Tch Handle PAC200T E 65 Deg Hand Torch Boot PAC200T E Torch PAC200E Torch Main Body Water Tube PAC200E Electd Cool O Ring Buna 1 301X 070 Spring Trigger PAC120 200T E Torch P S 6X3 4 PH Pan Leads SA PAC200T E Torch PS 25 ft Electrode PAC200E Swirl Ring MAX200 Air N2 H35 Nozzle PAC200E N2 Shield Cap PAC200E Torch Shield PAC200E Torch PAC200E Gouging Torch Assembly 25 Ft Part 5 3 073111 002244 001440 001217 020908 020913 044027 027254 075365 029865 020933 020607 020934 020882 020891 Y O See Figure 4 37 MAX200 Service Manual Number Description PAC200E Gouging Torch Assembly 25 ft Safety Trigger PAC120 200T E Tch Handle PAC200T E 65 Deg Hand Torch Boot PAC200T E Torch PAC200E Torch Main Body Water Tube PAC200E Electd Cool O Ring Buna 1 301X 070 Spring Trigger PAC120 200T E Torch P S 6X3 4 PH Pan Leads SA PAC200T E Torch PS 25 ft Electrode PAC200E Swirl Ring MAX200 Air N2 H35 Nozzle PAC200E N2 Shield Cap PAC200E Torch Shield PAC200E Torch PARTS LIST O 8 ES ANDA
9. agua para eliminar la posibilidad de la detonaci n del No corte dep sitos que hayan contenido materiales Consulta la sa ion dal apendice as eee combustibles manual para conocer detalles acerca del m ltiple de aireaci n 1b 2 Hypertherm Sistemas plasma 11 98 SEGURIDAD EN EL CHOQUE EL CTRICO PUEDE PROVOCAR LA MUERTE El contacto directo con piezas el ctricas conectadas puede provocar un electrochoque fatal o quemaduras graves Al hacer funcionar el sistema de plasma se completa un circuito el ctrico entre la antorcha y la pieza cortar La pieza a cortar es una parte del circuito el ctrico como tambi n cualquier cosa que se encuentre en contacto con ella Nunca toque el cuerpo de la antorcha la pieza a cortar o el agua en una mesa de agua cuando el sistema de plasma se encuentre en funcionamiento Prevenci n ante el electrochoque Todos los sistemas por plasma de Hypertherm usan alto voltaje en el proceso de corte son comunes los voltajes CD de 200 a 400 Tome las siguientes precauciones cuando se utiliza el equipo de plasma Use guantes y botas aislantes y mantenga el cuerpo y la ropa secos No se siente se pare o se ponga sobre cualquier super ficie h meda cuando est trabajando con el equipo A slese el ctricamente de la pieza a cortar y de la tierra utilizando alfombrillas o cubiertas de aislamiento secas lo suficientemente grandes como para impedir todo contacto f sico
10. 5 Circuit Descriptions uuu ARR MN isti it m E n ass Theory of Operation High Frequency ttr rs a uu k Circuit Description Seduericeof EOS tico m sa LL Nested eM Initial y sasha aaa da dic Troubl shooting Test Aia Arc transfer Test EUER IIR REX SEHE mn ins Chopper Module Test Voltage Divider Test Procedure Machine Torch Systems in MAX200 Rev 1 90 Hand Torch Removal and Replacement ire ne A daa MAX200 Rev 1 90 Hand Torch Lead Set and Individual Leads Removal Replacement Torch Set Q u i Qa saa lere EE vi MAX200 Service Manual 14 TABLE OF CONTENTS select 3 36 Individual Torch ERE 3 36 morir PH 3 36 cereum L 3 38 MAX200 Rev 1 90 Hand Torch Lead Set Assemblies sise 3 39 MAX200 Rev 1 Machine Torch Removal and Replacement
11. MAX200 Plasma Arc Cutting System Service Manual 801620 Revision 15 EE HA k Bd DA The world leader in plasma cutting technology C EN50199 EN50192 EN60974 1 MAX200 Plasma Arc Cutting System Service Manual P N 801620 for Serial Numbers beginning with 200 003200 Revision 15 April 2008 Hypertherm Inc Hanover NH USA www hypertherm com 2008 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 technical service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email Hypertherm Automation 5 Technology Drive Suite 300 West Lebanon NH 03784 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm 5 Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 Technical Ser
12. Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar rea de corte Prepare el rea de corte para reducir la reflexi n y la transmisi n de la luz ultravioleta Pinte las paredes y dem s superficies con colores oscuros para reducir la reflexi n Utilice pantallas o barreras protectoras para proteger a los dem s de los destellos Advierta a los dem s que no debe mirarse el arco Utilice carteles o letreros SEGURIDAD DE TOMA A TIERRA Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa de trabajo la mesa de trabajo a una buena toma de tierra de conformidad con los c digos el ctricos nacionales o locales apropiados Potencia primaria de entrada Asegurese de que el alambre de toma a tierra del cord n de alimentaci n est conectado al terminal de tierra en la caja del interruptor de corriente Si la instalaci n del sistema de plasma supone la conexi n del cord n de alimentaci n primaria a la fuente de energ a aseg rese de conectar correctamente el alambre de toma a tierra del cord n de alimentaci n primaria Coloque en primer lugar el alambre de toma a tierra del cord n de alimentaci n primaria en el esp rrago
13. Verify that plasma gas supply is set to specifications in Cut Chart Tables in Section 4 of MAX200 Instruction Manual 800870 or 800980 Verify that all Plasma Gas connections are secure and that there are no leaks in the hosing See Figure 4 10 for location of plasma gas supply bulkhead MAX200 Service Manual 3 19 1 97 MAINTENANCE Problem 3f COOLANT TEMP LED illuminated 3g 3 20 1 97 STATUS 0 tRansrormer COOLANT LEVEL gt e sueco gt PLASMA GAS O COOLANT TEMP gt COOLANT FLOW LED illuminated STATUS O inTeRLock 0 tRansrormer COOLANT LEVEL SHIELD GAS CAP gt PLASMA GAS O cooLanT TEMP gt Q cooranT Possible Causes and Solutions 3e 2 Pressure switch PS1 not functioning This switch is normally open and closes when plasma gas pressure is at or above 60 psi After PS1 is closed the 12 VDC extinguishes the PLASMA GAS LED Using the 013 2 179 wiring diagram check pins connectors and associated wiring from RECS on the Power Distribution Board to PS1 Repair and or replace defective component s if necessary 3f 1 Coolant too hot This LED will extinguish when temperature switch TS2 senses that the temperature of coolant in the coolant reservoir is under 160 F See Figure 4 13 for location of TS2 and the cool
14. 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 Hypertherm Technical Services Department at 1 800 643 0030 Problem 1 green POWER pushbutton switch PB1 is pressed but the fans are not operating and the green POWER ON indicator does not illuminate 2 The green POWER ON pushbutton switch PB1 is pressed the POWER ON indicator illuminates but the fans are not running 3 16 1 97 Possible Causes and Solutions 1 1 1 2 1 3 2 1 2 2 2 3 The green POWER PB1 pushbutton is defective Check that switch is operating correctly and that good contact is being made The POWER ON switch is normally open The red POWER OFF O PB2 pushbutton is defective Check that switch is operating correctly and that good contact is being made The POWER OFF switch is normally closed Associated wiring not making good contact Check wiring and repair or replace if necessary CR2 on the Power Distribution Board is defective Check switches when POWER ON pushbutton is pressed See Figure 3 2 for location of CR2 If CR2 is defective desolder CR2 and replace PL31 and REC31 located near the fans see Figure 4 1 for location of fans are not seated together securely and or not getting 120VAC from Power Dist
15. CI iem 028496 Lead Extensions Hand Torch 028497 Lead Extensions Hand Torch For more detailed information on hand torch lead extensions and their installation please refer to instruction manual IM 140 P N 801400 MAX200 Service Manual 4 37 1 99 PARTS LIST 4 38 020566 020618 020424 020448 020688 020485 Shield Retaining Cap 020423 Nozzle Swirl Ring Electrode 020605 020604 020616 020617 a 220021 020415 120547 020608 020611 020689 I I I 020607 020613 1 1 1 020615 Figure 4 17 200 Machine Torch Consumable Parts MAX200 Service Manual PARTS LIST MAX200 Machine Torch Consumables See Figure 4 17 40 200 gouging O Air 200 100 H35 N 200 100 Part Numbers Plasma Gas Nozzle Type Retaining Shield Gas Amps Cap Electrode Air Air 200 100 020424 020423 020608 020607 020448 020423 020611 020607 020688 020423 020689 020613 020485 020423 020615 020607 020424 020423 020605 020604 020448 020423 020616 020617 020602 020423 020608 020607 020448 020423 020611 020607 200 gouging Air Air 200 100 O Air 200 100 N A r MAX200 Service Manual 020485 020423 020615 020607 020424 020423 020608 020607 020424 020423 020608 020607 Consumables Used with MAX200 Water Muffler 020566 020423 020608 020607 020618 020423 020611 020607 020566 020423 020605 020604 020618 020423 020616 020617 020566 02
16. Changed Page Description IM162 Revision 13 9 99 SUBJECT li Added plumbing electrical code statement to warranty page 6 Deleted section 6 Standards included in section 1 Page 1 Changed Page Description IM162 Revision 12 1 99 Cover Title Page Reduced General description text N IN IN N Added 073036 amp 073039 power suppl m LI LI i 1 Removed Rev 1 reference to machine torch Removed Rev 1 reference to machine torch I LI 4 28 29 4 81 4 82 33 4 35 4 36 37 4 88 thru 40 4 41 41a 41b Added new machine torch and optional torches Added new HIS for the optional 2 torch 4 70 thru 72 4 74 4 75 m IO Ple 2 4 4 78 Diagrams aja LI 1 t A N olo o m w Page 1 Changed Page Description IM162 Revision 11 8 98 ew Revision ew Revision evise warning evise Figure 3 1 ew power distribution board PCB6 elete Figure 3 14 data included in Diagrams evise Figure 4 13 New Solenoid valve subassembl ew Solenoid valve subassembl evise Figure 4 34 to include 020917 shield ew Coolant MSDS 13179 Add sheet 9 dd 029313 Coolant Diagram T N IN oo gt Page 1 Changed Page Description IM162 Rev 9 to 10 5 98 A A P napa fa fe qa fa f
17. NN c add dd 4 23 PARTS LIST 3 amp k O SS NN Se 5 a A p 1 S o Figure 4 11 Power Supply Spark Gap Assembly 4 24 MAX200 Service Manual 15 PARTS LIST Spark Gap Assembly MAX200 Power Supply Part Item Number Description Designator Qty 009350 Spark Gap Assembly SG1 1 1 004061 Electrode Spark Gap 1 8 X 1 6 3 2 004140 Block Spark Gap 1 3 004141 Tungsten Mount End 2 4 004142 Tungsten Mount Center 1 5 004143 Plate Capacitor Mtg 1 6 004144 Bar Capacitor Mtg 1 7 009280 022uF 15KV C7 1 8 009280 022uF 15KV C8 1 9 075034 M S 8 32 X 1 4 SL Rnd Brs 4 10 075036 M S 8 32 X 3 4 SL Rnd Brs 3 11 075147 Hexnut 8 32 Brs 3 12 075152 Hexnut 5 16 18 Finish Brs 1 13 075191 Lkwshr 8 Splitlock Brz 7 14 075193 Lkwshr 5 16 Splitlock Brz 1 15 075213 Flwshr 8 202 436 037 Brs 3 Two of three electrodes shown MAX200 Service Manual 4 25 PARTS LIST Note Refer to page 4 58 for the list of internal hose to from terminations as indicated by the letters above 4 26 3 96 Figure 4 12 Power Supply High Frequency amp I O PCB Assembly MAX200 Service Manual High Frequency and I O PCB MAX200 Power Supply Part Item Number 029312 1 004136 2 004259 3 004311 4 004312 5 004313 6 004314 7 015131 8 015132 9 015133 10 015157 11 015532 12 041152 13 075153 14 075156 15 075194 16 075217 17
18. Y ATE er Limi 041065 149 GRN 7271 GRN m Lec 1 Upp ake i A THC Motherboard PCB 1 GATTBEASS 150 BLK isl BLK LES eine ee ha ee 041150 PCB 041186 SCH 119 1 Tr er I I m bg lon 041294 Assy 152 RED i RED a ni L ap 5 Complete ptional 041294 SCH i IQ aisi 151 BLK J iai BLK Ja Feel a al 2 1 4 181 ill 1 153 WHT 14 WHT 181 p 120 1 16 i 154 BLK HJ BLK Uy dal ess Initial I 171 Height LX Toe SEX U og al Sensor BILL Lec ELI LE I n D O qa D 4 1 9 023859 8X1 A MATERIAL DRAWN BY DATE J r BC 5 9 96 M4oomnacnbilbacmes ae DUG 600090000 APP BY DATE Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES TOLERANCES ARE ELEC GAS SCHEM MAX200 V y THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 4 005 ITEM NO DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 5 PR 013179 013 2 179 013179B5 PURPOSES WITHOUT PERMISSION PART MUST BE FREE SHARP EDGES BREAK SHARP EDGES IF SCALE MODEL SHEET FROM HYPERTHEBM ING NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 5 OF 9 4 3 2 1
19. Y O O1 Part Number 073187 002244 001440 001217 020907 020963 044027 027254 075365 029865 220021 020607 020608 020915 020918 Description PAC200T 65 Cutting Torch Assembly Safety Trigger PAC120 200T E Tch Handle PAC200T E 65 Deg Hand Torch Boot PAC200T E Torch PAC200T 65 Torch Main Body Water Tube PAC200T Electd Cool O Ring Buna 1 301X 070 Spring Trigger PAC120 200T E Torch P S 6X3 4 PH Pan Leads SA PAC200T E Torch PS 25 ft Electrode MAX200 Air Oxygen Swirl Ring MAX200 Air N2 H35 Nozzle MAX200 086 200A Air N2 H35 Shield Cap PAC200T Cutting Torch Shield PAC200T 200A PAC200T 65 Cutting Torch Assembly 25 Ft 5 3 N Y O O1 See Figure 4 36 4 78 Part Number 073110 002244 001440 001217 020907 020963 044027 027254 075365 029865 220021 020607 020608 020915 020918 Description PAC200T 65 Cutting Torch Assembly 25 ft Safety Trigger PAC120 200T E Tch Handle PAC200T E 65 Deg Hand Torch Boot PAC200T E Torch PAC200T 65 Torch Main Body Water Tube PAC200T Electd Cool O Ring Buna 1 301X 070 Spring Trigger PAC120 200T E Torch P S 6X3 4 PH Pan Leads SA PAC200T E Torch PS 25 ft Electrode MAX200 Air Oxygen Swirl Ring MAX200 Air N2 H35 Nozzle MAX200 086 200A Air N2 H35 Shield Cap PAC200T Cutting Torch Shield PAC200T 200A A O ANDA 8 O ANDA 8
20. 4 20 MAX200 Service Manual PARTS LIST Chopper SA Front Wall Inside Right MAX200 Power Supply Part Item Number Description Designator Qty 128789 Kit chopper 15KW CH2 1 1 005199 Switch temperature 82 C TSW1 1 e e 14 o C C g COSE SC E 0 i Jn xP hoyo Fe i RS Cone Am 4 s 9 Li a gt e Figure 4 9 Power Supply Chopper SA Front Wall Inside Right MAX200 Service Manual 4 21 PARTS LIST Xs 4 v2 6 O For detail of Ra High Frequency see page 4 26 For detail of Spark Gap SA see page 4 24 Note Refer to page 4 58 for the list of internal hose to from terminations as indicated by the letters above Figure 4 10 Power Supply Rear Wall Inside 4 22 MAX200 Service Manual 3 96 Rear Wall Inside MAX200 Power Supply Part Item Number Description Designator 029314 Plasma G
21. 5 Disconnect the torch coolant supply hose blue w green band from the bulkhead adapter 6 Disconnect the torch coolant return hose blue w red band from the bulkhead adapter 7 Disconnect the torch from the torch lead as described in the Removal and Replacement of Hand Torch procedure on page 3 34 Replacement 1 Connect the torch lead to the power supply by reversing directions in steps 1 6 of the above Removal procedure 2 Connect the torch lead to the torch by referring to the Replacement of Hand Torch procedure on page 3 34 Individual Torch Leads To remove and replace individual leads from the torch lead set perform the following procedure and see Figure 3 5 Removal 1 Disconnect the torch lead from the power supply as described above under Removal 2 Remove the torch from the torch lead as described in the Removal and Replacement of Hand Torch procedure on page 3 34 3 Lay the torch lead on the floor and stretch it out completely 4 Cut away the heat shrink 8 and any tape underneath at both ends of the torch lead 3 36 MAX200 Service Manual MAINTENANCE Pilot Shield Gas TB2 Hose Blue TORCH COOLANT SUPPLY HOSE BLUE W GREEN BAND 3 e ae 2 A C T COIL Torch Start ADAPTER Switch Leads Plasma Gas Hose Red Work Cable Torch Coolant Return Hose 4 Blue w Red Band Ke Ses Se w 2 b 1 AM u Figure 3 4 200 Rev 1 90 Hand Torch Lead Set C
22. 63 771 i i Y E sl E 4 480 VAC ey Tj 415 VAC l joo C4 1 i ul 1 4 si I I I Ur Rn 1 500VAC 6 ATA I I I F til 1 F L1 Fl De F A 1 12 EA E los 1 L 220 T2 i 11 T2 js T2 240 DP I bs 4 380 l 400 480 L 415 VAC EE ET4 500 VAC x ese IT A A ey ee Pe SY ee SE 1 1 1 1 in lii en de AP ot am ipt ie t J MATERIAL DRAWN BY CHECKED BY BC 5 9 96 g g e Lo EH 000 CU tonto 000 APP BY Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES ELE A HEM MAX2 THIS DRAWING AND ALL INFORMATION ta C G s Sc 00 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 005 ITEM NO DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 31 64 FOR MANUFACTURING OR FABRICATION ANGULAR 3 55 013179 013 2 179 013179B8 PURPOSES WITHOUT PERMISION SHARP EDGES BREAK SHARP EDGES IF SOALE MODEL SHEET FROM ING NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 8 OF 9 1
23. Ferrule PARTS LIST 2 N ND N S o D 4 69 PARTS LIST Power Supply 1 Power Supply 2 X Ft 047125 Belden 9320 20 AWG 87 Red I M Red 1 Pair Overall Shielded CSA Certified 25 86 Black Shield Qty 6 074027 Terminal Insulated Locking Fork 22 18 AWG 6 T amp B RA2217 Legend Power Supply 1 End Legend Power Supply 2 End 86 86 Black Hold Signal Black Hold Signal 87 Red Hold Common 87 Red Hold Common Shield Hold Shield Shield Hold Shield 15 ft 4 5m 25 ft 7 6m 50 ft 15m 100 ft 30 5m 150 ft 46m Figure 4 33 Hold Cable Power Supply 1 to Power Supply 2 4 70 MAX200 Service Manual PARTS LIST PAC200T E Hand Torch Systems onl PAC200T 90 Hand Torch Cutting Systems CUTTING PAC200T 90 HAND TORCH CUTTING SYSTEMS PAC200T Torch w 200VAC 208VAC 380 415VAC 240 480VAC 500VAC 600VAC 25 Leads 073163 073139 073151 073115 073175 073127 50 Leads 073164 073140 073152 073116 073176 073128 75 Leads 073165 073141 073153 073117 073177 073129 100 Leads 073166 073142 073154 073118 073178 073130 125 Leads 073167 073143 073155 073119 073179 073131 150 Leads 073168 073144 073156 073120 073180 073132 MAX200E Hand Torch Gouging Systems MAX200E 65 HAND TORCH GOUGING SYSTEMS PAC200E Torch w 200VAC 208VAC 380 415VAC 240 480VAC 500VAC 600VAC 25 Leads 073169 073145 073157 073121 073181 073133 50 Leads 073170 073146 073158 073122 073182 0
24. PARTS LIST 008176 PIN 9 008186 Socket 7 Power Supply End IHS End 1X3 047002 Cable 23 3 PR 008187 Strain Relief 008192 Strain Relief 008185 Plug Shell 13 9 008202 Plug Shell 17 14 008190 Key Insert key in face of plug tapered end first until it locks in detent Legend Power Supply End PIN COLOR FUNCTION Legend IHS End IHS Complete Sig Upper Limit Sw Sig IHS Complete Com Upper Limit Sw Com IHS Complete Sig Upper Limit Sw Sig Upper Limit Sw Com IHS Complete Com Shield Grn BIk Key AC Power AC Power __ Shield Wht BIk Shield Red BIk Shield Grn BIk AC Power AC Power OANA GQ N J Indicates Pairs Indicates Pairs w Drain Note IHS End cut Red Black Shield 8 25 ft 7 6m White Black Shield Wires 50 ft 15m 75 ft 23m 100 ft 30 5m 150 ft 46m 200 ft 61m Figure 4 32 Interface Cable Power Supply to IHS 4 68 MAX200 Service Manual IHS Fittings Kit Part Number 028243 008144 008176 008185 008186 008187 008190 008192 008195 008202 008211 015259 015140 MAX200 Service Manual Description Kit Fittings IHS HT400 Plug 3 Pin F Ind Sensr UW IHS Pin 20 24 AWG Plug Shell 13 9 Size Socket Amp 24 20 AWG Strain Relief W 008185 Key Plug Strain Relief W 008191 196 202 Strain Relief W 008194 Plug Shell Size 17 14 Plug 11 4 Rev Sex Swivel 4
25. Problem 11 3 MAINTENANCE Possible Causes and Solutions IHS system not getting start command from Control Board PCB7 or 1 PCB9 is defective After START command is given look to see if D2 on PCB9 illuminates See Figure 3 15 for location of D2 If D2 illuminates 120VAC should be sent to the IHS system and be present at terminals 2 amp 3 of 1TB of IHS module See Figure 5 4 If there is no 120VAC at the terminals after the START command is given check pins connectors cables and associated wiring from Initial Height Sensor to REC4 of Repair or replace defective component s if necessary If wiring is O K replace CR1 on If there is 120VAC at terminals 2 amp 3 of 1TB of IHS there may be a problem with the IHS or its hookup Verify that air to IHS is and pressure is 20 psi Verify that 1SOL activates when 120VAC is applied See Figure 4 23 for location of 1SOL Verify that cables from IHS sensors are mated securely in their receptacles If D2 on PCB9 does not illuminate after START command is given check pins connectors machine interface cable and wires from machine to MAX200 power supply See Figure 3 10 in Setup section of instruction manual 800980 for machine interface cable detail Repair replace or reconnect if necessary MAX200 Service Manual If wiring is correct check 9 of REC2 of PCB9 for 0 volts after START command is given If 0 volts is not
26. 11 015090 Clamp Hose 1 5 16 2 1 4 1 MAX200 Service Manual 4 47 PARTS LIST Machine Torch Lead Assemblies cont Note Hypertherm does not recommend using torch leads longer than 75 Feet 100 Ft 125 Ft and 150 Ft leads will cause problems with starting Part Number Description Qty 028782 Shield Torch Lead 125 Ft 1 1 023809 Lead Pilot Shield Gas 125 Ft blue 1 2 024417 Lead Plasma Gas 125 Ft red 1 3 024414 Lead Cap Sensor 125 Ft gray 1 4 023806 Cable Water Cooled 125 Ft 1 blue red band 5 023806 Cable Water Cooled 125 Ft 1 blue green band 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046114 1 5 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 4 1 028783 Shield Torch Lead 150 Ft 1 1 023810 Lead Pilot Shield Gas 150 Ft blue 1 2 024418 Lead Plasma Gas 150 Ft red 1 3 024415 Lead Cap Sensor 150 Ft gray 1 4 023807 Cable Water Cooled 150 Ft 1 blue red band 5 023807 Cable Water Cooled 150 Ft 1 blue green band 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046114 1 5 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 4 1 Figure 4 19 Machine Torch Lead Assemblies 4 48 MAX200 Service Manual PARTS LIST
27. 131 BRN La 161 I RED 133 Da Tos AC Complete pg 158 BLK BK I W isi ae 1 0 d lt s lt gt Je pares Remote 1 I i E 9 Sueny gui ice pem 1 155 YEL aes YEL T Initial Height ee 91 lt gt fa H PCB 82 2 1 MO Plasma __________ lol S1 of 156 BLK E T 7 7 10N Open l lt 141 q l WHT 83 1901919 START Signal 1017 6 1 T 3 F I 1 1 1 RED 167 ma UP iL w H t Ti I L a lt BLK gt 2 gt GND y I I RED BLK 168 1 Hd Relay GND 161 tq 162 BLK dal dea issue GND 073001 i NES sig 1800 i i RED 169 H SIG SOD 5 161 RED A 191 RED 7 1910 ____ SIG Voltage Current I 4 lt T gt 1 4 112 1 Down 191 191 Ty Remote RED BLK 170 1 41 H 14 U dl 13 BLU 171 GND le 164 BLK 18 BLK a po Looo GND SE L 1 WHT 172 i sl Auto SIG SID 1 131 163 14 GRN J jg 1S0D____sia 36 lt gt 8 X TR 1 4 BLU 173 Height I L Le lasl lt WHT 1 SE n_ 1 1 IHS 1 165 1 l BLK 1 1 1 I T 1 1 I NET Complete L 121 1361 51 Rome L 1 PCB10 N 120 VAC UL 166 WHT 135 WHT he 120 VAC __ I Le 310 4 NE Bay c ss I Le I1 I s Torch Height Control t gu re i 1X4 A mc ie 4 J SS ra
28. 6 Brass Electrode MAX200 Air Oxy Electrode MAX200 N2 H35 Shield PAC200T Hand Torch 200A Swirl Ring MAX200 Nozzle MAX200 082 200A Oxy Swirl Ring MAX200 Air N2 H35 Nozzle MX200 086 200A Air N2 Lubricant Silicone 1 4 Oz Tube Nozzle Wrench MAX200 HT2000 O Ring BUNA 70DURO 1 301X 070 Tool Water Tube Replacement PAC200E Gouging Torch Consumable Parts Kit 028751 4 74 Part Number 028751 001067 015015 015193 020607 020891 020918 020933 220021 020934 020615 020608 027055 027194 044027 027347 027524 Description Parts Kit PAC200E Box Gray Plastic Adapter 1 4NPT X 6 Male 90 Brass Cap 6 Brass Swirl Ring MAX200 Air N2 H35 Shield PAC200E Torch Shield PAC200T 200A Electrode PAC200E Torch Electrode MAX200 Air Oxy Nozzle PAC200E Torch N2 H35 Nozzle MAX200 Air H35 Gouging Nozzle MAX200 086 200A Air N2 H35 Lubricant Silicone 1 4 Oz Tube Nozzle Wrench MAX200 HT2000 O Ring BUNA 70DURO 1 301X 070 Tool Water Tube Replacement Nozzle Wrench 1 open end 2 O1 OH O1 O1 O1 A 8 aga O1 QI dl 200 Service Manual PARTS LIST This page left blank intentionally MAX200 Service Manual 4 75 PARTS LIST PAC200T 90 Cutting Torch Assembly g 3 N Y O O1 Part Number 073190 002244 001412 001217 120045 020963 044027 027254 075365 029865 220021 020607 020608 020915 020918 Description PAC200T 90 Cutting Torch
29. Iriductive IHS Control Module ii i 4 57 MAX200 Power Supply Internal Has a 4 58 Machine arid Remote Cables a decere ia rentre iege 4 59 to 4 63 Inductive IHS Torch Mounting Assembly 4 64 Interconnecting Leads for Inductive IHS Systems nn 4 67 IHS Fittings Kikuu ade ia inc dia 4 69 Rez mE 4 70 MAX200T E Hand Torch Systems manga dima mama 4 71 PAC200T E Trigger Torch Gonsumables u sine ner nee 4 72 PAC200T Consumable Parts Kit 028750 A t aee dee dg Da neat 4 74 PAC200E Consumable Parts Kit 0287571 eue eee msn tna EEA ania ANAA paene 4 74 200 90 Cutting Torch Assembly certe ca 4 76 PAC200T 90 Cutting Torch Assembly 25 a tette ttn tentent ttt tte ten ttti tetti tette ttn tts ttn tna tenias 4 76 200 65 Cutting Torch Assembly im 4 78 200 65 Cutting Torch Assembly 25 Ft eee 4 78 PAG200E Gouging Torch s 4 79 PAC200E Gouging Torch Assembly 25 uquna eines 4 79 Trigger Torch 25 Foot Lead Assembly Torch to Power Supply a 4 81 Extended leads l i a aet a das 4 82 Trigger Torch 25 Foot Lead Assembly Torch to Extension Box 4 83 APPENDIX A TORCH COOLANT REQUIREMENTS amp COOL
30. Up seen 280 VDC Output Current 5 aiai 40 200 amps Output Voltage Us uu arene 150 VDC Duty Cycle Rating X 100 up to 30kW Input Power Input Voltage U4 x Input Current 1 079002 240 480 VAC 30 60 Hz 90 45 amps 073020 0730037 nd 600 VAC 30 60Hz 36 amps 073021 atinada 208 VAC 39 60Hz 104 amps 3t 073022 2 2 MAX200 Service Manual 1 99 SPECIFICATIONS 079005 erinin sn ten 220 380 415 VAC 30 50 Hz 98 57 52 amps 073023 0739020 rii nie i 200 VAC 30 50 Hz 108 amps 073024 073090 tn e dien oai 500 VAC 30 50 Hz 43 amps 073039 Dimensions ei Ge 28 1 4 71 run 35 1 2 90 cm w o casters 43 109 cm w casters E 41 1 4 104 w o handle 50 127 cm w handle La ets 780 pounds 351 kg Forced Air Class F Torch Coolant Tank Capacity 2 9 gallons 11 liters Torch Coolant Requirements and Coolant Safety Data See Appendix B MAX200 Power Supply Machine Torch w o THC Configuration 200 Power Supply Machine Torch w THC Configuration MAX200 Service Manual 2 3 1 99 SPECIFICATIONS Gas Requirements Gas Air compressed clean dry oil free Oxygen 0 9
31. instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise Electric shock can kill Do nottouch live electrical parts AN Keep all panels and covers in place when the machine is connected to a power source Insulate yourself from work and ground wear insulating gloves shoes and clothing Keep gloves shoes clothing work area torch and this machinery dry Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area If ventilation is inadequate use an approved respirator WARNING 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 Explosion will result if pressurized Heat splatter and sparks cause fire and containers are cut burns Do not cut near combustible material Do not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Pilot arc can cause burns Keep the torch nozzle away from yourself Arc rays can injure eyes and burn skin Wear correct eye and body protection Noise can damage hearing Wear correct ear protection and others when the switch is depressed Wear correct eye and body protection NE PAS
32. potencia primaria para permitir la descarga de los condensadores Nunca opere el sistema de plasma sin que las tapas de la fuente de energ a est n en su lugar Las conexiones expuestas de la fuente de energ a presentan un serio riesgo el ctrico Al hacer conexiones de entrada conecte el conductor de conexi n a tierra en primer lugar Cada sistema de plasma Hypertherm est dise ado para ser utilizado s lo con antorchas Hypertherm espec ficas No utilice antorchas diferentes que podr an recalentarse y ser peligrosas lt Use precauciones adecuadas cuando maneje tablillas impresas de circuito ELECTRICIDAD EST TICA PUEDE DA AR TABLILLAS DE CIRCUITO Almacene las tablillas PC en recipientes antiest ticos Use la defensa de mufieca conectada a tierra cuando maneje tablillas PC Hypertherm Sistemas plasma 1b 3 8 06 SEGURIDAD El arco plasma por si solo la fuente de calor que se uSa para cortar Segun esto aunque el arco de plasma no ha sido identificado como la fuente de humo t xico el material que se corta puede ser la fuente de humo o gases t xicos que vacian el oxigeno El humo producido var a seg n el metal que esta cort ndose Metales que pueden liberar humo t xico incluyen pero no est n limitados a acero inoxidable acero al carb n cinc galvanizado y cobre En algunos casos el metal puede estar recubierto con una sustancia que podr a lib
33. xu amp o asd 5 43 2 1 1 2 3 4 8 7 11 12 16 15 19 20 24 23 27 28 32 31 36 35 34 3 3029 2625 21 22 18 17 14 13 10 9 6 5 1 A A A Y Y Y Y Y oo Y Y Y REC3 e 1 1 1 I 7 FA H4 ya I 1 1 1 I t 1 I 1 1 z 1 08 1 F1 F2 u 4 A 3 POWER DISTRIBUTION Bez uo 41 m 00 PCB ASSY 041534 WSS RES IS ES SS A I I x 3 1 041535 I l ASSY 041536 1 1 J2 MOV3 1 n Lr 1 I I ni i I 1 1 gt 1 1 2 gt 14 2 D9 I I I l RN2A 1 7 D7 77 l we 16 gt 13 J r b 023354 I RN2B I U2C n 2 I LED6 6 11 12 CR4 CR5 CRE CR9 CR10 7 l N RN2E NT 5 7 12 vi gt 11 pe Mus y 1 lt 11 lt RN2F I 1145 1145 11145 1145 1145 1145 gt 2 2 lt t 2 t E rr LEDS 8 U2D 9 10 d EL aA gt 3 1 3 lt 1 RN2G 7 7 D5 5 4 gt 4 t 4 lt AW 10 gt RN2H I gt 5 5 lt 2 UIA 15 gt 6 4 6 lt LED4 8 1 gt 7 T 7 lt om 114 16 gt 8 x 8 RN1B 1 I LED3 4 VIB 13 gt
34. 075335 18 075347 19 075229 20 075351 21 075360 22 075361 23 009349 24 041145 25 029202 26 015134 27 075072 MAX200 Service Manual Description HF amp PCB SA 200 Connector cathode Adapter Cathode Connector Standoff MAX200 Anode Standoff MAX200 Cathode Spacer 42ID X 750 X 50 Ig Block MAX200 Cathode Fitting 3 8 Tube X 1 4 NPT Fitting 90 3 8 Tube X 1 4 NPT Ferrule 3 8 OD Tube Delrin Adapter 90 1 4 NPT X 5 Street Elbow 1 4 Panel MAX200 Output Hexnut 3 8 16 Finish Brs Hexnut 1 2 20 Finish Jam Brs Lkwshr 3 8 Splitlock Brz Flwshr 3 8 390 875 063 Brs M S 8 32 X 1 2 SL Bin Nyl Bolt 5 16 X 11 4 Hex Brz Bolt 3 8 16 X 1 1 2 FTH Hex Brs Bolt 3 8 16 X 1 Hex Brs Flwshr 5 16 328 520 032 Brs Flwshr 3 8 394 625 032 Brs Assembly Coil High Frequency T6 PC BD Assy MAX200 1 0 PCB5 Current Sensor SA CS1 Insert 3 8 OD X 062 Brass M S 8 32 X 1 2 Designator PARTS LIST 4 27 PARTS LIST Rear Wall Outside Figure 4 13 Power Supply MAX200 Service Manual 4 28 9 99 Rear Wall Outside Part Item Number 129252 1 128385 2 128384 3 031122 129383 4 006046 029361 5 005119 6 006053 7 027978 8 027139 9 027005 10 011025 11 011027 12 002304 13 022036 14 129618 15 029323 16 006099 128410 MAX200 Power Supply Description Pump Motor Subassembly Kit Replacement Motor 1 3 HP Kit Replacement Pump 7
35. 1 5 16 2 1 4 ko mb h h MAX200 Service Manual Machine Torch Lead Assemblies cont See Figure 4 19 Part Item Number 028383 023326 024194 024192 023013 023013 020536 046026 046114 027015 004080 015090 2000 JO 028457 023432 024229 024224 023014 D 023014 020536 046026 046114 027015 004080 015090 Y OD 028458 023433 024218 024225 023015 Q N 023015 020536 046026 046114 027015 004080 015090 ON O MAX200 Service Manual Description Shield Torch Lead 25 Fi Lead Pilot Shield Gas 25 Ft blue Lead Plasma Gas 25 Ft red Lead Cap Sensor 25 Ft gray Cable Water Cooled 25 Ft blue red band Cable Water Cooled 25 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 Shield Torch Lead 30 Ft Lead Pilot Shield Gas 30 Ft blue Lead Plasma Gas 30 Ft red Lead Cap Sensor 30 Ft gray Cable Water Cooled 30 Ft blue red band Cable Water Cooled 30 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid R
36. 3 008709 Fuse 20Amp 500V F2 1 4 008301 Fuseholder 2 Pole 30 amp 1 5 003092 Contactor 90A 3 Pole 24VAC CON1 1 6 003093 Switch aux contactor SW2 1 7 075237 M S 10 32 X 3 8 PH TRS SSB 8 075062 M S 6 32 X 1 2 SL 5 2 2 9 075055 M S 6 32 X 5 8 PH Rnd S Z 4 10 075056 M S 6 32 X 1 PH Rnd S Z 4 11 075241 M S 1 4 20 X 1 2 SL IHW S Z 2 075160 Kepnut 1 4 20 S Z 2 12 075200 Flwshr 10 250 562 047 S Z 2 13 008603 Grommet Strip 18 029315 Shield Gas SA MAX200 see page 4 23 for more part numbers 14 005233 Switch Pressure 0 90 PSI PS2 1 15 006037 Valve Sol 24VAC 50 60 Hz 60 psi V4 1 16 015165 Orifice 032 ID X 1 8 NPT 1 17 015540 Tee 1 8 1 18 015141 Fitting 90 1 8 Tube X 1 8 NPT 2 19 015135 Insert 1 8 OD Brass 2 20 029316 Incoming Power TB1 SA MAX200 TB1 1 21 041534 PC BD Assy Pwr Dist PCB6 1 22 029359 Linkboard SA MAX200 240 480V 1 23 029318 Cont Xf mer SA 240 480V 3 60 Hz T1 1 029441 Cont Xf mer SA 208V 3 60 Hz T1 1 029362 Cont Xf mer SA 220 380 400 415V 3 50 Hz T1 1 029404 Cont Xf mer SA 600V 3 60 Hz T1 1 Used when incoming power is 380V 400V 415V or 480V Used when incoming power is 208V 220V or 240V Used when incoming power is 240 or 480V MAX200 Service Manual 4 15 PARTS LIST See page 4 21 for detail of CH2 See page 4 19 for detail of CH1 Figure 4 7 Power Supply Front Wall Inside 4 16 MAX200 Service Manual PARTS LIST Front Wall Inside
37. 4 21 Changed part no of chopper Added temp sw 4 29 New coolant reservoir part no added part nos for gauge drain valve 4 30 Changed part nos in Recommended Spare Parts a 03 Changed reference from 220 380 415V CE to 400V CE b 02 Changed warning on propylene glycol to not induce vomiting 8 sheets MAX200 wiring diagram format change 013 2 179 Rev K Page 1
38. 6 REC4 1 4 3 7 ux D3 1 w 14 gt 15 1 l RN1D 1 I LED2 6 1 la 1 AE US i RN1E 6 C2 1 I I U1D 1 I I 8 2 gt 2 RN1H p D1 I I WW 2d xq gt 1 I RN1G oS tama DA d 3 PS REC5 Vv REC2 1 2 2 1 3 4 7 8 11 12 15 16 19 20 23 24 27 28 31 32 35 36 2 1 6 5 10 9 14 13 18 17 22 21 26 25 30 29 E ceri ge ae een Y Y PL2 RA DA AA RA DA RA A A A RA RA RA A ol N m RR 5 8 3 8 8 a 1 V7 106 su gt x aE o a i u E c m x x X 3 X zi m a m m m gt E 4 1 uS a PL31 ala n a mi a x E 4 3 de 8 580 207 E El 8 I S REC31 7106 PBI PB2 2 M4 M3 o 1 107 20S M8 8 M5 M6 M7 MATERIAL DRAWN BY DATE 7 perc sa J Y cn i 000 APP BY DATE Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES TOLERANCES ARE ELEC GAS SCHEM MAX200 THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 005 ITEM NO DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 5 0
39. 8 4 79 PARTS LIST T See page 4 81 for detail of torch leads tt Heat Shield 020881 not included in PAC200E Torch Assembly Order separately Figure 4 37 200 Gouging Torch Assembly 4 80 MAX200 Service Manual 1 99 PARTS LIST Trigger Torch 25 Foot Lead Assembly Torch to Power Supply Part Item Number Description Qty 029865 Leads SA PAC200T E Trch PS 25 ft 1 1 024375 Hose 200T E Cap Sensor Trch PS 1 2 024194 Hose Assy 3 16 Red LH 1 3 023714 Cable 200T E Water Cooled Blue 1 4 023716 Cable 200T E Water Cooled Red 1 5 023715 Cable 200T E Shield Gas 1 6 047203 Cable 16 1 Pair 1 74 005094 Push Button Switch Torch 1 8 024197 Sheath MAX200 Hand Torch Leads 25 1 9 046065 Tube 9 16 ID X 03 WL Nat Tef 333 ft Note If leads longer than 25 feet are needed use extended leads see page 4 82 Red w Red shrink wrap Grey w Blue shrink wrap ME mo Figure 4 38 PAC200T E Trigger Torch Lead Assemblies MAX200 Service Manual 4 81 PARTS LIST Extended Leads Part Number Description Qty Length 028715 PAC200T E Torch Leads Ext 50 1 50 ft 029866 Leads SA PAC200T E 25 1 029867 Leads SA PAC200T E XBT PS 25 1 001313 Box Torch Leads Ext one half 1 pair 075365 Screws 8 028716 PAC200T E Torch Leads Ext 75 1 75 ft 029866 Leads SA PAC200T E 25 1 029594 Leads MAX200 Hand Torch XT 50 PS End 1 001313 Box Torch Leads Ext 1
40. Assembly Safety Trigger PAC120 200T E Tch Handle PAC200T E 90 Deg Hand Torch Boot PAC200T E Torch PAC200T Torch Main Body Water Tube PAC200T Electd Cool O Ring Buna 1 301X 070 Spring Trigger PAC120 200T E Torch P S 6X3 4 PH Pan Leads SA PAC200T E Torch PS 25 ft Electrode MAX200 Air Oxygen Swirl Ring MAX200 Air N2 H35 Nozzle MAX200 086 200A Air N2 H35 Shield Cap PAC200T Cutting Torch Shield PAC200T 200A PAC200T 90 Cutting Torch Assembly 25 Ft 5 3 N Y O O1 4 76 Part Number 073189 002244 001412 001217 120045 020963 044027 027254 075365 029865 220021 020607 020608 020915 020918 Description PAC200T Cutting Torch Assembly 25 ft Safety Trigger PAC120 200T E Tch Handle PAC200T E 90 Deg Hand Torch Boot PAC200T E Torch PAC200T Torch Main Body Water Tube PAC200T Electd Cool O Ring Buna 1 301X 070 Spring Trigger PAC120 200T E Torch P S 6X3 4 PH Pan Leads SA PAC200T E Torch PS 25 ft Electrode MAX200 Air Oxygen Swirl Ring MAX200 Air N2 H35 Nozzle MAX200 086 200A Air N2 H35 Shield Cap PAC200T Cutting Torch Shield PAC200T 200A A O ANDA 8 O ANDA 8 200 Service Manual PARTS LIST T See page 4 81 for detail of torch leads Figure 4 36 200 Cutting Torch Assembly MAX200 Service Manual 4 77 1 99 PARTS LIST PAC200T 65 Cutting Torch Assembly g 3 N
41. ENLEVER CET AVIS DO NOT REMOVE THIS MARKING 010298 Rev TLF Hypertherm Sistemas plasma 1b 7 8 99 SEGURIDAD Etiqueta de advertencia Esta etiqueta de advertencia se encuentra adherida a la fuente de energia Es importante que el operador y el tecnico de mantenimiento comprendan el sentido de estos s mbolos de advertencia seg n se describen El texto numerado corresponde a los cuadros numerados de la etiqueta 1b 8 8 99 Las chispas producidas por el corte pueden causar explosiones o incendios Mantenga los materiales inflamables lejos del lugar de corte Tenga mano un extinguidor de incendios y asegurese de que alguien est preparado para utilizarlo No corte dep sitos cerrados El arco de plasma puede causar quemaduras y lesiones Apague la fuente de energ a antes de desarmar la antorcha No sostenga el material junto al trayecto de corte Proteja su cuerpo completamente Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque Col quese guantes aislantes No utilice guantes da ados o mojados A slese de la pieza de trabajo y de la tierra Antes de trabajar en una m quina desconecte el enchufe de entrada o la potencia primaria La inhalaci n de los humos provenientes del rea de corte puede ser nociva para la salud Mantenga la cabeza fuera de los gases t xicos Utilice ventilaci n forzada o un sis
42. IF SCALE MODEL SHEET FROM HYPERTHERM ING NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 70F9 1 4 2 1 3 L3 L3 12 480 073002 amp 073020 L2 500 VAC 073036 amp 073039 2 52 ater 073200 amp 07321 3 3 Phase L1 3 Phase ase ti 240 480 60 pe Hez 480 500 50 pe Hertz I 380 415 50 CE WIRED 480 VAC See WIRED FOR 500 VAC TT IE mee WIRED FOR 415 VAC A ERA 415 I 1 T 4JZIE Stop Pres I 1 1 ZE Stop I 1 ZIE Stop I A A I I I 1 Fuse A 2 DEB 2 EISE As M ES E I Em A1 A1 1 TB FL1 jee 1 A TB1 AE s i A2 A2 5 _CON1 I lw nw 1 6 CONI I A4 L poi 3 I pod I 1 NS RES 13 1 A4 A4 A4 L3 4 1 1 1 iw a Brit EW EA I 1 1 2 8273 I I ig Ms I por i D Do r ecc B B4 Fil 5 1 6 21 I V 2 L he B4 TEM I Ly elle m 1 U i 1 1 paa 1 Lid C2 ca Tom Es e 5 380 VAC e o4
43. MAX200 Power Supply Part Item Number Description Designator Qty 1 128789 Kit chopper 15KW CH1 1 005199 Switch temperature 82 C TSW1 1 2 128789 Kit chopper 15KW CH2 1 005199 Switch temperature 82 C TSW2 1 For detail of CH1 parts list see page 4 19 For detail of CH2 parts list see page 4 21 MAX200 Service Manual 4 17 PARTS LIST 4 18 This page intentionally left blank MAX200 Service Manual PARTS LIST Chopper SA Front Wall Inside Left MAX200 Power Supply Part Item Number Description Designator Qty 128789 Kit chopper 15KW CH1 1 1 005199 Switch temperature 82 C TSW1 1 e e 15 op off Compe g E 0 i eE ae t NB hoyo Vii t A Cone Am 4 OOH 9 pa de gt e Figure 4 8 Power Supply Chopper SA Front Wall Inside Left MAX200 Service Manual 4 19 PARTS LIST This page intentionally left blank
44. Pushbutton 2 NO Green Illumin represent items not under parent assembly 4 2 MAX200 Service Manual PARTS LIST 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 Note Items that appear on exploded views as single letters and do not appear on opposing pages represent hosing or tubing connection points A complete hosing run list with part numbers and lengths appears on page 4 58 MAX200 Service Manual 4 3 PARTS LIST wa a LEE Note Refer to page 4 58 for the list of internal hose to from See Figure 4 2 for detail of control panel terminations as indicated by the letters above Figure 4 1 Power Supply Front Wall Outside MAX200 Service Manual 4 4 3 96 Front Wall Outside MAX200 Power Supply Part Item Number Description 001233 Panel MAX200 Front 2 027080 Fan 225 CFM 120VAC 50 60Hz 3 027080 Fan 225 CFM 120VAC 50 60Hz 4 027079 Fan 450 550 CFM 120VAC 50 60Hz 5 008509 Bushing 1 75 MTG X 1 37 ID 6 008245 Bushing 7 8 Hole X 11 16 ID 7 041143 PC BD Assy Control MAX200 029315 Shield Gas SA MAX200 8 006032 Valve Sol Shield Gas 9 008503 Cap Comm Mnl 2 Circuit 10 008504 Pin Comm Mnl 24 18 AWG 11 015563 Plug 3 8 12 015132 Fitting 90 3 8 Tube X 1 4 NPT 13 015133 Ferrule 3 8 OD Tube Delrin 029303 THC SA MAX2
45. Shock can iii ata 1 3 Static electricity can damage circuit boards tritt its 1 3 Toxic fumes can cause injury or death inner cera 1 4 A plasma arc can cause injury and DUrns ii rina dates art dn dude done ra 1 5 Arc FAVS CAN purn eyes SN aia 1 5 1 5 Compressed gas equipment Sale acie nete tu mire trie ate pi ca de prie 1 6 Gas cylinders can explode if damaged u u teret tti ita 1 6 NOISE Cam damage HE iii E 1 6 Pacemaker and hearing aid operation eese tata sasana tette 1 6 A plasma arc can damage frozen pipes eee 1 6 Additional Safety information R 1 6 Warning labels u ttc rite a dia cri ti 1 7 Section SECURITE 1a 1 Identifier les consignes de s curit inner ra la 2 Suivre les instructions de s curit sise 1a 2 Le coupage peut provoquer un incendie ou une explosion sese u 1a 2 Les chocs lectriques peuvent tre dai dcn desde st da 1a 3 L lectricit statique peut endommager les cartes de circuits imprim s 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des br lures sn 1 5 Le
46. Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 Shield Torch Lead 45 Ft Lead Pilot Shield Gas 45 Ft blue Lead Plasma Gas 45 Ft red Lead Cap Sensor 45 Ft gray Cable Water Cooled 45 Ft blue red band Cable Water Cooled 45 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 Shield Torch Lead 50 Ft Lead Pilot Shield Gas 50 Ft blue Lead Plasma Gas 50 Ft red Lead Cap Sensor 50 Ft gray Cable Water Cooled 50 Ft blue red band Cable Water Cooled 50 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 ko mb h h MAX200 Service Manual PARTS LIST Machine Torch Lead Assemblies cont See Figure 4 19 Part Item Number Description Qty 028773 Shield Torch Lead 60 Ft 1 1 023515 Lead Pilot Shield Gas 60 Ft blue 1 2 024260 Lead Plasma Gas 60 Ft red 1 3 024259 Lead Cap Sensor 60 Ft gray 1 4 023052 Cable Water Cooled 60 Ft 1 blue red band 5 023052 Cab
47. Switch Remote SR Wiring Dia 2 Digital Remote DR Signal AC Diagram usines c 3 Programmable Remote PR Signal AC Diagram sss 4 Initial Height Sensing IHS Wiring Diagram usine 5 MAX200 Electrical Schematic amp Block Diagram 013 2 79 9 Sheets Coolant System Schematic Diagram 029 2 313 1 Sheet MAX200 Service Manual c 1 9 99 lENUEN 3911195 g0cXVIW r 029302 Filter Panel PC Bd SA DR SR V C 200 Initial Height N VOLT SET AMP SET Auto Height 52 Start PB1 Stop PB2 Remote Switch SR Wiring Diagram RED 17 je WHT RED Md 18 NH Ou B Signal Name at Cable Ad PL1 RECP2 GRN SID SIG BLK SID COM RED SOD sic SID Common SOD Signal SOD Common 120 VAC Neut 120 VAC Hot N BLK 120VAC HOT Initial Height COM ON Open Auto Height com ON Open 24 VAC Neut 24 VAC Hot Plasma Start COM Start Maintained Closed w c SPP equ nl MAX200 06 9 XIGNAddV lENUEN 5 06 6 9 029302 FILTER PANEL PC BOARD SA DR SR V C GRN SID DATA 7 6 SOD 3 BRN S0D COM 2 041187 PC BD ASSY DR SR V C HT400 FN 500 OHM RED I TRANS wrr ac 7 ut quu POTENTIOMETER gt ULA 8 500 OHM _ RED CURRENT S
48. Thermostat 160 C 6 Amp Valve solenoid Switch pressure 0 90 psi CH130 Chopper SA CE LVD PCB power distribution Fuse 7 5 Amp 600VAC Fuse 20 Amp 500VAC Fuse semiconductor 125 Amp 250 V Relay 120 VAC Switch pressure SPDT 0 15 psi Transformer High Voltage SA Sensor current Filter coolant Filter regulator Filter Element used with 011025 Gauge high pressure Kit coolant Pump with clamp Switch water temperature 162 F Switch level Switch flow 0 5 gom Valve check 1 3 psi 1 4 NPTH Coolant propylene glycol 30 deionized water 70 standard mixture Coolant propylene glycol 100 Power Supplies with THC Used when incoming power is 380V 415V 400V or 480V Used when incoming power is 208V 220V or 240V 4 30 Designator 61 1 2 R9 M2 M4 M3 PCB9 PCB10 PCB7 TS1 V1 PS1 CH1 CH2 PCB6 F1 F2 F1 F2 F3 F4 CR1 PS3 T5 CS1 FR1 TS2 LS1 FS1 MAX200 Service Manual Recommended Spare Parts cont MAX200 Rev 1 90 Hand Torch and Torch Leads Part Number Description 020484 Torch Main Body 029309 Hand torch lead 25 ft 029310 Hand torch lead 50 ft MAX200 Machine Torch and Torch Leads Part Number Description 120584 Torch Main Body 028383 Shielded torch lead 25 ft 028384 Shielded torch lead 50 ft PAC200T 90 Cutting Torch and Torch Lead Part Number Description 120045 Torch Main Body 029865 Leads SA PAC200T E 25 ft torch to p
49. a mano un extinguidor de incendios Retire todos los materiales inflamables coloc ndolos a ADVERTENCIA Peligro de explosi n Arg n Hidr geno y metano por lo menos 10 metros del rea de corte El hidr geno y el metano son gases inflamables que Remoje los metales calientes o permita que se enfrien suponen un peligro de explosi n Mantenga el fuego lejos de antes de que entren en contacto con materiales los cilindros y las mangueras que contengan mezclas de combustibles hidr geno o metano Mantenga la llama y las chispas lejos Nunca corte dep sitos que contengan materiales de la antorcha al utilizar metano o arg n hidr geno como inflamables primero es necesario vaciarlos y limpiarlos plasma debidamente Antes de realizar cortes en atm sferas potencialmente ADVERTENCIA inflamables aseg rese de ventilar bien Detonaci n de hidr geno con Al realizar cortes utilizando ox geno como gas plasma se el corte de aluminio requiere tener un sistema de ventilaci n de escape M Al cortar aluminio bajo agua o con agua en contacto con el lado inferior del aluminio puede acumularse gas hidr geno bajo la pieza a cortar y detonar durante la operaci n de corte por plasma Prevenci n ante explosiones No corte en atm sferas que contengan polvo o vapores explosivos Instal de aireaci I fondo de d No corte dep sitos o tubos a presi n ni cualquier dep sito U MUNS e AESA ge
50. accessory that uses or generates a hazardous voltage is added There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification CE marking constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking 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 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 ili 6 07 WARRANTY obligation to indemnify shall be conditioned upon Hypertherm s sole
51. and Solutions 5 1 5 2 6 1 6 2 7 1 V6 is closed Open V6 shield gas knob See Figure 3 14 for gas interconnect diagram V2 not opening Disconnect PL30 from REC30 and check for 120VAC from Control Board PCB7 See Figure 4 1 for location of V2 If there is 120VAC at V2 replace V2 If there is no 120VAC at V2 use 013 2 179 wiring diagram to check pins connections and associated wiring from V2 to REC2 of Control Board PCB7 If wiring is O K replace PCB7 51 TEST RUN switch is defective Do a continuity check to verify that 51 is functioning properly V1 V2 or V3 not closing Using the 013 2 179 wiring diagram verify that 120VAC is not at V1 V2 and V3 when S1 is in the RUN position See Figures 4 3 and 4 4 for location of V1 and V3 and Figure 4 1 for location of V2 If there is 120VAC at any one of these valves while in the RUN position replace PCB7 If 120VAC is not at the valves troubleshoot each valve to determine which one is stuck open Repair and or replace defective valve s There is no spark between the spark gap electrodes Clean with emery cloth align and or regap 020 per gap the electrodes if necessary Ensure that the electrode surfaces between the gaps are flat If surfaces are rounded replace and regap See Figure 4 11 for part number information Visually inspect the high voltage transformer T5 for leaking oil or overheating See Figure 4 10 for location of
52. at pin 9 replace Control PCB7 3 27 1 97 MAINTENANCE Problem Possible Causes and Solutions 12 IHS in use no auto retract 12 1 No upper limit switch defective upper limit switch or after cut machine torch switch improperly installed adjusted systems with IHS option See Install the Upper Limit Switch and Cable under Install the MAX200 with IHS Option in Setup section of instruction manual 800980 for details See also specifications on purchased upper limit switch 13 No torch UP machine torch 13 1 Torch lifter motor defective systems with THC option Replace torch lifter motor if necessary 13 2 Machine interface connections incorrect and or external AC or DC source not functioning or interfaced incorrectly See Figure 3 10 in Setup section of instruction manual 800980 for detail and specifications for machine interface 13 3 THC board not being activated Check to see if D5 on 9 illuminates after the STATUS indicators all extinguish See Figure 3 15 for location of D5 If D5 is notilluminated then PCB9 may not be getting 120VAC from Power Distribution Board PCB6 Check pins connectors and associated wiring from REC5 of PCB9 to of PCB6 Repair and or replace defective component s if necessary 13 4 2 relay on PCB9 defective See if D3 illuminates during cut sequence If D3 illuminates and there is no torch motion up and wiring to machine is O K replace CR2 13 5 Problem with
53. 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 ADDITIONAL SAFETY INFORMATION 1 ANSI Standard 249 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard 749 2 Fire Prevention the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 3 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 1 6 11 98 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 1235 Jefferson Davis Highway Arlington VA 22202 7 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada 8 NFPA Standard 51B C
54. ce font partie du circuit lectrique jamais toucher le corps de la torche la pi ce couper ou l eau de la table a eau pendant le fonctionnement du systeme plasma Pr vention des chocs lectriques Tous les systemes plasma Hypertherm utilisent des hautes tensions pour le coupage souvent de 200 a 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 S 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 S 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 LES CHOCS LECTRIQUES PEUVENT TRE FATALS Installer 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 po
55. 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 tort 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 any 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 Transfe
56. de d monter la torche the torch Utiliser exclusivement les torches indiqu es dans le Use torches specified in the instruction manual manual d instructions This plasma cutting machine must be connected Le raccordement au r seau de cette machine de to power source in accordance with applicable coupage arc plasma doit tre comforme aux codes electrical codes de l lectricit pertinents Plasma arc cutting can be injurious to operator Le coupage arc plasma comporte des risques pour and persons in the work area Before operating l utilisateur et les personnes se trouvant dans la zone read and understand the manufacturer s instruc de travail Avant le coupage lire et comprendre les tions and know your employer s safety practices instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise Electric shock can kill Do not touch live electrical parts AN Keep all panels and covers in place when the machine is connected to a power source Insulate yourself from work and ground wear insulating gloves shoes and clothing Keep gloves shoes clothing work area torch and this machinery dry Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area If ventilation is inadequate use an approved respirator WARNING This product when us
57. de l air Ne pas inhaler les vapeurs Porter un respirateur adduction d air quand on coupe des m taux rev tus d l ments toxiques ou qui en contiennent ou sont susceptibles d en contenir S assurer que les personnes qui utilisent un mat riel de soudage ou de coupage ainsi que les dispositifs de respiration par adduction d air sont qualifi s et ont recu la formation sur la bonne utilisation d un tel mat riel Ne jamais couper les contenants dans lesquels il peut y avoir des mat riaux toxiques En premier lieu vider et nettoyer correctement le contenant Contr ler ou prouver la qualit de l air au site selon les besoins Consulter un expert local pour mettre en oeuvre un plan du site afin d assurer une qualit de l air s re 1a 4 8 06 Hypertherm Systemes plasma _ S CURIT Torches allumage instantan L arc plasma s allume imm diatement apr s que la torche Soit mise en marche L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de m tal pr s de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes 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 confor
58. de r cipients ferm s L arc plasma peut provoquer des blessures et des br lures Couper l alimentation avant de d monter la torche Ne pas tenir la surface couper pr s de la trajectoire de coupe Porter des v tements de protection couvrant tout le corps Un choc lectrique caus par la torche ou les c bles peut tre fatal Se prot ger contre les risques de chocs lectriques Porter des gants isolants Ne pas porter de gants mouill s ou abim s S isoler de la surface de travail et du sol D brancher la prise ou la source de courant avant de manipuler l quipement L inhalation des vapeurs produites par le coupage peut tre dangereuse pour la sant Garder le visage l cart des vapeurs Utiliser un syst me de ventilation par aspiration ou d chappement localis pour dissiper les vapeurs Utiliser un ventilateur pour dissiper les vapeurs Les rayons de l arc peuvent br ler les yeux et provoquer des l sions de la peau Porter un casque et des lunettes de s curit Se prot ger les oreilles et porter une chemise dont le col peut tre d boutonn Porter un casque de soudure dont la protection filtrante est suffisante Porter des v tements protecteurs couvrant la totalit du corps Se former la technique du coupage et lire les instructions avant de manipuler l quipement ou de proc der au coupage Ne pas retirer ou peindre recouvrir les tiquettes de s curit Hy
59. displays value on LEDs Control Range u cscs Current 40 to 200 Amps Voltage 100 to 200 Volts Control Resolution Current 20 Amps Voltage 5 Volts Dimensions Va AR Rd nn nn 11 1 2 29 cm 5 13 EH 13 1 4 34 WIG cm 6 pounds 2 7 kg MAX200 Service Manual 2 5 1 99 SPECIFICATIONS Digital Remote DR V C Control Optional Control Voltage adjust pot Adjusts arc cutting voltage and displays value on LEDs Current adjust pot Adjusts arc cutting current and displays value on LEDs Dimensions ca 11 1 2 29 3 7 6 Depilacion 13 3 8 34 cm ee 5 pounds 5 oz 2 4 kg Programmable Remote PR V C Control Optional None Controlled through guidance machinery computer Dimensions fiim 11 1 2 29 cm MM 3 7 6 cm uM UM 12 1 2 31 8 cm tee reta cun 5 pounds 5 oz 2 4 kg Initial Height Sensing Optional POWO teens 120 VAC from power supply AIT FP VOSS SUMO a u u de Duo 20 psi 1 4 bar regulated shop air input to solenoid Dimensions 9 23 tacos 4 1 2 11 A 11 1 2 29 L au 13 pounds 6
60. 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 LES BOUTEILLES DE GAZ COMPRIME PEUVENT EXPLOSER EN CAS DE DOMMAGES Les bouteilles gaz contiennent du gaz a 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 Ne 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 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 ee PEUT ENDOMMAGER LES TUYAUX GELES Les tuyaux gel s peu
61. eq dos dos GIS GIS Lol ed dis v ea ais NOILONN4S HO109 NOILONNS 80102 1705 aXL Ajddns samog pu 7 Hd Hq PU9697 pue louu 1 UO SPISIUS 91oN SY90 y pun 5 8 2 1811 pue 6 jo H SU 061800 200 6 941800 9 19 005 981800 9215 26 60 602800 215 6 61 981800 5 681800 Jeyeu 181800 p pl uS 6 26 24 200270 Ajddns MAX200 Service Manual 4 62 15 PARTS LIST Y OS y SZ OOLEzO 660620 SNINAV3859023d 1N33309 Jejndujo Hung Q30N3NWOO3M SLNSNNYLSNI 5 Q30N3 M0233 Q3ISIML TIVY3AO LON 9 A Hd 2 sissey IHM NO 118 didar ie ME s 08A 00 Po HH THA OZA MUNE 5 01 0284 0 1 HH SA 1 9 81 59 co HH 001 038 NO JHM 08 11 BEBE mg NO
62. eyes and harmful or fatal if swallowed Upon contact flush skin or eyes with water If swallowed drink water and calla physician immediately Do not induce vomiting Caution Always use propylene glycol in the coolant mixture Do not use anti freeze in place of propylene glycol Anti freeze contains corrosion inhibitors that will damage the torch coolant system Always use purified water in the coolant mixture in order to prevent corrosion in the torch coolant system The hardness of purified water should be between 206 and 8 5 ppm If using a conductivity meter to measure water purity the recommended level is between 5 and 18 pSiemens cm at 77 25 C C F 32 0 2 I 10 F 12 C 1 30 mixture resists freezing to this 7 20 temperature 12 10 48 0 o a 23 10 29 20 34 30 E 40 40 46 50 51 60 57 70 0 10 20 30 40 50 60 Propylene Glycol a 2 MAX200 Service Manual 1 97 MATERIAL SAFETY DATA SHEET SECTION 1 CHEMICAL PRODUCT AND COMPANY IDENTIFICATION Date EMERGENCY TELEPHONE NUMBERS ISSUE DATE Product Information 603 643 3441 DISTRIBUTOR Hypertherm Inc Etna Road Hanover N H 03755 SECTION 2 COMPOSITION INFORMATION ON INGREDIENTS Hazardous EXPOSURE LIMITS Component CAS No by wt OSHA PEL ACGIH TLV R Phrases SECTION 3 HAZARDS IDENTIFICATION Emergency Causes eye irritation Overview May be harmful if swallowed May ca
63. kg Water Muffler Optional Refer to Water Muffler Instruction Manual P N 802050 Must use optional 1 75 diameter torch to install Water Muffler MAX200 Service Manual Section 3 MAINTENANCE In this section E 3 2 Routine gt 2 da 3 3 Torch and Torch tet u 3 3 Heres 3 3 Power S upply uuu as uu EE 3 3 Theory of Operation Chopper Power Supply siennes 3 4 MD 3 4 Circuit E 3 4 Theory of Operation High Frequency siennes 3 6 OCTO ee A a E tre 3 6 6 DESCRIPTION PE 3 6 Sequence Of EVEMIS UU ii ad teens 3 7 initial ETS 3 13 Biete ceee gre uu u E D u T 3 16 ESA 3 30 Arc Transter Test Procede RER 3 30 Chopper Module Test Procedure e coi 3 31 Voltage Divider Test Procedure Machine Torch Systems 3 33 MAX200 Rev 1 90 Hand Torch Removal and Replacement 1 3 34 Removal 3 34 m 3 34 MAX200 Rev 1 90 Hand Torch Lead Set and Individual Torch Leads Removal and Replacement 3 36 Tor
64. lt lt P1 5000 0 VACL_ 2 2 CH2 Lere 8 TS 283 VDC 480 VAC TSW2 AA 120 C4 2B 2e BLU PA ELECTRODE E Pilot Arc pal 2C 2C CH130 CHOPPER SA 488 R2 7 129118 T CS1 Tc2 PL26 NOZZLE 026 C P 488 71418 2 T2 N2 3 N23 45 1 WORKPIECE al mg d ol col 182 Hand QE WHT 177 Torch RED Remote ue peers 9 X m al la SHEET x 3 D3 4 B F SHEET 6 D3 MATERIAL DRAWN BY DATE mem 00 07 i APP BY DATE Y Box 5010 Hanover NH 03755 5010 603 643 3441 IUNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES TOLERANCES ARE ELEC GAS SCHEM MAX200 THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 005 ITEM NO DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION 013179 013 2 179 01317982 PURPOSES WITHOUT PERMISSION SHARP EDGES BREAK SHARP EDGES IF SCALE MODEL SHEET FROM HYRERTHERM ING NECESSARY WITH CHAMFER OR RADIUS 015 N A 200 20 9 4 3 2 1
65. luego coloque cualquier otro alambre de tierra sobre el conductor de tierra del cable Ajuste firmemente la tuerca de retenci n Aseg rese de que todas las conexiones el ctricas est n firmemente realizadas para evitar sobrecalentamientos Hypertherm Sistemas plasma 1b 5 5 02 SEGURIDAD SEGURIDAD DE LOS EQUIPOS DE GAS COMPRIMIDO Nunca lubrique reguladores o v lvulas de cilindros con aceite o grasa Utilice solamente cilindros reguladores mangueras y conectores de gas correctos que hayan sido dise ados para la aplicaci n espec fica Mantenga todo el equipo de gas comprimido y las piezas relacionadas en buen estado Coloque etiquetas y c digos de color en todas las mangueras de gas para identificar el tipo de gas que conduce cada una Consulte los c digos locales o nacionales aplicables LOS CILINDROS DE GAS PUEDEN E EXPLOTAR SI ESTAN DANADOS Los cilindros de gas contienen gas bajo alta presi n Un cilindro da ado puede explotar Manipule y utilice los cilindros de gas comprimido de acuerdo con los c digos locales o nacionales aplicables No use nunca un cilindro que no est de pie y bien sujeto Mantenga la tapa de protecci n en su lugar encima de la v lvula excepto cuando el cilindro se encuentre en uso o conectado para ser utilizado No permita nunca el contacto el ctrico entre el arco de plasma y un cilindro No exponga nunca los cilindr
66. o 14 RECP 15 RECP Initial Height Sensing IHS Wiring Diagram MAX200 Service Manual c 5 9 99 4 3 2 1 3 Phase Power w Ground IHS Sensor Cable E 8x2 023869 PS IHS Cable Units AirH se 1 9 8 1 IHS lt e 024144 023859 028390 IHS Sensor Cable 8x3 023870 95 E Shielded Torch Leads 028546 Positive Lead 023403 OFF Valve VO Machine Interface Cable IHS Probe 1x6 Unite 029334 023334 Na Computer Interface 1 Torch amp Customer Supplied Motor Valve Lead tu 028548 Unit 1 Ly MAX200 Workpiece Power Supply 200 Amp Remote V C Unit 5 Digital or Prog Switch Programmable Remote only W O THC 1 4 5x1 Remote 5X2 023319 V C 023100 073002 240 480 60 Switch 073001 073003 600 60 Digital 073007 m 073004 208 60 2288 Programmable 055004 L 073005 380 415 50 023675 073026 200 50 W THC Y 073020 240 480 60 073021 600 60 073022 208 60 073023 380 415 50 Unit 15 073024 200 50 Remote Current Control RCC 073193 15X1 Hold Cable 2nd MAX200 System 023340 Optional control w Machine I O Cable MATERIAL DRAWN BY DATE perte APP BY DATE Box 5010 Hanover NH 03755 5010 603 643 3441 UNLES
67. r cipients ferm s et pressuris s Ne pas couper de r cipients contenant des mati res combustibles LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT Risque d explosion argon hydrog ne et m thane L hydrog ne et le m thane sont des gaz inflammables 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 hydrog ne 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 pi ce 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 Se r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration 1a 2 11 98 Hypertherm Systemes plasma SECURITE Le JN Toucher une pi ce lectrique sous tension peut provoquer un choc lectrique fatal ou des br lures graves La mise en fonctionnement du syst me plasma ferme un circuit lectrique entre la torche et la pi ce a couper La pi ce couper et tout autre l ment en contact avec cette pi
68. 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 ELECTRIC SHOCK CAN KILL 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 Before 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 Use
69. the fumes 5 Arc rays can burn eyes and injure skin 5 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 110261 6 Become trained and read the instructions before working on the machine or cutting 7 Do not remove or paint over cover warning labels 1 8 Hypertherm Plasma Systems 8 99 Section 1 SECURITE Dans cette section Identifier les consignes de s curit sise 1a 2 Suivre les instructions de s curit nns 1a 2 Le coupage peut provoquer un incendie ou une explosion iii 1a 2 Les chocs lectriques peuvent tre fatals iii 1a 3 L lectricit statique peut endommager les cartes de circuits 1a 3 Les vapeurs toxiques peuvent provoquer des blessures OU la mort 1a 4 plasma peut provoquer des blessures ou des 1 5 Les rayons de l arc peuvent br ler les yeux et la sie 1a 5 Mise la masse et la terre 1a 5 S curit des bouteilles de gaz comprim sise 1a 6 Les bouteilles de gaz comprim peuvent exploser cas de dommages 1a 6 Le bruit peut provoquer des probl mes auditifs si 1a 6 Pacemakers et proth ses 011 11 sise 1a 6 Un arc p
70. the cause of unlit STATUS indicators 3a 1 No jumper between terminals 34 and 35 of TB4 If your unit does not have a Remote High Frequency Console this LED will be satisfied if there is a jumper between terminals 34 and 35 of TB4 See Figure 4 10 for location of TB4 If the jumper is there Using the 013 2 179 wiring diagram check pins connectors and associated wiring from REC3 on the Power Distribution Board PCB6 to terminals 34 and 35 of TB4 Repair and or replace defective component s if necessary 3b 1 Main transformer T2 or one of the choppers is overheating This LED will extinguish when the main transformer T2 is operating in a normal temperature range under 165 C and choppers CH1 and CH2 are also operating in the normal temperature range under 82 C See Figure 4 3 for location of T2 and connector to TS1 Chopper temperature switches TSW1 and TSW2 are located on choppers CH1 and CH2 respectively See Figures 4 7 4 8 and 4 9 3 17 1 97 MAINTENANCE Problem Possible Causes and Solutions Check temperature switches normally closed Check pins connectors and associated wiring to temperature switches Leave the fans running and try restarting the unit after one hour If LED still illuminates one of the choppers or the main transformer may need to be replaced 3c COOLANT LEVEL LED 3c 1 Coolant level is low illuminated This LED will extinguish when a proper coolant level in the c
71. the volt division circuit See Voltage Divider Test Procedure later in this section 13 6 THC PCB10 defective See if D3 illuminates during cut sequence If D3 does not illuminate and voltage division and CR2 are O K replace PCB10 3 28 MAX200 Service Manual 1 97 Problem 14 torch DOWN machine torch systems with THC option MAX200 Service Manual MAINTENANCE Possible Causes and Solutions 14 1 14 2 14 3 14 4 14 5 14 6 Torch lifter motor defective Replace torch lifter motor if necessary Machine interface connections incorrect and or external AC or DC source not functioning or interfaced incorrectly See Figure 3 10 in Setup section of instruction manual 800980 for detail and specifications for machine interface THC board not being activated Check to see if D5 on 9 illuminates after the STATUS indicators all extinguish See Figure 3 15 for location of D5 If D5 is not illuminated then PCB9 may not be getting 120VAC from Power Distribution Board PCB6 Check pins connectors and associated wiring from REC5 of PCB9 to REC2 of PCB6 Repair and or replace defective component s if necessary CR3 relay on PCB9 defective See if D4 illuminates during cut sequence If D4 illuminates and there is no torch motion down and wiring to machine is O K replace CR3 Problem with the volt division circuit See Voltage Divider Test Procedure later in this section THC PCB10 defecti
72. torch or torch leads Removal 1 2 Remove the six 6 Screws securing the two Handle halves and separate Remove the torch Switch and Safety Trigger from the handle Take care not to lose the Trigger Spring On the two largest leads use a 3 8 open end wrench to hold the torch body fittings and a 1 2 open end wrench to turn the torch lead fittings On the two next smaller leads use a 5 16 open end wrench to hold the torch body fittings and a 7 16 open end wrench to turn the torch lead fittings Note that the red lead fitting is reverse threaded and must be turned in the opposite direction clockwise to loosen On the smallest lead grey use a 5 16 wrench to loosen Remove the Torch Main Body Replacement 1 Connect the torch leads to the replacement torch main body Thread the torch main body fittings and the torch lead fittings together clockwise cw Use the size wrenches called out in the Removal procedure above Note that the red lead fitting is reverse threaded and must be turned in the opposite direction ccw Ensure the Lead Insulator is positioned over the shield gas grey w blue band lead fitting Insert the torch main body into one of the handle halves and then align the body and handle slots Insert the torch Switch Safety Trigger and Trigger Spring into the handle half that it was removed from Insert the top rib of the Boot into the handle just above the screw holes Align b
73. transfer sensed D8 Xfer on PCB7 lights pilot arc relay CR1 opens power off to high voltage transformer T5 high frequency and pilot arc off Step valve V3 and quick charge valve V9 on PS4 opens quick charge valve V9 off Machine motion delay D31 on PCB9 active installed Machine motion starts machine torch only Cutting begins MAX200 Service Manual MAINTENANCE D3 D4 deactivated on PCB9 ULS 3 12 Plate overrun Torch retracts to From page 3 11 D3 UP and Yes D4 DOWN active THC installed on PCB9 No STOP pressed machine torch START button released hand torch Machine motion stops machine torch only main contactor CON1 opens DC ON light off choppers off D6 D8 D21 D22 on PCB7 off THC installed No IHS installed and ON No 1 second of gas post flow Plasma gas valve V1 shield gas valve V2 step valve V3 close Cut sequence complete MAX200 Service Manual MAINTENANCE Initial Checks Before trouble shooting specific problems it is good practice to do a visual check and verify that voltages are present at the power source transformer and power distribution board SHOCK HAZARD High voltages inside the power supply can kill Always use caution when servicing a power supply that is plugged in and has an access panel removed 1 Disconnect line power by turning main disco
74. 0 11 12 13 14 want to lengthen the leads you cannot use these 25 foot leads with any of the extended leads sets You must use the 029866 25 foot leads See pg 4 82 Remove the eight 8 screws from the extension box halves and separate Slide the three lead insulators away from the pilot shield lead and the two coolant hose connections Loosen connections using 1 2 wrenches on the coolant hose fittings and 7 16 wrenches on all other fittings Add or remove lead sections as required Match color coded leads when connecting Note that the red plasma gas leads are all left hand threaded After making the connections slide the lead insulators over the connection joints Using tyraps secure the two coolant hoses together Also secure the other leads and torch switch leads together Do this on both sides of the connections Position the two coolant hoses and other leads into one of the box halves Coolant hoses go to narrow side of the divider other leads go to the wider side Position each boot into the box half so that the top rib fits over the lip just above the screw holes Align both halves of the box press together and secure with the eight 8 screws Route the torch leads prior to connecting the torch and power supply Connect extension leads to power supply See page 3 48 Connect leads to torch See page 3 46 After installing the torch to the torch leads check coolant level in the
75. 0 DR V C MDL FR Flg HT400 DR PR V C MDL Fr FR HT400 DR PR ST V C Mdl LS FR HT400 DR PR ST V C RS Filter PNL PCB SA DR SR V C Potentiometer 500 Ohm 10 turn Receptacle Shell Size 13 9 Pin 20 24 AWG Term 22 18 250 FEM QC Insul Term 22 18 FEM QC Insul Term 22 18 6 Ring Uninsul Term 22 18 25 MAL QC Insul PC BD Assy Opto Iso Terminal PC HHS 2022C PC BD Assy Dig Sta V C MAX200 Heatsink DR PR SR V C IC LM340AK 5 0 Capacitor 2600 UF 15VDC Terminal PC HHS 2022C Terminal PC CAM PC BD Assy Rem Volt Disp PC BD Assy Rem Curr Disp PARTS LIST Figure 5 2 Designator 1 1FU 1TRANS 029302 Volt Set Curr Set 7RECP 2PC 1PC 2 NO ANA mb PO ad gt gt O 4 53 PARTS LIST al Dnm iluwan ima uwa i oes pr 1 lunas EJ DE 23 Figure 4 22 Programmable PR V C Control 4 54 MAX200 Service Manual Programmable Remote PR V C Control Part Item Number 055004 1 002107 2 002106 3 002123 4 008069 5 008165 6 014012 7 004119 002122 8 001139 9 001131 10 001137 11 001138 029089 12 008175 13 008176 14 008193 074016 074038 074041 074067 15 041070 008097 16 041085 17 004116 18 009274 19 042059 008097 008098 20 041076 21 041077 MAX200 Service Manual Description Conir
76. 0 GPH Drive Coupling Pump to motor Valve Subassembly w elec connectors Valve Sol 240V 3 8 NPT NC Flowswitch Subassembly w elec connector Flowswitch 0 5 GPM Valve Check 1 3 PSI 1 4 NPTM Heat Exchanger Water Air Filter Housing 10 X 3 8 NPT Filter Element Filter Regulator Gauge High Press for 011025 Reservoir coolant Gauge liquid level Level Switch Subassembly 1 2 NPT Temp Switch Subassembly 162 Deg F Bib drain valve 1 4 NPT Kit coolant resevoir upgrade Designator M1 LS1 TS2 PARTS LIST wk dd 8 nB For older systems Item numbers 12 through 16 can not be used if the tank has been upgraded with the 128410 kit MAX200 Service Manual 4 29 PARTS LIST Recommended Spare Parts Power Supply Part Number 005041 005121 005122 005151 005168 005091 009604 027080 027079 027080 041151 041186 041143 005102 006014 005093 129118 041534 008551 008709 008317 003021 005130 029317 029202 027005 011025 011031 011027 128384 029323 029326 029361 006053 028872 028873 Description Switch tog 2p Maint ON ON Pushbutton green illmn Pushbutton red extended Holder lamp Bulb 28 VDC Lens white Resistor variable 100 K 1 turn Fan 225 CFM 120 VAC 50 60 Hz Fan 450 550 CFM 120 VAC 50 60 Hz Fan 225 CFM 120 VAC 50 60 Hz PCB THC motherboard PCB SA THC PCB Control
77. 00 14 001297 Cov MAX200 THC Dust 15 004338 Hinge THC Pan MAX200 16 075092 M S 10 32 X 1 2 PH Pan S Z 17 075160 Kepnut 10 32 S Z 18 041151 PC BD Assy THC Mother 19 041186 PC BD SA THC MAX200 20 075078 M S 8 32 X 5 8 PH Pan S Z 21 075073 M S 8 32 X 1 2 PH Pan S Z 22 075159 Kepnut 8 32 S Z 001566 Panel MAX200 front filter 001567 Cover MAX200 front filter panel 027441 Filter 24 X 24 X 2 fiberglass air PARTS LIST Designator PCB9 PCB10 THC SA available only on MAX200 power supplies 073020 073021 073022 073023 073024 and 073213 CE Items not shown in Figure 4 1 MAX200 Service Manual 1 97 PARTS LIST Note 4 6 3 96 Refer to page 4 58 for the list of internal hose to from terminationsas indicated by the letters above Q 200 gt CLA A A AA Figure 4 2 Power Supply Control Panel SA Front MAX200 Service Manual Control Panel SA MAX200 Power Supply 5 3 O1 gt 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Part Number 029319 001222 004117 005151 005187 005089 006002 006027 015131 015132 015133 015135 015136 015141 015196 015520 015532 015570 015593 022008 022008 075198 075250 029360 001246 008328 075394 075165 029383 005123 008186 008233 029394 008492 008503 009604 041536 008516 008517 009063 009705 041148 005041 005121 005122 001250 001247 008164 008492
78. 008503 009604 Description Contr SA MAX200 Thumb Pot Pnl Max200 Cont Cap valve flow control Lamp holder Bulb 28 VDC Lens white for 005088 Valve needle 1 4 NPT 125 Ori Valve needle 1 4 NPTF Fitting 3 8 tube X 1 4 NPT Fitting 90 3 8 tube X 1 4 NPT Ferrule 3 8 OD tube delrin Insert 1 8 OD brass Fitting 90 1 8 tube X 1 8 NPTF Fitting 90 1 8 tube X 1 8 NPT Fitting 3 8 tube X 1 8 NPT Elbow 1 8 Street elbow 1 4 Reducer bushing 1 4 X 1 8 Street tee 1 4 Gauge Press 2 1 2 Dia 1 100 Gauge Press 2 1 2 Dia 1 100 Flwshr 6 156 375 045 5 7 M S 6 32X1 4 PH TRS S B Thumbwheel Pot Panel SA MAX200 Panel MAX200 Thumbwheel Mach Knob 930 Dia BIk Nat 1 4 Sktcap 6 32X3 8 HX Btn S B Hexnut 6 32 WXF 250 093 S Z Thumbwheel switch SA Thumbwheel switch Socket 20 24 AWG Type Plug In line 16 pos Pot SA MAX200 Machine Delay Pin gold Cap comm mnl 2 circuit Res Var 100K 1 Turn PC BD Assy Intlk Display Post Header 8 pin RA MTA 156 Standoff 19 OD 12 ID 50 LG Diode Ind LED Amber Clip amp Retain ring T1 3 4 LED PC BD only Dsply 200 1070 Switch Tog 2 Maint On On Pushbutton 2 NO Green Pushbutton 2 NC Red Extended Pnl MAX200 THC Fr Pnl MAX200 Mach Delay Knob Pin Gold Cap comm mnl 2 circ Res Var 100K 1 Turn Designator LT2 V6 V5 PG2 PG1 PCB9 1 PB1 PB2 Power Supplies without THC 073002 0
79. 01067 015015 015193 220021 020415 020423 020446 020604 020605 020607 020608 027055 027194 044027 027347 Description Enclosure Consumable Parts Kit Adapter 90 1 4 NPT x 6 Cap 6 JIC Electrode Air Oxygen Electrode Nitrogen Cap Shield Shield Swirl Ring Oxygen Nozzle Shield Oxygen 082 Swirl Ring Air No Nozzle Shield 200 Amp 086 Lubricant Silicon 1 4 Oz Tube Wrench Nozzle 3 4 O Ring Tool Wtr Tube Replacement 020615 020607 Q Q O1 Q 8 PARTS LIST 220021 120547 220021 220021 220021 120547 020415 020415 020415 020415 020415 4 33 PARTS LIST 9 p EL Figure 4 15 MAX200 Rev 1 Hand Torch Assembly 4 34 MAX200 Service Manual PARTS LIST MAX200 Rev 1 Hand Torch Assembly The following is a listing of the MAX200 Rev 1 90 Hand Torch with 25 foot and 50 foot leads Refer to Figure 4 15 Part Item Number Description Qty 073189 MAX200 90 Deg Hand Torch 25 1 1 020484 MAX200 90 Deg Hnd Tch Main Body 1 3 029309 Leads SA MAX200 Hand Torch 25 1 073190 200 90 Deg Hand Torch 50 1 1 020484 MAX200 90 Deg Hnd Tch Main Body 1 3 029310 Leads SA MAX200 Hand Torch 50 1 The following items are common to the MAX200 Rev 1 Hand Torch assemby 2 020536 Lead Insulator 9 16 X 2 5 Tef 1 4 001258 Handle MAX200 Hand Torch 1 5 002178 Boot MAX200 Torch 1 6 005094 Switch PB Torch 1
80. 0423 020608 020607 020566 020423 020608 020607 220021 120547 220021 220021 220021 120547 020415 020415 020415 020415 020415 220021 120547 220021 120547 020415 020415 4 39 PARTS LIST MAX200 Machine Torch Consumable Parts Kits 4 40 Part 028392 001067 015015 015193 220021 020415 020423 020424 020448 020605 020607 020608 020604 020611 020616 020617 027055 027194 044027 027347 020963 120547 Part 028429 001067 015015 220021 020415 020423 020424 020448 020688 020605 020607 020608 020604 020611 020689 020613 027055 027194 044027 027347 120547 Description Kit Consum Parts MAX200 Mach Enclosure Consumable Parts Kit Adapter 90 1 4 NPT x 6 Cap 6 JIC Electrode Air Oxygen Electrode Nitrogen H35 Cap Shield Shield Machine 200A Shield Machine 100A Nozzle Shield Oxygen 082 Swirl Ring Air Nitrogen Nozzle Shield 200A 086 Swirl Ring Oxygen Nozzle Shield 100A 059 Nozzle 100A 055 Oxygen Swirl Ring 100A Oxygen Lubricant Silicon 1 4 Oz Tube Wrench Nozzle 3 4 O Ring Tool Wtr Tube Replacement Tube Water Electrod 100A Air Oxygen Description Kit Cons Parts MAX200 Mch Intl Enclosure Consumable Parts Kit Adapter 90 1 4 NPT x 6 Electrode Air Oxygen Electrode Nitrogen H35 Cap Shield Shield Machine 200A Shield Machine 100A Shield 40A Nozzle Shield Oxygen 082 Swirl Ring Air Nitrogen Nozzle Shield 200A
81. 086 Swirl Ring Oxygen Nozzle Shield 100A 059 Nozzle 40A Swirl Ring 40A Lubricant Silicon 1 4 Oz Tube Wrench Nozzle 3 4 O Ring Tool Wtr Tube Replacement Electrod 100A Air Oxygen Quantity Q WW Q Q O1 O1 Quantity JN HAH a WwW O1 O1 01 O1 MAX200 Service Manual MAX200 Machine Torch Assembly with 1 75 diameter Torch Body and 2 diameter PARTS LIST Sleeve Standard 3 N Part Number Description 128380 MAX200 Machine Torch Assembly 120894 Sleeve Insul MAX200 Mach 2 0 diameter 120584 MAX200 Machine Torch Main Body 020536 Lead insulator 9 16 X 2 5 Tef 044027 O ring Buna N The following consumables are part of the MAX200 Machine Torch Assembly See Figure 4 17 for details 020424 Shield MAX200 Mch 200A 020423 Cap Nozzle Retaining MAX200 020608 Nozzle MX200 200A 086 Air N2 H35 020607 Swirl ring MAX200 Air N2 H35 220021 Electrode MAX200 Air O 2 LAN lt lt PD a MANN TT 00 y MANZOO O7 TIF Hes Figure 4 18 MAX200 Machine Torch Assembly MAX200 Service Manual mb mb 8 nB de 4 41 PARTS LIST MAX200 Machine Torch Assembly with 2 Stainless Steel Torch Body and 2 diameter Sleeve Optional Part Item Number Description Qty 128365 MAX200 Machine Torch Assembly 1 1 020041 Sleeve Insul MAX200 Mach 2 0 diameter 1 2 120356 MA
82. 10 for location of Shield Gas Supply bulkhead 3 18 MAX200 Service Manual 1 97 MAINTENANCE Problem Possible Causes and Solutions Verify that the torch cap is on tight and that no hissing from gas leakage is heard Check for damage to O rings in the torch main body See Figure 3 3 for location of torch main body and O rings for hand torch and Figure 3 6 for machine torch 3d 2 Pressure switch PS2 not functioning PS2 is normally open and closes when shield gas pressure is 70 psi or greater After PS2 is closed the SHIELD GAS CAP LEDextinguishes Using the 013 2 179 wiring diagram check pins connectors and associated wiring from REC3 on the Power Distribution Board to PS2 3d 3 Solenoid valve V4 not functioning V4 is normally closed and opens when 24VAC is applied See Figure 4 6 for location of V4 Using the 013 2 179 wiring diagram check pins connectors and associated wiring from REC3 on the Power Distribution Board to V4 Repair and or replace defective component s if necessary 3e PLASMA GAS LED 3e 1 Plasma gas pressure too low illuminated This LED will extinguish when PS1 senses plasma gas pressure of 60 psi or greater Refer to Figure 4 4 for location of PS1 and Figure 3 14 for gas interconnect diagram STATUS O intervock 0 O COOLANT LEVEL gt e O sueco gt PLASMA GAS O COOLANT TEMP gt
83. 13179 013 2 179 013179B3 PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND SHARP EDGES BREAK SHARP EDGES IF SCALE MODEL SHEET FROM HYPERTHERM INC NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 30F9 4 T 3 T 2 1 SHEET 3 D2 va gt gt CON1 LT2 a are es m a 2 Raya Ss 38 gt 7172 7 1 1 1 I 1 Workpiece R1 Shunt Plasma l dI MN EK ha 4 tL R2Shunt Interlocked I I WHT 74 181 Gas 2 I EST_RED 75 lol I Test Run I CH2 Duty Contactor 4 I I I 51 RUN 117 Switch I Cycle Main I I I Z L 127 141 A CH1 Dury DC Power V2 M IBEDIBLK 128 Shield Cycle PCB7 ON Light Hara ae RECSO PL30 1512105 Control PCB I I 62 RED I 161 Pilot A Step Gas 520 20 i CR1 63 151 Relay d 50 dq Eee 10A 5 6 RED BLK 16 y 50 Current Machine Motion Plasma Gas J a RED BL I b IT Reduction 5 Delay Relay 7 ber COM 1 iel 20 120 _ LT Machine Motion o TEN
84. 2 020536 046026 046114 027015 004080 015090 028455 023430 024217 024222 023034 023034 020536 046026 046114 027015 004080 015090 028456 023431 024228 024223 023012 023012 020536 046026 046114 027015 004080 015090 Description Shield Torch Lead 10 Ft Lead Pilot Shield Gas 10 Ft blue Lead Plasma Gas 10 Ft red Lead Cap Sensor 10 Ft gray Cable Water Cooled 10 Ft blue red band Cable Water Cooled 10 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 Shield Torch Lead 15 Ft Lead Pilot Shield Gas 15 Ft blue Lead Plasma Gas 15 Ft red Lead Cap Sensor 15 Ft gray Cable Water Cooled 15 Ft blue red band Cable Water Cooled 15 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 Shield Torch Lead 20 Ft Lead Pilot Shield Gas 20 Ft blue Lead Plasma Gas 20 Ft red Lead Cap Sensor 20 Ft gray Cable Water Cooled 20 Ft blue red band Cable Water Cooled 20 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose
85. 200 Service Manual SPECIFICATIONS PAC200T 90 amp 65 Cutting PAC200E 65 Gouging MAX200 Rev 1 90 Hand Torches Maximum cutting thickness 2 inches 50 mm Maximum current at 100 duty cycle 200 amps Plasma Gas ne 66 Air 60 scfh 70 scfh H35 72 scfh Shield Gas Flow 220 scfh 280 scfh Air 290 scfh N gt Water Coolant Flow Rate 0 8 gpm 3 0 l min Welght A dixe niu rea 3 1 4 kg MAX200 Rev 1 90 2 1 2 lbs 1 1 kg PAC200T E MAX200 Machine Torch Maximum cutting thickness 2 inches 50 mm Maximum current at 100 duty cycle 200 amps Plasma Gas 66 scfh Air 60 scfh 70 scfh H35 72 scfh O5 Shield Gas ecrire 220 scfh 280 scfh Air 290 scfh No Water Coolant Flow Rate 0 8 3 0 l min Weight m 2 1 2 lbs 1 1 kg Switch Remote SR V C Control A cevatiow deed da Start button Activates IHS if on and initializes pilot arc Stop button Deactivates main contactor in power supply IHS On Off switch Turns IHS system on or off Auto Height On Off switch Activates THC in power supply Voltage adjust pot Adjusts arc cutting voltage and displays value on LEDs Current adjust pot Adjusts arc cutting current and
86. 20615 020607 220021 2 Steel H35 Air 020891 020882 020934 020607 020933 m Stainless H35 N2 020891 020882 020934 020607 020933 GOUGING Steel Aluminum H35 2 020891 020882 020934 020607 020933 4 72 200 Service Manual 14 PARTS LIST Shield Nozzle Swirl Ring 020605 200A O 020604 0 20918 200A 020918 1200A 020608 200A Air H35 020607 Air H35 _ Retaining A NAN LLL LI Cap Electrode 220021 Air 020915 020415 H35 120547 100A Air 020917 40A 1 4 y 020611 100A Air H35 020613 40A Air 020919 100A 020616 100A O5 020617 100A 020920 200A H35 Stniss only 020689 40A Air 020607 Air H35 Figure 4 34 PAC200T Cutting Trigger Torch Consumable Parts Nozzle 020615 Air Electrode 2 220021 Air JD Retaining Shield Cap 020891 020882 020607 0 Swirl Ring I 2 d Q La 020934 H35 020933 H35 Figure 4 35 PAC200E Gouging Trigger Torch Consumable Parts MAX200 Service Manual 4 73 PARTS LIST PAC200T Cutting Torch Consumable Parts Kit 028750 Part Number 028750 001067 015015 015193 220021 020415 020918 020604 020605 020607 020608 027055 027194 044027 027347 Description Parts Kit PAC200T Box Gray Plastic Adapter 1 4NPT X 6 Male 90 Brass Cap
87. 7 220021 Electrode MAX200 Air O 2 1 8 020607 Swirl Ring MAX200 Air N2 H35 1 9 020608 Nozzle MX200 200A 086 Air N2 H35 1 10 020423 Cap Nozzle Retaining MAX200 1 11 020446 Shield MAX200 Hnd 200A 1 12 044027 O ring Buna N 1 Lead subassemblies are broken down on page 4 36 MAX200 Service Manual 4 35 PARTS LIST MAX200 Rev 1 Hand Torch Lead Assembly Parts Item Part Number Description 029309 Hand Torch Lead 25 Ft 1 023326 Lead Pilot Shield Gas 25 Ft blue 2 024194 Lead Plasma Gas 25 Ft red 3 024192 Lead Cap Sensor 25 Ft gray 4 023013 Cable Water Cooled 25 Ft blue red band 5 023013 Cable Water Cooled 25 Ft blue green band 6 047032 Cable Switch 26 Ft 7 020536 Lead Insulator 9 16 ID x 2 1 2 8 046026 Tubing 1 1 2 ID Shrink Black 9 024197 Sheath 25 Ft 029310 Hand Torch Lead 50 Ft 1 023327 Lead Pilot Shield Gas 50 Ft blue 2 024195 Lead Plasma Gas 50 Ft red 3 024193 Lead Cap Sensor 50 Ft gray 4 023199 Cable Water Cooled 50 Ft blue red band 5 023199 Cable Water Cooled 50 Ft blue green band 6 047032 Cable Switch 51 Ft 7 020536 Lead Insulator 9 16 ID x 2 1 2 8 046026 Tubing 1 1 2 ID Shrink Black 9 024198 Sheath 50 Ft eh p kh 4 36 Figure 4 16 Hand Torch Lead Assemblies MAX200 Service Manual PARTS LIST MAX200 Rev 1 Hand Torch Lead Extensions
88. 73003 073004 073005 073026 and 073200 CE Power Supplies with THC 073020 073021 073022 073023 073024 and 073213 CE MAX200 Service Manual PARTS LIST a NINN A SB Nm Nm RH DR 42 J 080 HHH ND dl 8 PARTS LIST ice Manu MAX200 Serv Base Plate MAX200 Power Supply Part Number z 3 001229 014078 014097 014088 014111 014082 005102 014080 014080 075241 075199 075242 029314 004336 J O O1 G ND N N N N Description Base MAX200 Transf mer 30KW 240 480 3 PH 60 Transf mer 30KW 208V 3 PH 60 Transf mer 30KW 220 380 400 415V PH 50 Transf mer 30KW 200V PH 50 Transf mer 30KW 600V 3 PH 60 Thermostat 160 C 6 Amp Inductor 4mh 100A Inductor 4mh 100A M S 1 4 20 X1 2 SL IHW S Z Flwshr 1 2 532 1 06 099 S Z M S 1 4 20 X 3 4 SL IHW S Z Plasma Gas SA MAX200 Panel MAX200 Plasma Gas MTG Used on 208 volt power supplies 073004 w o THC and 073022 w THC PARTS LIST Designator N 8 Used 220 380 415 volt power supplies 073005 w o THC and 073023 w THC and 400 volt CE power supplies 073200 w o THC and 073213 w THC Used on 200 volt power supply 073026 w o THC and 073024 w THC Used on 600 volt power supplies 073003 w o THC and 073021 w THC See page 4 11 for subassembly breakdow
89. 73134 75 Leads 073171 073147 073159 073123 073183 073135 100 Leads 073172 073148 073160 073124 073184 073136 125 Leads 073173 073149 073161 073125 073185 073137 150 Leads 073174 073150 073162 073126 073186 073138 Heat shield 020881 included in MAX200E systems MAX200 Service Manual 4 71 PARTS LIST PAC200T E Trigger Torch Consumables Figures 4 34 4 35 Note See page 4 74 for consumable part kits Plasma Gas Retaining Swirl Amps Shield Gas Shield Cap Nozzle Ring Electrode Air Air 020918 020915 020608 020607 220021 Air Air 020919 020915 020611 020607 120547 Air Air 020917 020915 020689 020613 220021 O Air 020918 020915 020605 020604 220021 O Air 020919 020915 020616 020617 120547 N gt CO 020918 020915 020608 020607 020415 Stainless Air Air 020918 020915 020608 020607 220021 Steel Air Air 020919 020915 020611 020607 220021 Air Air 020917 020915 020689 020613 220021 No Air 020918 020915 020608 020607 020415 CO 020918 020915 020608 020607 020415 H35 No 020920 020915 020608 020607 020415 H35 No 020919 020915 020611 020607 020415 Aluminum Air Air 020918 020915 020608 020607 220021 Air Air 020919 020915 020611 020607 220021 Air Air 020917 020915 020689 020613 220021 N Air 020918 020915 020608 020607 020415 CO 020918 020915 020608 020607 020415 H35 N 020918 020915 020608 020607 020415 H35 N 020919 020915 020611 020607 020415 Mild Air Air 020891 020882 0
90. 8 Inductive IHS Torch Mounting Assembly 4 64 MAX200 Service Manual 1 99 Part ltem Number 1 004085 2 005078 3 005085 4 008145 5 004656 Rear Description Nut Ins Ind Sensor Cap Sensor UW IHS Sensor Inductive Plug 3 Pin M Ind Sensor UW IHS Heat shrink View Inductive Sensor End Legend Inductive Sensor End PIN COLOR MAX200 Service Manual FUNCTION Power 15 VDC Common Signal Figure 4 29 Inductive Sensor Assembly PARTS LIST Qty 2 2 2 2 1 LI 4 65 PARTS LIST 10 2 eunbiy ees 15 6 SH 40 5195 peo 0 y MAX200 Service Manual 4 66 PARTS LIST Interconnecting Leads for Inductive IHS System 028244 028245 028282 028246 028247 028356 25 ft 50 ft 75 ft 100 ft 150 ft 200 ft 024144 024144 024144 024144 024144 024144 023115 023115 023115 023115 023115 023115 023115 023115 023115 023115 023115 023115 023111 023112 023155 023113 023114 023284 008176 PIN 4 IHS End Inductive Sensor End P15 P16 P17 P18 047029 Cable 22 3 TW OA Shielded 008195 Strain Relief 009211 Plug Shell 11 4 Rev Sex 008144 Plug 3 Pin F Amphenol 9 Legend Inductive Sensor End P17 P18 Legend IHS End P15 P16 Signal Common Shield Power 15 VDC A Power 15 VDC B Common C Signal Note Cut Shield Sensor End Figure 4 31 Cable IHS P15 16 Sensor 17 18 MAX200 Service Manual 4 67
91. 80 10 5 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 Charts in the Operation section of MAX200 Instruction Manual 800870 or 800980 Check cable from power supply to remote V C control See Parts List section for information on the remote V C cables 10 6 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 10 7 Transfer of arc is not sensed See Arc Transfer Test Procedure later in this section to troubleshoot 10 8 Choppers 1 and or 2 defective or not functioning See Chopper Module Test Procedure later in this section to troubleshoot 11 No Initial Height Sensing 11 1 Torch lifter motor defective machine torch systems with Replace torch lifter motor if necessary IHS option 11 2 THC board not being activated Check to see if D5 on 9 illuminates after the STATUS indicators all extinguish See Figure 3 15 for location of D5 If D5 is notilluminated then PCB9 may not be getting 120VAC from Power Distribution Board PCB6 Using 013 2 179 wiring diagram check pins connectors and associated wiring from REC5 of PCB9 to REC2 of PCB6 Repair and or replace defective component s if necessary 3 26 MAX200 Service Manual 1 97
92. 9 2 313 029313B4 PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND FROM INC SHARP EDGES BREAK SHARP EDGES IF SCALE MODEL SHEET NE NECESSARY WITH CHAMFER OR RADIUS 015 N A A k Description of change for revision 15 date of change 4 2008 Added changes for revisions 14 and 15 Pages moved to the end of the manual change pages Updated EMC and Warranty information to the latest version Updated table of contents to reflect changes for the new revision scis Updated section 1 and 1a with the latest safety sections Added the Spanish safety section 1b 4 7 Changed part numbers for items 3 4 and 24 005088 to 005151 005168 to 005187 and 075104 to 075394 respectively Changed part number for item 7 from 008316 to 008945 Added a note to shield gas SA to see page 4 23 Removed components for Incoming power TB1 SA 029316 and made 02916 item number20 Renumbered item numbers 24 through 26 They are now item numbers 21 through 23 A ee Changed the part number for the chopper SA from 129118 to 129789 Added a note to shield gas SA to see page 4 15 4 25 Removed HF amp I O PCB SA 029312 and item numbers 16 and 17 Changed heat exchanger part number from 027136 to 027978 Added part number 128410 coolant reservoir upgrade kit and a note for older systems Changed the part number for the lamp holder from 005088 to 005151 Changed the part number for the cool
93. 9 5 liquid Nitrogen 99 995 liquid Carbon Dioxide CO 99 5 compressed or liquid Argon Hydrogen H35 35 Hydrogen 65 Argon Plasma Gases Air No H35 Shield Gases ias Air CO No Plasma Gas 66 Air 60 scfh 70 scfh H35 72 scfh Shield Gas Flow 220 280 scfh Air 290 scfh N gt Plasma Gas Inlet Pressure 90 120 psi 6 2 8 3 bar flowing Shield Gas Inlet Pressure 90 psi 6 2 bar flowing Plasma Gas Pressure Test Run See Cut Charts in Operation section of IM87 800870 or IM98 800980 Shield Gas Pressure 70 psi 4 8 bar MAX200 CE Power Supplies The specifications specific to the 400V CE power supplies 073200 and 073213 are listed below These CE power supplies conform to all other CE power supply specifications as listed above Refer to Appendix A for EMC requirements power cable connections and parts information specific to the MAX200 CE power supplies 1 99 Input Power Input Voltage Uy x Input Current 073200 without THC 400 VAC 30 50 Hz 56 amps 073213 with 400 VAC 30 50 Hz 56 amps Dimensions 40 3 4 104 cm w o casters 48 1 4 122 cm w casters sami 800 pounds 363 kg MAX
94. 98 Hypertherm Sistemas plasma SEGURIDAD Etiqueta de advertencia Esta etiqueta de advertencia se encuentra adherida a la fuente de energia Es importante que el operador y el t cnico de mantenimiento comprendan el sentido de estos s mbolos de advertencia seg n se describen El texto numerado corresponde a los cuadros numerados de la etiqueta WARNING Protect yourself and others Read and under stand this marking AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Disconnect power source before servicing Couper l alimentation avant d effectuer le d pann ge Disconnect power source before disassembly of Couper l alimentation avant de d monter la torche the torch Utiliser exclusivement les torches indiqu es dans le Use torches specified in the instruction manual manual d instructions This plasma cutting machine must be connected Le raccordement au r seau de cette machine de to power source in accordance with applicable coupage arc plasma doit tre comforme aux codes electrical codes de l lectricit pertinents Plasma arc cutting can be injurious to operator Le coupage arc plasma comporte des risques pour and persons in the work area Before operating l utilisateur et les personnes se trouvant dans la zone read and understand the manufacturer s instruc de travail Avant le coupage lire et comprendre les tions and know your employer s safety practices
95. ANT MISDS a 1 APPENDIX B ELECTROMAGNETIC COMPATIBILITY b 1 APPENDIX C WIRING DIAGRANMsS U UU u Q u UU U J Q J EHE EE EE anaa c 1 Switch Remote SR Wiring Diagramme c 2 Digital Remote DR Signal AC Diagramme c 3 Programmable Remote PR Signal AC Diagramme c 4 Initial Height Sensing IHS Wiring Diagramme c 5 MAX200 Electrical Schematic 8 Block Diagram 013179 Coolant System Schematic amp Diagram au uu orinar nr rin a ii a 029313 viii MAX200 Service Manual 15 Section 1 SAFETY In this section Recognize Safety INTOMMATION coccion 1 2 Follow safety instructions 1 2 Cutting can cause fire or explosiOn u ias esters ner ieu a hed A derided 1 2 l ctric Shock Can killu ua sk 1 3 Static electricity can damage circuit sr 1 3 Toxic fumes can cause injury ee tete ua nt dr 1 4 A plasma arc can cause injury and 1 5 Arc rays can burn eyes and 1 5 Grounding Salety 1 5 Compressed gas equipment safety iii 1 6 Gas cylinders can explo
96. AX200 SR V C Plug Shell 13 9 Size Socket 20 24 AWG Type 111 Receptacle Shell 17 16 Size Pin 20 24 AWG Term 22 18 250 FEM QC Insul Term 22 16 6 LCK Fork Insul Term 22 18 FEM QC Insul Term 22 18 6 Ring Uninsul Term 22 18 FEM QC Inusl Term 22 18 25 MAL QC Insul Rear Panel SA MAX200 Pnl MAX200 SR V C Rear Fuse 3 8 Amp 313 375 Fuseholder Rem HT400 Transf mer DR PR SR V C HT400 Relay 24VAC DPDT Bifurcated Cont Figure 5 1 Designator Vols Amps PCB2 PCB1 RECP1 1 52 PB1 PB2 PL1 RECP2 F1 T1 CR1 PARTS LIST N O m P N 8 N 4 51 PARTS LIST 4 52 Figure 4 21 Digital Remote DR V C Control MAX200 Service Manual Digital Remote DR V C Control Part Item Number 073007 1 002107 2 002106 3 002119 4 004119 5 008069 6 008165 7 008164 8 014012 002118 9 001133 10 001131 11 001137 12 001138 029302 13 009871 14 008175 15 008176 074016 074038 074041 074067 16 041070 008097 17 041187 18 004116 19 042059 20 009274 008097 008098 21 041076 22 041077 MAX200 Service Manual Description Control Station Digital Remote V C Cov DR PR V C Top Cov DR PR V C Bottom Panel Rear DR V C Bracket Mtg DR PR V C Fuse 3 8 Amp 313 375 Fuseholder REM V C Knob Transf mer DR PR SR Encl Assy DR V C PI HT40
97. Amp 1B3 009041 1 11 015001 Adapter Bulkhead 1 4 NPTF 2 12 015005 Adapter 1 4 NPT x 4 4 015259 Swivel 4 1 13 015100 Adapter 1 4 NPT x 1 4 Poly 1 14 015502 Nipple 1 4 x CL 1 15 024038 Hose Assy 4 x 7 1 16 041043 PC BD Assy UW IHS 041043 1 17 041023 Power Source IHS 1 18 008094 Terminal Strip 8 2TB 1 MAX200 Service Manual 4 57 PARTS LIST MAX200 Power Supply Internal Hosing To identify hosing find lettered item where one of the ends of the hosing terminates from the exploded views and find the same lettered item and page number under the column From Item on Page or To on Page in chart below From Item on Page To Item on Page Part No Description 046067 046067 046067 046067 046067 046067 046067 046067 046048 Tubing 1 8 OD Blk Air Brake 046048 046047 Tubing 3 8 OD Blk Air Brake 046047 046047 046047 046047 046047 046047 046016 Hose 3 8 ID 046016 Tm T gt O gt U P gt m p O U U O gt 0 A D E F G D B A B C D B E J L N P 4 58 MAX200 Service Manual 3 96 PARTS LIST 10 ajqed 29831974 2 4 BIS peoueApy uen Bis peAejeq uono peo Aejay dn peo Aejay BIS euseld Bis dois euise d 0145 ueis Bis peoueApy UONON Yen PIUS 09
98. Bis peAejeq nig plus eur pius eur pleius Bis PuIseld BIS euseld nig pius 9015 UOWUWOD 0S 0145 uopo yoe 1 118 0145 pe ejeq uonoW peus BIS 09 uano Cane Bis 1 olnv 002 655550 y 091 855550 wos Y 001 165550 wez 4 SZ 955520 558820 9 7 y SZ 20 OVALE 14M Bis Jenu NO sf 10 CO plus 19145 BIS PIOH UM 0 LXL pug Ajddns LXL pug Ajddns ecce AWK padvjag pepuswwosa 1 05190 dv IXI UO LOW PIS ZE EQ 2ZIS Neus 956800 Addns Janod I 8ET902 dy 5 62 laus UNMS 681800 WW UO ZOW uU U2 DIN fF dn 6 8 PEPISIUS 98 22 91092 921 0 0199 III d JAY 2 02 3205 981800 30 PIYOFIMS OVA 1491
99. DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 3 55 013179 013 2 179 013179B4 PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND SHARP EDGES BREAK SHARP EDGES IF SCALE MODEL SHEET FROM HYREE THERM ING NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 4 OF 9 1 D aA SHEET 1201 023319 2 2 i er 191 Xi nues 1 l 76 29 i RE Fi ES i 1 Current eU WHT 23 BLK APS SES zt pan 1 Remote V C 1 elect 010111 1241 i 1 073007 175 bauen 159 BLU 1 BLU 4 2 Plasma Start Relay orl I 013007 i 13 Voltage n 111 1 a DN 176 1 ivi 10 I 1 160 I l BK LESES Stop 02387 i SHEET 4 Divide 111 151 141 I lop 3 A2 L 100 121 Shan Common ERAS pra ar E no I 1 1 pcne uM e Auto Height 1 1 I 1 101 1 CH1 CH2 Current A na la 157 BRN
100. ETPOINT i POTENTIOME TER A d Digital Remote DR Signal AC Diagram 9 66 6 p 9 enuen 9919S 002 7 RECPJ 041085 041076 GRN SID DATA 3 PC BD ASSY 2PC PR HT400 OPTO ISO BLK SID COM 6 EBD 122 1 l m lt 115 l 1FU ORN 8 E P RECOMMENDED INTERFACE 1 TIL 117 DARLINGTON 6 RECP RECOMMENDED Use Texas wun I instruments 1 R vs Cand s 9 V10 ABEL 10 V20 mene 4 waa BCD 10 s 11 VOLTAGE W YEL V8O BLK ON REQ vso PROGRAMMING 100 13 WHT QN RN 100 W RED V200 cab HHT ON RED 200 BCD 100 7 WHT COMPUTER COMMON GRA 120 I 4 a 120 BLU I49 2b ___ LU 140 gt BCD 10 EN180 gm pS iE EL 1190 4 VHT 1100 PROGRAMMING QRN i299 sb ___ 1200 BCD 100 s RED 1400 8 Rm co 1400 AR I W BLK SPARE 5 UN 16 ue BELDEN 9541 15 Shielded Twisted Overoll Wires 929089 FILTER PANELCPC BOARD PR m43 COMPUTER INTERFACE 1 Drwg 13 2 056 Programmable Remote PR Signal AC Diagram 9 XIGNAddV APPENDIX C 16 RECP 1 E ez
101. Health of the people around for example the use of pacemakers and hearing aids f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures Hypertherm ELECTROMAGNETIC COMPATIBILITY EMC h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking 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 manufacturer s 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 permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected 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
102. IHM SI 17668 N30738 JOVANSINI M3lndNOO Q30N3 WOO3M 5 261800 9215 91 21 1945 4 Sc0Zr0 161800 pIeIus WMA peuAauM UD UM p y Alg nigauM XIgaAuM peu s 001 aaf La ed om Oe M OBA H EE NO ME 02 Juano 01A Lol S en re mio iu NO sf 10 OR 1795 91 194905 981800 MAX200 Service Manual 4 63 15 PARTS LIST Inductive IHS Torch Mounting Assembly Parent Item numbers 028390 and 028720 includes items listed below as well as IHS Control Module 053016 listed on pages 4 54 and 4 55 Part Item Number Description Qty 028720 Inductive IHS 2 used with standard amp stainless steel torch 029044 Torch MTG SA Induct IHS MAX200 1 004082 Bracket IND Sensor UW IHS 1 2 004083 Bracket MTG Torch UW IHS MAX200 1 3 015005 Adapter 1 4 NPT x 4 1 4 027024 Cylinder IND Sensor UW IHS 1 5 005074 Inductive Sensor Assembly 2 Part Item Number Description Qty 028390 Inductive IHS 1 3 4 used with optional torch 029334 Torch MTG SA Induct IHS MAX200 1 004082 Bracket IND Sensor UW IHS 1 2 004349 Bracket MTG Torch UW IHS MAX200 1 3 015005 Adapter 1 4 NPT x 4 1 4 027024 Cylinder IND Sensor UW IHS 1 5 005074 Inductive Sensor Assembly 2 Figure 4 2
103. IHS Complete Supply Hold I 1 i po Gies IHS Start 100 I Delay Pot 200A 11 Arcon I 4 1125676 2345678 1234567 1234567 res f Y E PULSE x 288 ld ie 1 a 145 WHT 156 BLK ry 657 SHIELD Py 39 M2 H PL20 144 VIO 6 162 BLK 115 BLK ig S T 143 BLU 1 1 161 1 1 WHT I BLU n ie ll 15 1 191 171 M2 2 I REC20 142 GRN el 164 BLK m El BLK X E Rd 1415 5110 1 M2 4 I S 141 YEL 15 163 GRN IS aqu GRN 139 e YEL 2 8 I Qu ol 140 ORN 165 BLK BLK jag 1 LORN 1 1 I 21218 3o FES 139 RED 1 166 WHT 1 RED 1 1195 1 135 1 162 1 2 RCC Option 023462 se 023675 m I Opitional Machine Delay L Potentiometer a 73045 ee 7 M1 COM I 145 WHT M2 COM 144 M2 143 BLU 1M22 Optional i 142 GRN 1 2 4 200 Thumbwheel 141 YEL M2 8 numb 140 ORN 3M1 1 l 139 RED 1M1 2 1 Thumbwheel Option 602 THC Option SHEET 5 D3 R MATERIAL DRAWN BY DATE BC 5 9 96 Janco es tanc pees AS DUG WSL 80080 000 APP BY DATE Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES TOLERANCES ARE ELEC GAS SCHEM MAX200 THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 005 ITEM NO
104. MMAGER LES CARTES DE CIRCUITS IMPRIMES On doit ranger les cartes de circuits imprim s dans des contenants antistatiques On doit porter un bracelet antistatique quand on manipule les cartes de circuits imprim s 1a 3 8 06 SECURITE N plasma est lui m me la source de chaleur utilis e pour le coupage Par cons quent bien que plasma n ait pas t reconnu comme une source de vapeurs toxiques le mat riau coup peut tre une source de vapeurs ou de gaz toxiques qui puisent l oxyg ne Les vapeurs produites varient selon le m tal coup Les m taux qui peuvent d gager des vapeurs toxiques comprennent entre autres l acier inoxydable l acier au carbone le zinc galvanis et le cuivre Dans certains cas le m tal peut tre rev tu d une substance susceptible de d gager des vapeurs toxiques Les rev tements toxiques comprennent entre autres le plomb dans certaines peintures le cadmium dans certaines peintures et enduits et le b ryllium Les gaz produits par le coupage plasma varient selon le mat riau couper et la m thode de coupage mais ils peuvent comprendre l ozone les oxydes d azote le chrome hexavalent l hydrog ne et autres substances pr sentes dans le mat riau coup ou en manent On doit prendre les pr cautions qui s imposent pour r duire au minimum l exposition aux vapeurs produites par tout processus industriel Selon la composition chimi
105. NLESS OTHERWISE SPECIFIED DESCRIPTION ARC TRANSFERS TO THE WORK PIECE WHICH EVER HAPPENS FIRST eS TOLERANCES ARES a U ELEC GAS SCHEM MAX200 V N 2 PL DECIMAL 01 ITEM NO DRAWING NO FILE NAME GAS SYSTEM DESIGNATOR CONTAINED THEREON IS CONSIDERED 3PL OME FOR MANUFACTURING OR FABRICATION ANGULAR Eso 013179 013 2 179 013179B9 PURPOSES WITHOUT PERMISSION CARE pees SCALE MODEL SHEET FROM NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 9 OF 9 1 ____ RESERVOIR OVERFLOW FLOAT SWITCH TEMP SWITCH RELIEF VALVE ON OFF PUMP PARTICULATE FILTER COOLING LEADS RHF CONSOLE TORCH LEADS HT2000 lt CATHODE BLOCK INSIDE POWER SUPPLY CN HEAT EXCHANGER O CHECK VALVE FLOW SWITCH N TORCH LEADS MAX200 DRAWN BY DATE ea BMD 8 13 90 U Jaa cs erae MER 10 1091 UEG CHUGH ad WVB id Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES THIS DRAWING AND ALL INFORMATION TOLERANCES ARE 2 PL DECIMAL 2 01 DESCRIPTION RSVR SA MAX200 HT2000 PWR SPLY AN CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 005 ITEM NO DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 029313 02
106. OSE BLUE W RED BAND Figure 3 7 200 Machine Torch Lead Connections to Power Supply MAX200 Service Manual 3 43 1 99 MAINTENANCE Individual Torch Leads To remove and replace individual torch leads perform the following procedure and see Figure 3 8 Refer to Section 4 Parts List pages 4 44 to 4 48 for machine torch lead assemby part numbers for different lead lengths and other torch lead parts Removal 1 Disconnect the torch lead from the power supply as described in Removal under Removal and Replacement of Machine Torch Lead Set on page 3 41 Disconnect the torch from the torch lead as described in the Removal and Replacement of Machine Torch procedure on page 3 40 Lay the torch lead on the floor and stretch it out completely Cut away the heat shrink 7 and any tape underneath at both ends Remove the hose clamp 11 shield collar 10 and compression ring 9 from the torch lead at the other end Cut away any tape under the compression ring Holding one end of the the torch lead pull the shield braid 8 off of the torch lead Cut the tape every 18 inches that holds the torch leads together Remove the lead 1 5 requiring repair or replacement Replacement 1 2 Replace the repaired or replacement lead s with the other leads Ensure the lead lengths 1 5 at both ends are in accordance with those called out in Figure 3 8 Tape the leads together every 18 inches Slide th
107. OWSV q 0S PUIAANI 1013101 4 59 MAX200 Service Manual PARTS LIST Description and Comments Plasma Emergency Stop 24VAC 1X1 pins 28 33 cable lugs 80 81 Open to stop To use remove jumper on TB3 80 and 81 in power supply Plasma Start 24VAC 1X1 pins 9 15 cable lugs 82 83 Close to start Open to stop Initial Height 12VDC 1X1 pins 2 6 cable lugs 173 174 Close for no IHS Open for IHS Auto Height 2VDC 1X1 pins 3 7 cable lugs 171 172 Close for no Auto Height Open for Auto Height Current 50 12VDC 1X1 pins 4 8 cable lugs 135 136 Reduces current to 50 of preset for cornering etc Close for 50 current Open for 100 current Hold 12VDC 1X1 pins 1 5 cable lugs 86 87 Synchronizes starting of two or more systems Close for no start Open for start Relay Down Solid state relay dry contacts rated to switch 24 to 240VAC 1 amp DC relay optional 1X1 pins 29 34 cable lugs 169 170 Relay Up Solid state relay dry contacts rated to switch 24 to 240VAC 1 amp DC relay optional 1X1 pins 30 35 cable lugs 167 168 Machine Motion Delayed 1X1 pins 31 36 cable lugs 84 85 Contact closes after arc transfer and time delay set on power supply front panel Relay dry contacts Machine Motion Advanced 1X1 pins 32 37 cable lugs 79 78 Contact closes approximately three
108. Power light on fan on All interlocks satisfied Yes Torch retracts to IHS installed Upper Limit Switch ULS and ON D2 and D3 on PCB9 illuminate No 24VAC 120VAC relay CR1 closes D5 amp D33 12VDC on PCB7 illuminate 240VAC relay CR3 closes coolant pump motor M1 on and V7 valve activates opens All status indicators extinguish THC installed D5 12VDC on 9 illuminate To page 3 9 3 8 MAX200 Service Manual 1 97 MAX200 Service Manual MAINTENANCE From page 3 8 Switch to TEST Plasma gas valve V1 shield gas valve V2 and step valve V3 all open Gases flow Adjust flow rates set current THC installed Yes Set machine delay Plasma gas valve V1 shield gas valve V2 and step To valve V3 all close page 3 10 Gases stop flowing 3 9 MAINTENANCE From page 3 9 Push START button IHS installed IHS probes extend and ON D2 on PCB9 active 1 2 second delay Plasma gas valve V1 shield gas valve V2 open D6 Start on PCB7 lights Torch indexes to work and IHS probes retract 2 seconds of gas preflow 3 10 MAX200 Service Manual MAINTENANCE Main Contactor closes pilot arc relay CR1 closes power to high voltage transformer T5 high frequency sparking and pilot arc initiated DC ON lights 021 Chopper1 D22 Chopper 2 on PCB7 light Transfer of arc Arc
109. 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 binding upon Hypertherm Hypertherm WARRANTY Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or near the data plate Each certification test mark means that the product and its safety critical components conform to the relevant national safety standards as reviewed by that testing laboratory Hypertherm places a certification test mark on its products only after that product is manufactured with safety critical components that have been authorized by the accredited testing laboratory Once the product has left the Hypertherm factory the certification test marks are invalidated if any of the following occurs The product is significantly modified in a manner that creates a hazard or non conformance Safety critical components are replaced with unauthorized spare parts Any unauthorized assembly or
110. S OTHERWISE SPECIFIED DESCRIPTION N TOLERANCES ARE ELEC GAS SCHEM MAX200 THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 005 ITEM NO DRAWING NO FILENAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 5 013179 013 2 179 013179B1 PURPOSES WITHOUT PERMISSION SHARP BOCES AK SHARE EDGEB IE SCALE MODEL SHEET FROM EXPER THERM ING NECESSARY WITH CHAMFER OR RADIUS 015 N A MAX200 1 OF 9 4 3 T 2 1 SHEET U 3 D3 1 NOTE SEE SHEETS 788 A FOR WIRING DIAGRAMS E 1 OF SUPPLY VOLTAGES 200 200 VAC F3 B A 208 39A 380 415 1A 1 240 480 T 39A x Customer 500 18 LiB 1B TSW1 d Supplied 575 600 Disconnect 1 1 1c CH130 CHOPPER SA Box 1 ul L1 445 TE A4 3 OZI 41A Ls NEG 123 123456 A m S 5561 9 9 J alas B4 SE F 5 E
111. T5 Replace T5 if leaking or overheating MAX200 Service Manual Problem 8 The green POWER ON indicator is illuminated the torch START command is given and the DC ON indicator illuminates and there is high frequency but there is no pilot arc MAX200 Service Manual MAINTENANCE Possible Causes and Solutions 7 2 8 1 8 2 Disconnect PL26 from REC26 and check for 120VAC at PL26 after START command is given REC26 is located near T5 high voltage transformer See Figure 4 10 for location of T5 If there is no 120VAC at PL26 use 013 2 179 wiring diagram and check pins connectors and associated wiring from PL26 to REC2 of Control Board PCB7 If connections are O K replace PCB7 If there is 120VAC at PL26 shut down system and remove capacitors C7 and C8 See Figure 4 11 for location of C7 and C8 Restart system and see if a faint spark is now observed across the gaps If a spark is not observed at the gaps replace T5 If there is a spark shut down system and replace capacitors C7 and C8 Always replace the capacitors in pairs 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 1 is not getting 120VAC from the Control Board PCB7 See if the CR1 relay contacts close after the START command is given See Figure 4 10 for location of CR1 If CR1
112. This page left blank intentionally MAX200 Service Manual 4 49 PARTS LIST Figure 4 20 Switch Remote SR V C Control Station MAX200 Service Manual Switch Remote SR V C Control Part Item Number 073001 1 002107 2 002125 3 004123 029302 4 009871 5 041070 008097 6 041187 7 004116 8 042059 9 009274 10 041076 11 041077 12 008175 13 008176 074016 074038 074041 074067 002179 14 001243 15 001141 16 001137 17 001138 18 005044 19 005082 20 005083 21 008164 029304 22 008185 23 008186 24 008193 25 008176 074016 074027 074038 074041 074053 074067 029301 26 002127 27 008069 28 008165 29 014012 30 003096 MAX200 Service Manual Description Conirol Station SW Rem V C MAX200 Cov DR PR V C Top Cov SR V C Bot Bracket Mtg SR V C HT400 Filter PNL PCB SA DR SR V C Potentiometer 500 Ohm 10 Turn PC BD Assy Opto Iso HT400 Terminal PC HHS 2022C PC BD Assy Dig Sta V C MAX200 Heatsink DR PR SR V C HT400 IC LM340AK 5 0 Capacitor 2600 UF 15VDC PC BD Assy Rem Volt Disp PC BD Assy Rem Curr Disp Receptacle Shell 13 9 Size Pin 20 24 AWG Term 22 18 250 FEM QC Insul Term 22 18 FEM QC Insul Term 22 18 6 Ring Uninsul Term 22 18 25 MAL QC Insul Encl MAX200 SR V C PI MAX200 SR Fr Flg HT400 SR V C Mal Fr FR 400 DR PR ST V C Mdl LS FR 400 DR PR ST V C RS Switch Tog 1PI Maint On On Switch PB Green Full Guard Switch PB Red Mushroom Head Knob Harness SA M
113. Water Cooled 25 Ft blue red band Cable Water Cooled 25 Ft blue green band Hand Torch Lead 50 Ft Lead Pilot Shield Gas 50 Ft blue Lead Plasma Gas 50 Ft red Lead Cap Sensor 50 Ft gray Cable Water Cooled 50 Ft blue red band Cable Water Cooled 50 Ft blue green band Cable Switch 51 Ft Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black Sheath 25 Ft or Sheath 50 Ft 33 NS 2 MAINTENANCE i A A ll dd A A dl l cl D DD P hy 5 Figure 3 5 200 Rev 1 90 Hand Torch Lead Set Assembly MAX200 Service Manual A MP 3 39 MAINTENANCE MAX200 Machine Torch Removal and Replacement To remove and replace the torch main body from the torch lead perform the following procedure and see Figure 3 6 Removal 1 Unscrew the insulating sleeve from the torch main body and slide the sleeve out of the way in order to expose the torch lead fittings On the larger leads use a 3 8 open end wrench to hold the torch body fittings and a 1 2 open end wrench to turn the torch lead fittings On the smaller leads use a 5 16 open end wrench to hold the torch body fittings and a 7 16 open end wrench to turn the torch lead fittings Turn the torch lead fittings counterclockwise ccw to loosen the connections Note that the red lead fitting is reverse threaded and must be turned in the opposite direction clockwise Remove t
114. X200 Machine Torch Main Body 1 3 020536 Lead insulator 9 16 X 2 5 Tef 1 4 044027 O ring Buna N 1 The following consumables are part of the MAX200 Machine Torch Assembly See Figure 4 17 for details 020424 Shield MAX200 Mch 200A 1 020423 Cap Nozzle Retaining MAX200 1 020608 Nozzle MX200 200A 086 Air N2 H35 1 020607 Swirl ring MAX200 Air N2 H35 1 220021 Electrode MAX200 Air O 2 1 Figure 4 18a MAX200 Machine Torch Assembly Optional 4 42 MAX200 Service Manual PARTS LIST MAX200 Machine Torch Assembly with 1 75 diameter Torch Body and 1 75 diameter Sleeve Optional Part Item Number Description Qty 128364 MAX200 Machine Torch Assembly 1 1 020431 Sleeve Insul MAX200 Mach 1 75 diameter 1 2 120584 MAX200 Machine Torch Main Body 1 3 020536 Lead insulator 9 16 X 2 5 Tef 1 4 044027 O ring Buna N 1 The following consumables are part of the MAX200 Machine Torch Assembly See Figure 4 17 for details 020424 Shield MAX200 Mch 200A 1 020423 Cap Nozzle Retaining MAX200 1 020608 Nozzle MX200 200A 086 Air N2 H35 1 020607 Swirl ring MAX200 Air N2 H35 1 220021 Electrode MAX200 Air O 2 1 Figure 4 18b MAX200 Machine Torch Assembly Optional MAX200 Service Manual 4 43 PARTS LIST Machine Torch Lead Assemblies See Figure 4 19 Ite GQ D O ON O D O O h h 4 44 Part Number 028454 023429 024216 024221 023032 02303
115. X200 power supply while in TEST mode adjust the PLASMA gas valve control by increasing the TEST pressure approximately 5 psi per 50 ft of lead length beyond 50 ft from what is called out in the Cut Charts See note on page 4 17 in IM87 A WARNING Use extreme caution when making the following adjustment 2 If the plasma gas RUN pressure does not quickly reach the value stated in the Cut Charts after arc transfer you may need to adjust PS4 Remove the right side panel of the power supply On the floor of the power supply locate pressure switch PS4 by referring to Figure 3 13 and adjust by turning the PS4 Adjustment screw clockwise direction TOP VIEW PS4 Adjustment 54 ejsra O 5 30 m 40 tE 56 E RIGHT SIDE VIEW Figure 3 13 Pressure Switch PS4 and Adjustment Location MAX200 Service Manual 3 53 MAINTENANCE 3 54 8 98 REC2 D5 12VDC D2 IHS REC4 CR1 03 CR2 7 CR3 4 Down L RECS Figure 3 14 PCB9 THC Mother Board REC3 1 D22 Chopper 2 D21 Choppe
116. Y WITH CHAMFER OR RADIUS 015 DESCRIPTION ELEC GAS SCHEM MAX200 AN ITEM NO DRAWING NO FILE NAME 013179 013 2 179 013179B6 SCALE MODEL MAX200 SHEET 6OF 9 3 7 4 073005 a 073004 amp 073022 m 073026 amp 073024 gt 415 VAC 600 VAC El 208 VAC LES 2 3 Phase 220 380 411 5 50 2 3 Phase 575 600 60 Y 3 Phase 208 60 50 OR 60 Hertz 11 a A L1 50 Hertz 60 Hertz 60 Hertz 200 50 60 PE WIRED FOR 415 VAC T PE WIRED FOR 600 VAC PE PE spe Bem WIRED FOR 208 VAC E Handle I LE Handie 7 Handle iT LE Handle 1 5 3 3 I ZTEsStop i 11 Y Esop La 147 SR I T PODES 1 I Fuse Fuse 1 I I a ruse I LISE Teese a a 94 1 Ld Ter 1 1 I I I I I 2181 CON1 ree is A I i I i i 1 1 I I 16 M 1 13 16 A4 I 6 l l L3 I A4 I 4 1 ret as n tsi r iss ET IW D I 1 I _ Li 1 1 I I ME ES 4 AE I I liga L aes B4 jy 15 o
117. _______ 4 Eos a a ve de Machine Motion LR HOLD DELAY Machine Interface Cable 023334 77 174 ex P EL ES T A ee 24 w STOP Initial Height h 76 173 ON Open 81 172 pos Remote STOP Auto Height Remote STOP ight _ 80 171 ONZOpen VDC Motor i VIO Motor ali E Remote START DOWN Relay ___ at Ld ORs 89 169 VDC Motor 88 168 Motor ys A Se ee igh SE ee re ee ee 4 O of E Machine HOLD UP Relay QO oR 77 1 PASAR gt age ae a te dent o0 ro Fg Ka ls VAC 85 196 ea to to to achine Motion DELAY 50 CURRENT 1 Machine HOLD Machine HOLD Machine HOLD TTTTTTT 84 185 7 Power Supply 4 Power Supply 3 Power Supply 2 Motor VAC 79 o Z Machine Motion ADVANCED DELAY 78 MATERIAL DRAWN BY DATE BC 5 9 96 Elon m m ahl a muro VIGO 800890 000 APP BY DATE Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES THIS DRAWING AND ALL INFORMATION CONTAINED THEREON IS CONSIDERED PROPRIETARY AND MAY NOT BE USED FOR MANUFACTURING OR FABRICATION PURPOSES WITHOUT PERMISSION FROM HYPERTHERM INC TOLERANCES ARE 2 PL DECIMAL 01 3 PL DECIMAL 005 FRACTIONS 1 64 ANGULAR 500 PART MUST BE FREE OF BURRS AND SHARP EDGES BREAK SHARP EDGES IF NECESSAR
118. ant filter from 027137 to 027005 Changed coolant pump SA 029325 to a kit number 128384 Corrected the part number for item 14 from 029618 to 129618 Corrected the part number for the torch main body It was 020584 and changed to 120584 Replaced obsolete part numbers for 90 hand torches with 25 foot 073008 to 073189 and 50 foot leads 073009 to 073190 4 36 Changed the part number for the 25 foot water cooled cable from 023324 to 023013 Changed the part number for the 50 foot water cooled cable from 023325 to 023199 4 44 through Changed the part number and description for item number 8 from 046061 2 inch ID tinned braid t 4 48 046114 1 5 inch ID tinned braid 4 51 and 4 53 Changed the part number for item number 4 from 009336 to 009871 same change for item number 13 on page 4 53 Changed the part number for item number 26 from 002176 to 002127 Changed the part number for swivel 4 below item number 12 from 015006 to 015259 Also added fer rule 015140 on page 4 69 463 Removed part number 023098 10 foot 3m Removed part numbers 027109 and 046023 and added the part number for the heat shrink that is used 4 65 now 004656 Added part number for screws 075365 qty 8 Schematics 013179 and 029313 changed from 8 5 x 11 to 11 x 17 fold outs us Description of change for revision 14 date of change 2 2000 4 45 and 4 46 Note added about extended leads over 75 causing start problems 4 57 and 4 69
119. ant reservoir Check to see if water coolant is above 160 C Disconnect PL24 located in the rear of the power supply near the coolant reservoir and check to see if TS2 is open TS2 is normally closed and is opened when a temperature above 160 F is reached Using the 013 2 179 wiring diagram check pins wires and connections from PL24 to REC3 of PCB6 See Figure 4 6 for location of PCB6 See Figure 3 2 for location of REC3 Repair and or replace defective component s if necessary 39 1 Coolant flow too slow This LED will extinguish when FS1 senses a coolant flow of at least 5gpm to the torch See Figure 4 13 for location of flow switch FS1 motor M1 pump P1 and filter element 39 2 Motor M1 not functioning Check to see if 240VAC is available at PL21 PL21 is located near the pump Note The 240VAC relay CR3 on PCB6 will not close until the first five interlocks STATUS indicators are satisfied MAX200 Service Manual MAINTENANCE Problem Possible Causes and Solutions 3g 3 4 All status indicators 4 1 extinguished switch to TEST but no gas flow 4 2 MAX200 Service Manual Using the 013 2 179 wiring diagram check pins connections and associated wiring from PL21 to REC5 of PCB6 See Figure 4 4 for location of PCB6 See Figure 3 2 for location of REC5 If 240VAC is not available at REC5 CR3 be defective Replace PCB6 if CR3 is defective Flowwitch FS1 not functioning FS1 is a
120. ards WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly 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 must 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 CUTTING CAN CAUSE FIRE OR EXPLOSION WARNING Explosion Hazard Argon Hydrogen and Methane A 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 A When cutting aluminum underwater or with
121. as Valve SA 1 005228 Switch 0 15 PSI Press PS3 2 015570 Reducer bushing 1 4 X 1 8 3 015605 Elbow 1 4 Long Street 4 015047 Adapt 1 4 MNPT X Acc A LH 5 015602 Street elbow 45 deg 1 4 NPT 6 015001 Adapter Bulkhead 1 4 NPTF 7 015593 Street Tee 1 4 8 015131 Fitting 3 8 Tube X 1 4 NPT 9 015133 Ferrule 3 8 OD Tube Delrin 10 015015 Adapter 90 1 4 NPT X 6 11 015134 Insert 3 8 OD X 062 w Brass 029315 Shield Gas SA MAX200 see page 4 15 for more part numbers 12 015001 Adapter Bulkhead 1 4 NPTF 13 015015 Adapter 90 1 4 NPT X 6 14 015131 Fitting 3 8 Tube X 1 4 NPT 15 015133 Ferrule 3 8 OD tube Delrin 16 015134 Insert 3 8 OD X 062 w Brass 17 015570 Reducer Bushing 1 4 X 1 8 18 015135 Insert 1 8 OD Brass 19 015137 Fitting 1 8 Tube X 1 8 NPT 20 015593 Street Tee 1 4 21 015050 Adapter Bulkhead 1 8 X 1 1 2 22 015601 Street elbow 45 deg 1 8 NPT 23 015116 Adapter 1 8 NPT X Oxy A 029358 Harness SA MAX200 24 008073 Terminal Strip 8 TB4 25 008134 Terminal Strip 16 TB3 26 008447 Receptacle 23 37 Std sex 1X1 27 008208 Receptacle 23 37 Rev sex 1X2 28 008201 Receptacle shell size 17 14 1X3 29 003021 Relay 120VAC NO SPST CR1 30 009015 Res 10K Ohm 10W R5 31 009438 Res 5 Ohm 50W R4 32 009684 Res 4 Ohm 420W R6 33 009506 Cap 2504F 350VDC c9 34 029317 HV Transformer SA T5 35 008212 Strain Relief 1 2 X 125 375 36 001234 Panel MAX200 Rear MAX200 Service Manual PARTS LIST 2 N MPO N HAH AH AH
122. ase solution SECTION 6 ACCIDENTAL RELEASE MEASURES Response to Small spills Mop up residues and place in a covered waste disposal container i Large spills Dike or dam spill Pump to containers or soak up on inert absorbent Place in spills ge sp pill Pump p covered waste dissposal container SECTION 7 HANDLING AND STORAGE Handling Keep container in upright position Avoid breathing or creating airborne mists Avoid contact precautions with skin eyes and clothing Avoid inhalation of vapor or mists DO NOT TAKE INTERNALLY Clean up spills immediately Storage Store in a cool dry place Keep from freezing Keep containers tightly closed when not in use precautions a 4 MAX200 Service Manual 15 MSDS Hypertherm Torch Coolant CODE Page3of4 SECTION 8 EXPOSURE CONTROLS PERSONAL PROTECTION Engineering controls Good general ventilation Eye wash station in immediate area of use M E L O E S Nil HSE EH 40 Not listed Personal protective equipment APRON X Glovs Recommended PVC Neoprene or Nitrile acceptable Bets 42 SECTION 9 PHYSICAL AND CHEMIICAL PROPERTIES pH of Concentrate Not applicable Specific gravit Not applicable solubility in water Not determined _ MN SECTION 10 STABILITY AND REACTIVITY ems XT s di del Hazardous products of BY FIRE Carbon Dioxide Carbon Monoxide Nitrogen Oxides decomposition Polymerization x Wnotocu x JMa
123. ble 4 70 MAX200 T E Hand Toreh Syste S Eu Sek as Se KR EU ERR E 4 71 PAC200T E Trigger Torch Consumables erste ie 4 72 PAC200T Consumable Parts Kit 028750 ttti dete sire tai 4 74 PAC200E Consumable Parts 028751 2 4 74 PAC200T 90 Cutting Torch Assembly 4 76 200 90 Cutting Torch Assembly 25 qeq 4 76 PAC200T 65 Cutting Torch Assembly 4 78 200 65 Cutting Torch Assembly 25 ai 4 78 PAC200E Gouging Torch Assembly usine 4 79 PAC200E Gouging Torch Assembly 25 uu E 4 79 Trigger Torch 25 Foot Lead Assembly Torch to Power Supply ss 4 81 Extended CAS S renare a 4 82 Trigger Torch 25 Foot Lead Assembly Torch to Extension Box 4 83 MAX200 Service Manual 4 1 PARTS LIST Introduction In this section is a parts list breakdown with accompanying drawings for the MAX200 machine and hand torch systems Internal power supply cabling and hosing are not shown in the drawings Part numbers for this hosing with
124. ch Lead SOU Et 3 36 Es PPP A 3 36 Replacement EE 3 36 Individual Torei dB did 3 36 miei er EE 3 36 misere 3 38 MAX200 Rev 1 90 Hand Torch Lead Set 3 39 MAX200 Machine Torch Removal and 3 40 ioci TS 3 40 Replace merni uuu tant 3 40 MAX200 Machine Torch Lead Set and Individual Torch Leads Removal and 3 42 Torch Lead SOU ex che eee a eda Seca neces be owe maa hasa 3 42 sa ELE 3 42 Replacement D 3 42 Individual TORN 3 44 Removal EEUU 3 44 Replacement E 3 44 PAC200T E Torches Removal and 3 46 Aa as 3 46 3 46 PAC200T E Torch Lead Assembly Removal and Replacement ss 3 48 FROMIOV PT 3 48 co 3 48 Increase or Decrease PAC200T E Torch Lead Lenglh ss 3 50 AdjustiPlasma Gauna 3 53 MAX200 Service Manual 3 1 MAINTENANCE Introduction The MAX200 and all Hypertherm plasma systems undergo rigorous testing prior to shipment and
125. ch lead assembly to the power supply by reversing the above procedure 2 Connect the torch lead assembly to the torch by referring to the Removal and Replacement of PAC200T E Torches procedure on page 3 46 3 48 MAX200 Service Manual MAINTENANCE Shield Gas TB2 grey w blue band 25 leads high frequency AMIS 2 blue ext leads coil D Plasma START 71 adapter 1 switch leads 2 IO CAP SENSE grey LL ANSE bulkhead adapter IN Plasma Gas bulkhead TT Y Coolant Supply blue w green band Work Cable Va J D Coolant Return Z red w red band 25 leads blue w red band ext leads Figure 3 10 PAC200T E Torch Lead Set Connections to Power Supply MAX200 Service Manual 3 49 MAINTENANCE Increase or Decrease PAC200T E Torch Lead Length In order to increase or decrease the torch lead length between 50 and 150 ft at 25 foot increments look at the torch lead part numbers on pg 4 82 to determine the leads that you need The center section leads 029593 and the torch to extension box leads 029866 come with the male adapters 015036 015049 and 015208 necessary to mate leads to the next section see Figure 3 12 After ordering the correct leads follow the general procedures below and refer to Figure 3 11 Note If you have the PAC200T E 25 foot leads 029865 that come with the 25 foot 200 system and you 1
126. checked occasionally for cracking and damage Torch Coolant A standard mixture of propylene glycol 30 deionized water 69 9 and benzotriazole 0 1 96 is recomended Refer to Appendix B for Torch Coolant Requirements and the Material Safety Data Sheets on propylene glycol and benzotriazolefor data on safety handling and storage Power Supply Inspect the power supply on a routine basis Check the exterior for any damage If there is damage ensure it does not affect safe operation of the power supply Remove covers and inspect the interior Check wiring harnesses and connections for wear and damage Check for loose connections and look for areas of discoloration due to overheating At the rear of the power supply inspect the particle filter element of the water coolant subassembly In the event that the filter becomes excessively dirty torch coolant flow can slow down causing the flow switch to open turn off and make the coolant flow interlock status LED illuminate The filter turns to a browish color when dirty Replace the filter element 027005 when it starts to change color Every 2 weeks inspect the air filter in the front panel of the power supply by removing the access cover and lifting the filter out Replace filter 027441 when dirty Every 6 months flush the power supply of its torch coolant and replace with new coolant 028872 MAX200 Service Manual 3 3 7 99 MAINTENANCE Theory of Operation Chopper Po
127. colors to 100 200 A No 10 No 11 12 reduce reflection Use protective screens or barriers to protect others Arc current fD AWS USA 1504850 reflection and transmission of ultraviolet light 200 400 A No 12 No 13 from flash and glare Over 400 A No 14 No 14 Warn others not to watch the arc Use placards or signs GROUNDING SAFETY Input power Be sure to connect the power cord ground wire to the ground in the disconnect box Work cable Attach the work cable securely to the If installation of the plasma system involves workpiece or the work table with good metal to metal connecting the power cord to the power supply be contact Do not connect it to the piece that will fal sure to connect the power cord ground wire away when the cut is complete properly Place the power cord s ground wire on the stud first Work table Connect the work table to an earth then place any other ground wires on top of the ground in accordance with appropriate national or power cord ground Fasten the retaining nut tightly local electrical codes Tighten all electrical connections to avoid excessive heating Hypertherm Plasma Systems 1 5 5 02 SAFETY 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 specific application Maintain all compressed gas equipment and associated parts in
128. con la pieza a cortar o con la tierra Si su nica opci n es trabajar en una rea h meda o cerca de ella sea muy cauteloso Instale un interruptor de corriente adecuado en cuanto a fusibles en una pared cercana a la fuente de energ a Este interruptor permitir al operador desconectar r pidamente la fuente de energ a en caso de emergencia Al utilizar una mesa de agua aseg rese de que sta se encuentre correctamente conectada a la toma a tierra Instale este equipo y con ctelo a tierra seg n el manual de instrucciones y de conformidad con los c digos locales y nacionales Inspeccione el cord n de alimentaci n primaria con frecuencia para asegurarse de que no est da ado ni agrietado Si el cord n de alimentaci n primaria est da ado reempl celo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha y reempl celas cuando se encuentren da adas No toque la pieza ni los recortes cuando se est cortando Deje la pieza en su lugar o sobre la mesa de trabajo con el cable de trabajo conectado en todo momento Antes de inspeccionar limpiar o cambiar las piezas de la antorcha desconecte la potencia primaria o desenchufe la fuente de energ a Nunca evite o descuide los bloqueos de seguridad Antes de retirar la cubierta de una fuente de energ a o del gabinete de un sistema desconecte la potencia primaria de entrada Espere 5 minutos despu s de desconectar la
129. connection point referencing are on page 4 58 The format to list and call out Hypertherm parts is as follows Part Item Number Description Designator Qty 029319 Contr Pnl SA MAX200 Thumb Pot 1 7 006027 Valve needle 1 4 NP TF V5 1 029360 Thumbwheel Pot Panel SA MAX200 1 25 075165 Hexnut 6 32 WXF 250 093 S Z 4 029383 Thumbwheel switch SA 1 27 008186 Socket 20 24 AWG 7 38 005121 Pushbutton 2 NO Green PB1 1 Item Refers to item call out on opposing or current page Number Ex 7 refers to numbered call out on opposing or current page Part Number Refers to Hypertherm part numbers Bold part numbers Ex 029319 signify parent or subassemblies that contain additional items Normal style part numbers Ex 006027 signify items under parent or subassembly Description Describes the item Bold descriptions not indented Ex Contr Pnl SA MAX200 Thumb Pot signify parent assemblies that contain additional items Normal style part numbers that are indented Ex Valve needle 1 4 NPTF signify items under parent or subassembly In this example parent is Contr Pnl SA MAX200 Thumb Pot Bold descriptions that are indented Ex Thumbwheel Pot Panel SA MAX200 represent subassemblies that are under a parent assembly In this example parent assembly is Contr Pnl SA MAX200 Thumb Pot and subassembly Thumbwheel Pot Panel SA MAX200 contains additional items Normal style part numbers that are not indented Ex
130. 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 adjustments covered in the manufacturer s instructions In particular the spark gaps 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 components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components 6 07 ELECTROMAGNETIC COMPATIBILITY EMC 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 equipment Where necessary the conn
131. d A Male Brass UN AC A Male Brass Adapter 5 Male X 5 Male Brass Term 22 18 25 Male QC Insul Tube 9 16 ID X 03 WL Nat Tef PARTS LIST N AH de 8 4 83 Appendix A TORCH COOLANT MATERIAL SAFETY DATA SHEETS In this section Torch Coolant Reg lremerits 2 it A ai 2 Material Safety Safety Data Hypertherm Torch 4 Sheets MAX200 Service Manual a 1 1 99 APPENDIX A Torch Coolant Requirements The power supply is shipped without any coolant in the tank A standard mixture of propylene glycol 30 deionized water 69 5 and 5 benzotriazole is recommended This mixture resists freezing to 10 F 12 C and contains a corrosion inhibitor benzotriazole to protect copper surfaces in the coolant loop This mixture is available in one gallon containers by ordering 028872 100 propylene glycol is available by ordering 028873 For operating temperatures colder than the temperature stated above the percentage of propylene glycol must be increased Refer to graph below Failure to do so could result in a cracked torch head hoses or other damage to the torch coolant system due to the coolant freezing Observe the warning and cautions below Refer to the Material Safety Data Sheets in this Appendix for data on safety handling and storage of propylene glycol and benzotriazole Propylene glycol and benzotriazole are irritating to skin and
132. d steel cutting with air supplied to both the plasma and shield gas inlets from a single pressure filter regulator The regulator ensures that the correct air pressure is supplied to the system at the proper quality For better cut quality on metals such as stainless steel aluminum and other non ferrous materials either nitrogen or argon hydrogen Hypertherm recommends a mixture of 35 hydrogen and 65 argon can be used as the plasma gas When cutting mild steel oxygen can also be used as the plasma gas Shield gases other than air which can be used are nitrogen and carbon dioxide The machine torch systems have several optional units available to control arc current and for units with the THC option arc voltage These units are the switch remote V C control the digital remote V C control and the programmable remote V C control Other optional units unique to the machine torch systems are the initial height sensing IHS unit and the water muffler An EMI filter standard with all 400V CE power supplies 073200 and 073213 meets the CE requirement for filtering incoming power Refer to Appendix A to connect incoming power to the filter and for part numbers specific to the CE power supplies Product Specifications MAX200 Power Supplies The MAX200 is a constant current secondary converter chopper power supply providing continuously variable amperage from 40 amps to 200 amps It conforms to the following specifications Maximum
133. de if uu uu tene n n da 1 6 Noise can damage larg uu itis tem ette u u nea teen 1 6 Pacemaker and hearing aid operation 1 6 A plasma arc can damage frozen 1 6 Additional safety NM tas 1 6 WamingilabelS uu m ES 1 7 Hypertherm Plasma Systems 1 1 8 06 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 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 is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific haz
134. does not close With an AC voltmeter between wires 62 and 63 see if 120VAC is coming from PCB7 after START command is given e If there is 120VAC check connectors terminals pins and associated wiring to REC2 of PCB7 If wiring is O K replace PCB7 Pilot arc relay CH1 is defective If there is 120VAC at wires 62 and 63 see above steps and CR1 does not close replace CR1 3 23 1 97 MAINTENANCE Problem 9 The green POWER ON indicator is illuminated and the START command has been given but the DC ON indicator does not illuminate 3 24 1 97 Possible Causes and Solutions 8 3 8 4 9 1 Main contactor CON1 or PCB7 is defective With an AC voltmeter see if contactor CON1 is getting 24VAC between pins 66867 after START command is given If there is no 24VAC check pins connectors and associated wiring from CON1 to pins 5 amp 6 of REC1 of PCB7 If wiring is O K replace PCB7 If CON1 is getting 24VAC from the Control Board as described above measure the voltage between all terminals 1A 1B and 1C of main transformer T2 after the START command is given See Figure 4 3 for location of T2 The voltage between any two of the three points should be equal to 200VAC Measure the voltage between all terminals 2A 2B and 2C of main transformer T2 after the START command is given The voltage between any two of the three points should be equal to 200VAC If there is no voltage at any of t
135. e NININA 02 III Page 1 Changed Page Description 162 Rev 8109 01 27 97 Cover Uprevved manual due to LVD compliance Title Page Uprevved manual due to LVD compliance 0 01 Changed reference from 220 380 415V CE to 400V CE 0 03 updated table of contents 0 04 updated table of contents 0 05 jupdated table of contents 0 06 updated table of contents 1 01 New Safety section 1 02 New Safety section 1 03 1 04 1a 01 New Safety section New Safety section New French Safety section 1a 02 New French Safety section 1a 03 New French Safety section 1a 04 New French Safety section 2 02 Changed reference from 220 380 415V CE to 400V CE 2 04 Changed reference from 220 380 415V CE to 400V CE 3 03 Power Supply Changed word extinguish after LED to illuminate 3 08 Updated flowchart Changed reference from 220 380 415V CE to 400V CE 3 13 3 21 New STATUS logic 3 22 3 29 Incorporated words illuminate and extinguish into text 4 07 Changed part nos of items 4 amp 5 4 09 Changed reference from 220 380 415V to 220 380 400 415V 4 15 Changed reference from 220 380 415V to 220 380 400 415V 4 17 Changed part nos of items 1 amp 2 Added temp switches 4 19 Changed part no of chopper Added temp sw
136. e chopper goes to the surge injection circuit R4 C7 filter inductors L1 L2 chopper module diode torch electrode transferred arc sensor CS1 and shunt resistors R1 R2 R3 Fuses F3 and F4 protect each chopper from exceeding 125 amps of output Surge Injection Circuit Surge injection circuit capacitor C7 charges to the open circuit voltage of the chopper module 283VDC When the arc is transferred from the electrode to the workpiece see THEORY OF OPERATION HIGH FREQUENCY later in this section for more information on arc transfer C7 discharges through the 5Q R4 and on to the torch electrode Current provided by C7 maintains the cutting arc while the chopper module and rectifier circuit responds to the current load of the cutting arc Filter inductors L1 and L2 and the chopper module diode begin to function once the arc is established 3 4 MAX200 Service Manual MAINTENANCE Filter Inductor and Chopper Module Diode Circuit During the off interval of the chopper module output cycle the magnetic fields of L1 and L2 will collapse and their polarity will reverse looking at page 1 of wiring schematic inductors L1 and L2 will now be negative on their left side This action of the inductor will forward bias the chopper output diode causing current flow to pass through it from bottom to top L1 and L2 then maintain the cutting arc current flow during the off chopper cycle Current Sensor Circuit The current sensor coil CS1
137. e component s if necessary 4 If wiring is O K replace PCB7 5 If there is 12VDC between pins 1 amp 2 of PL12 reconnect PL12 to CS1 and take voltage between pins 13 amp 14 of REC2 on PCB7 after arc is established This should read 0 volts If there is no O volts replace CS1 3 30 MAX200 Service Manual 6 94 MAINTENANCE Test Procedures Cont Chopper Module Test Procedure The chopper module operation is described earlier in this section under Theory of Operation Chopper Power Supply In order to troubleshoot the chopper section for proper functioning perform the following procedure SHOCK HAZARD Use extreme care when working near the chopper modules The large electrolytic capacitor s blue cased cylinder s store largeamounts 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 1 Turn all power to the MAX200 OFF Disconnect PL26 from REC26 to disable high frequency transformer T5 See Figure 4 10 for location of T5 2 Remove large fuses F3 and F4 Check to see if fuse s is are open 3 Place the positive lead to the side of the bridge and the negative lead to the side of the bridge See Figure on page 3 32 Note that actual connection points are hidden by ca
138. e is O K LT2 may not be getting 24VAC from Control Board Proceed as follows see Figure 4 2 for location of LT2 Monitor between points 64 amp 65 with an AC volt meter 64 amp 65 are terminal points to the LT2 bulb Press START Voltage between these points should read 24VAC If there is no 24VAC use the 013 2 179 wiring diagram and check wires and conncectors from LT2 to REC1 of PCB7 Repair and or replace defective component s if necessary If wiring is OK replace PCB7 If there is 24VAC between points 64 amp 65 after START is pressed replace bulb LT2 The work clamp is not connected or it is broken Connect or repair the work clamp Arc not transferring to workpiece Check work clamp and cable connecting clamp to workpiece Good contact must be made in order for the arc to transfer to the workpiece There is insufficient air or gas pressure Check gas inlet pressure specifications under Cut Charts in Operation section of MAX200 Instruction Manual 800870 or 800980 Check plasma and shield gas pressures in TEST and RUN modes as specified under Cut Charts in Operation section of MAX200 Instruction Manual 800870 or 800980 3 25 1 97 MAINTENANCE Problem Possible Causes and Solutions 10 4 Torch is getting insufficient current Check the arc current setting for the type and thickness of metal you are cutting from the Cut Charts in the Operation section of MAX200 Instruction Manual 800870 or 8009
139. e operating l utilisateur et les personnes se trouvant dans la zone read and understand the manufacturer s instruc de travail Avant le coupage lire et comprendre les tions and know your employer s safety practices instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise Electric shock can kill Do not touch live electrical parts AN Keep all panels and covers in place when the machine is connected to a power source Insulate yourself from work and ground wear insulating gloves shoes and clothing Keep gloves shoes clothing work area torch and this machinery dry Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area If ventilation is inadequate use an approved respirator WARNING 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 Explosion will result if pressurized Heat splatter and sparks cause fire and containers are cut AAN burns Do not cut near combustible material Do not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Pilot arc can cause burns Keep the torch nozzle away from yourself Arc rays ca
140. e shield braid 8 over the torch lead ends and pull the sheath until it approximates the length requirements called out in Figure 3 8 Tape both ends of the shield braid to the torch lead Slide the heat shrink 7 over torch end of the shield braid Heat the heat shrink until it tightly bonds around the shield braid and torch lead Replace the compression ring 9 shield collar 10 and hose clamp 11 over the power supply end of the shield braid Tighten the hose clamp Connect the torch lead to the power supply Connect the torch lead to the torch 3 44 MAX200 Service Manual 1 99 MAINTENANCE 5 3 Description Lead Pilot Shield Gas blue Lead Plasma Gas red Lead Cap Sensor gray Cable Water Cooled blue red band Cable Water Cooled blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 2 ID Tinned Braid Ring Compress Shield Torch Lead 0 Collar Shield Torch Leads 1 Clamp Hose 1 5 16 2 1 4 e ek cle 00 O1 Note Refer to Section 4 Parts List pages 4 44 to 4 48 for machine torch lead assembly part numbers for different lead lengths and other torch lead parts Figure 3 8 MAX200 Machine Torch Lead Set Assembly MAX200 Service Manual 3 45 1 99 MAINTENANCE PAC200T E Torches Removal and Replacement Press the OFF O pushbutton switch on the power supply and place the wall mounted disconnect box switch to OFF before working on the
141. eated properly If JP9 is connected disconnect one side of the thermo switch wire TS1 and try again If voltage comes up and LEDS turns green the unit is either too hot or thermo switch is shorted Allow unit to cool and repeat test If LED3 still turns green replace chopper module MAX200 Service Manual 3 31 MAINTENANCE 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 through control board PCB7 as an analog level from 0 to 8 VDC which varies the duty cycle and subsequent output current of the chopper These analog signals are on pins 3 amp 4 REC3 of PCB7 for CH1 and 5 amp 6 REC3 for CH2 To determine if there is a problem with the chopper modules or with control board PCB7 proceed as follows Ensure that high frequency is still disabled see step 1 Disconnect PL7 REC3 on PCB7 Place voltmeter across output terminals of chopper positve lead to WORK and negative lead to TORCH and press the START command If the voltmeter reads 280 VDC replace control board PCB7 If the voltmeter reads 0 volts replace corresponding chopper module CH1 or CH2 Input Bridge Bridge Thermo Switch TS1 LED1 LED3
142. ection 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 reasons Changing the earthing arrangements should only be authorized 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 TS 62081 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 8 06 Hypertherm Attention 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 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 work
143. ed 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 Explosion will result if pressurized Heat splatter and sparks cause fire and containers are cut AAN burns Do not cut near combustible material Do not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Pilot arc can cause burns Keep the torch nozzle away from yourself Arc rays can injure eyes and burn skin Wear correct eye and body protection Noise can damage hearing Wear correct ear protection and others when the switch is depressed Wear correct eye and body protection NE PAS ENLEVER CET AVIS DO NOT REMOVE THIS MARKING 010298 Rev TLF Hypertherm Syst mes plasma 1a 7 8 99 SECURITE Etiquette de s curit 1 Cette tiquette est affich e sur la source de courant est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Les num ros de la liste 14 correspondent aux num ros des images 110261 1a 8 8 99 Les tincelles produites par le coupage peuvent provoquer une explosion ou un incendie Pendant le coupage loigner toute mati re inflammable Conserver un extincteur proximit et s assurer qu une personne soit pr te l utiliser Ne jamais couper
144. erar humos t xicos Los recubrimientos t xicos incluyen pero no est n limitados a plomo en algunas pinturas cadmio en algunas pinturas y rellenos y berilio Los gases producidos por el corte por plasma var an bas ndose en el material a cortarse y el m todo de cortar pero pueden incluir ozono xidos de nitr geno cromo hexavalente hidr geno y otras substancias si est n contenidas dentro o liberadas por el material que se corta Se debe tener cuidado de minimizar la exposici n del humo producido por cualquier proceso industrial Seg n la composici n qu mica y la concentraci n del humo al igual que otros factores tales como ventilaci n puede haber el riesgo de enfermedad f sica tal como defectos de natividad o c ncer Es la responsabilidad del due o del equipo y instalaci n el comprobar la calidad de aire en el lugar donde se est usando el equipo para garantizar que la calidad del aire en el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales HUMOS T XICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables espec ficas al sitio tales como Dise o de mesa mojada seca bajo agua La composici n del material el acabado de la superficie y la composici n de los recubrimientos Volumen que se quita del material La duraci n del corte o ranura Tamafio volumen del aire
145. etely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity In such cases it may be necessary to use other measures to further reduce interference This cutting equipment is designed for use only in an industrial environment Installation and use The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of Workpiece 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 electromagnetic 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 equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e
146. good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes 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 in 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 NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing Use approved ear protection when using plasma system 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 o PACEMAKER AND KR HEARING AID OPERATION Pacemaker and hearing aid operation can be affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work
147. h Frequency Generation Circuit A high voltage is necessary to activate the high frequency generation 120 VAC is sent through REC26 to a high voltage transformer T5 T5 steps up the 120 VAC to 5000VAC This voltage charges C7 and C8 Once voltage across the caps gets sufficiently high the space between the sparkgaps SG1 breaks down causing a virtual short circuit which creates a damped oscillating LC circuit between C7 C8 and the high frequency coil T6 The frequency of this oscillating circuit is determined by the equation F 1 2x x Y LC As C7 and C8 discharge the decaying voltage across the spark gap causes the gap to once again become open The capacitors charge again and the process repeats It is important that the proper spark gap be maintained The MAX200 requires a spark gap setting of 020 If the gaps are too wide they will not break down at all because there will not be enough voltage available to jump the air space between the gaps If the gaps are too close together an almost continuous series of pulses is produced but the amplitude and duration of each pulse may not be large enough to initiate the pilot arc Once there is ionized plasma flow between nozzle and electrode the current present at the electrode will jump the gap to the nozzle completing the circuit through the parallel pilot arc resistors R6 The pilot arc is now initialized Pilot Arc Circuit The current level for the pilot arc is determined by the pa
148. he above points replace CON1 If there is voltage at some but not all of the above points check wiring and connections to and from T2 If wiring checks out OK replace T2 Choppers 1 and or 2 defective or not functioning See Chopper Module Test Procedure later in this section to troubleshoot The torch start button is defective on hand torch system The interface between the machine START button and the MAX200 power supply is wrong or defective on machine torch system Check to see if D6 on PCB7 see Figure 3 16 illuminates when START command is given If D6 does not illuminate use 013 2 179 wiring diagram and check wiring from On Hand Torch system Torch start button normally open to terminals 177 amp 178 of TB2 of power supply TB2 to I O PCB5 to TB3 to REC3 of PCB6 REC3 of PCB6 to REC1 of PCB7 MAX200 Service Manual MAINTENANCE Problem Possible Causes and Solutions 9 2 10 The unit stops cutting during 10 1 cut or cuts poorly 10 2 10 3 MAX200 Service Manual Machine Torch system Cutting machine switch normally open to terminals 82 amp 83 of TB3 of power supply e to REC3 of PCB6 of PCB6 to REC1 of PCB7 Repair and or replace defective component s if necessary Control Board PCB7 or LT2 bulb is defective Check to see if D5 and D33 on PCB7 are illuminated see Figure 3 16 If these indicators are illuminated and wiring checkout as described abov
149. he container first Monitor or test the air quality at the site as needed Consult with a local expert to implement a site plan to ensure safe air quality 1 4 8 06 Hypertherm Plasma Systems SAFETY A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant on torches The plasma arc will cut quickly through gloves Plasma arc comes on immediately when the torch and skin switch is activated Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others ARC RAYS CAN BURN EYES AND SKIN Eye protection Plasma arc rays produce intense Skin protection Wear protective clothing to protect visible and invisible ultraviolet and infrared rays that against burns caused by ultraviolet light sparks and can burn eyes and skin hot metal Use eye protection in accordance with applicable Gauntlet gloves safety shoes and hat national or local codes Flame retardant clothing to cover all exposed areas Wear eye protection safety glasses or goggles with Cuffless trousers to prevent entry of sparks and side shields and a welding helmet with appropriate slag lens shading to protect your eyes from the arc s Remove any combustibles such as a butane lighter ultraviolet and infrared rays or matches from your pockets before cutting Lens shade Cutting area Prepare the cutting area to reduce Up to 100A No 8 No 11 Paint walls and other surfaces with dark
150. he torch main body Replacement 1 Connect the torch leads to the replacement torch main body Thread the torch main body fittings and the torch lead fittings together clockwise cw Use the size wrenches called out in the Removal procedure above Note that the red lead fitting is reverse threaded and must be turned in the opposite direction counterclockwise 2 Ensure the lead insulator is positioned over the pilot shield gas lead fitting 3 Slide the insulating sleeve to the torch main body and screw together INSULATING SLEEVE E 0 TORCH LEAD LEAD INSULATOR Figure 3 6 MAX200 Machine Torch Assembly 3 40 MAX200 Service Manual 1 99 MAINTENANCE This page intentionally left blank MAX200 Service Manual 3 41 1 99 MAINTENANCE MAX200 Machine Torch Lead Set and Individual Leads Removal and Replacement Torch Lead Set To remove and replace the torch lead set perform the following procedures Refer to Figure 3 7 Removal 1 Disconnect the cap sensor hose gray from the adapter 2 Disconnect the plasma gas hose red from the adapter This connection is lefthand threaded and must be turned in a clockwise cw direction to loosen 3 Disconnect the pilot shield gas hose blue from the A C T coil adapter 4 Disconnect torch coolant supply hose blue w green band and torch coolant return hose blue w red band from the bulkhead adapter 5 Disconnect the torch from the torch lead as described in the Rem
151. hopper SA Front Wall Inside Left MAX200 Power Supply Chopper SA Front Wall Inside Right MAX200 Power Supply essere uu teens 4 21 Rear Wall Inside MAX200 Power Supply ici rt dert nen rr eh eei rec ctor rn ce ir 4 23 Spark Gap Assembly MAX200 Power Supply sise 4 25 High Frequency and PCB MAX200 Power Supply sees cerrara arar 4 27 Rear Wall Outside MAX200 Power Supply nine 4 29 Recommended Spare Parts cc 4 30 MAX200 Rev 1 Hand Torch Consumables sn 4 33 Hand Torch Consumable Parts Kit ite att 4 33 MAX200 Rev 1 Hand Torch Assemblies a ias 4 35 Hand Torch Lead Assembly Parts i ia Bland Torch Lead Extensions SQ ead eee lis MAX200 Machine Torch Consumables MAX200 Service Manual vii TABLE OF CONTENTS Machine Torch Consumable Parts Kiss ia 4 40 200 Machine cciicssccscisscccsccucsassascascsstsecsesscrasassdstesedscrsesscrasesecdntancsstastasninedposecatupesasnassassapessraes trast dre dea 4 41 Machine Torch Lead 4 44 Switch Remote SR V C Controle l a SSS 4 51 Digital Remote DR Control rincon ea 4 53 Programmable Remote PR V C Control miii teta tiere dia ci de cte tcd d drei 4 55
152. ific material designated and does not relate to any process or use involving other materials This information is based on data believed to be reliable and the Product is intended to be used in a manner that is customary and reasonably foreseeable Since actual use and handling are beyond our control no warranty express or implied is made and no liability is assumed by Hypertherm Inc in connection with the use of this information a 6 MAX200 Service Manual 15 Appendix B ELECTROMAGNETIC COMPABILITY EMC In this section GSMO Al tushunata a 2 Power italia ais a 2 Connect Power Cable a a 2 Power S pblys pL a 2 Line Disconnect Switch 4 IVI IS AMS em td a 5 MAX200 Service Manual b 1 APPENDIX B ELECTROMAGNETIC COMPABILITY EMC General This appendix will enable a qualified electrician to install the power cable to the EMI filter on 400V CE power supplies 073200 without THC and 073213 with THC for machine or hand torch systems Power Cable The power cable is customer supplied See Power Cable on pages 3 6 in IM 87 or page 3 8 in IM 98 for recommended cable sizes Final specification and installation of the power cord should be made by a licensed electrician and according to applicable national or local codes See also Mains Supply on page a 2 for further
153. ificar los posibles peligros Cuando vea un simbolo de seguridad en este manual o en su maquina recuerde que existe posibilidad de que se produzcan lesiones personales PELIGRO ADVERTENCIA PRECAUCION y siga las instrucciones correspondientes para evitar el peligro Las palabras PELIGRO y ADVERTENCIA se utilizan conjuntamente con un simbolo de seguridad La palabra 2 SIGA LAS INSTRUCCIONES DE PELIGRO se utiliza para identificar los mayores peligros SEGURIDAD Encontrara etiquetas de seguridad con las inscripciones PELIGRO y ADVERTENCIA en su maquina junto a Lea atentamente todos los mensajes de seguridad de este peligros especificos manual y las etiquetas de seguridad en su maquina En este manual la palabra ADVERTENCIA va seguida de Mantenga las etiquetas de seguridad de su m quina en instrucciones que si no se siguen correctamente pueden buen estado Reemplace las etiquetas que se pierdan o se provocar lesiones e inclusive la muerte da en inmediatamente En este manual la palabra PRECAUCI N va seguida de Aprenda a utilizar la m quina y a utilizar los controles de la instrucciones que si no se siguen correctamente pueden manera correcta No permita que sea utilizada por alguien provocar da os en el equipo que no conozca su funcionamiento LOS CORTES PUEDEN PROVOCAR INCENDIOS O EXPLOSIONES Prevenci n ante el fuego Aseg rese de que el rea sea segura antes de proceder a cortar Tenga
154. ing Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 Shield Torch Lead 35 Ft Lead Pilot Shield Gas 35 Ft blue Lead Plasma Gas 35 Ft red Lead Cap Sensor 35 Ft gray Cable Water Cooled 35 Ft blue red band Cable Water Cooled 35 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID Shrink Black 1 5 ID Tinned Braid Ring Compress Shield Torch Lead Collar Shield Torch Leads Clamp Hose 1 5 16 2 1 4 PARTS LIST 2 4 45 PARTS LIST Machine Torch Lead Assemblies cont See Figure 4 19 Ite GQ D D 2000 O 4 46 Part Number 028459 023434 024230 024226 023016 023016 020536 046026 046114 027015 004080 015090 028460 023435 024231 024227 023387 023387 020536 046026 046114 027015 004080 015090 028384 023327 024194 024193 023199 023199 020536 046026 046114 027015 004080 015090 Description Shield Torch Lead 40 Ft Lead Pilot Shield Gas 40 Ft blue Lead Plasma Gas 40 Ft red Lead Cap Sensor 40 Ft gray Cable Water Cooled 40 Ft blue red band Cable Water Cooled 40 Ft blue green band Lead Insulator 9 16 ID x 2 1 2 Tubing 1 1 2 ID
155. inner 3 40 are a dame muet metre eee nm E Replacement MAX200 Rev 1 Machine Torch Lead Set and Individual Leads Removal and Replacement 3 42 Tole D CAU u tito RemMOVA D Replace MGM m aia Individual Torch Leads Pur Replacement ein A PAC200T E Torches Removal and Replacement eee hermovals ence etium E LII AN IRL cere rime m PAC200T E Torch Lead Assembly Removal and Replacement R MOVAl m Je e Increase or Decrease PAC200T E Torch Lead Length Adjust Plasma sn a iea ct 4 PARTS LIST X legerem Front Wall Outside MAX200 Power Supply Control Panel SA MAX200 Power Supply essent tenente tenente tenente tenter tnter tentent tente tenente tente tenens Base Plate MAX200 Power Supply mc Plasma Gas SA MAX200 Power l ii ia nn n s re lus ds Center Wall Left Side MAX200 Power Supply coccion Center Wall Right Side MAX200 Power u ras Front Wall Inside MAX200 Power Supply mociones C
156. is a magnetic device that produces a voltage when current is sensed from the cable passing through it The cable is directly attached to the workpiece and the sensing of current will occur when the arc is transferred This type of sensing phenomena is known as the Hall effect This voltage is transmitted from pin 3 on PL12 to pin 14 of REC2 on the Control PCB PCB7 Shunt Circuit R1 and R2 are shunt resistors for choppers CH1 and CH2 respectively R3 carries the sum of the currents flowing to R1 and R2 The voltage taken across R1 and R2 is sent to Control PCB7 This shunt voltage will be compared with the current control voltage Any difference between the two voltages is sensed and the output control signal to the chopper module is adjusted to correct any error MAX200 Service Manual 3 5 MAINTENANCE Theory of Operation High Frequency Introduction The MAX200 power supply uses a high frequency transformer to initiate a pilot arc between the nozzle and the electrode to start the plasma torch When the torch is sufficiently close to the workpiece the arc will transfer to the workpiece Once the arc has been transferred relays open to disable the high frequency transformer and the pilot arc Circuit Description The following is a description of the operation of the high frequency section of the MAX200 power supply See wiring diagram 013 4 179 as well as component placement figures in the Parts List section for reference Hig
157. lasma peut endommager les tuyaux gel s 1a 6 tiquettes de s curit ui icicisacessondascasssnicieassinasatocedandasoagsdnianscusibindtadesanndesluesanssncesdabisadadesndanacedshdabulldssnasaeasdtadalnceniaetsae 1a 7 Hypertherm Systemes plasma 1 1 8 06 SECURITE IDENTIFIER LES CONSIGNES 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 a faire fonctionner la machine et a utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non 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 PRECAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant au
158. le Water Cooled 60 Ft 1 blue green band 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046114 1 5 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 4 1 028599 Shield Torch Lead 75 Ft 1 1 023622 Lead Pilot Shield Gas 75 Ft blue 1 2 024319 Lead Plasma Gas 75 Ft red 1 3 024318 Lead Cap Sensor 75 Ft gray 1 4 023262 Cable Water Cooled 75 Ft 1 blue red band 5 023262 Cable Water Cooled 75 Ft 1 blue green band 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046114 1 5 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 4 1 Note Hypertherm does not recommend using torch leads longer than 75 Feet 100 Ft 125 Ft and 150 Ft leads will cause problems with starting 028781 Shield Torch Lead 100 Ft 1 1 023808 Lead Pilot Shield Gas 100 Ft blue 1 2 024416 Lead Plasma Gas 100 Ft red 1 3 024413 Lead Cap Sensor 100 Ft gray 1 4 023805 Cable Water Cooled 100 Ft 1 blue red band 5 023805 Cable Water Cooled 100 Ft 1 blue green band 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046114 1 5 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1
159. lead fitting is reverse threaded and must be turned in the opposite direction counterclockwise 2 Ensure the lead insulator is positioned over the pilot shield gas lead fitting 3 Insert the torch main body into one of the handle halves and then align the body and handle slots 4 Insert the torch switch into the handle switch holder 5 Insert the top rib of the boot into the handle just above the screw holes 6 Align both halves of the handle press together and secure with the nine 9 screws 3 34 MAX200 Service Manual MAINTENANCE 001258 005094 002178 TORCH SWITCH CS y lt BOOT s m URS ID 2 029309 TORCH LEAD 25 FT 7 6 M 029310 TORCH LEAD 50 FT 15 2 M V BODY REV 1 y P SCREW 9 Figure 3 3 200 Rev 1 90 Hand Torch Assembly MAX200 Service Manual 3 35 MAINTENANCE MAX200 Rev 1 90 Hand Torch Lead Set and Individual Leads Removal and Replacement Torch Lead Set To remove and replace the torch lead set perform the following procedure and see Figure 3 4 Removal 1 Disconnect torch start switch leads from terminal block TB2 2 Disconnect the cap sensor hose gray from the adapter 3 Disconnect the plasma gas hose red from the adapter This connection is lefthand threaded and must be turned in a clockwise cw direction to loosen 4 Disconnect the pilot shield gas hose blue from the A C T coil adapter
160. m 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 Puissance des verres teint s Courant de l arc AWS U 1504850 Jusqu 100 A N 8 N 11 100 200 A N 10 NO 11 12 200 400 A NO 12 N 13 Plus de 400 A NO 14 NO 14 LES RAYONS DE L ARC PEUVENT BRULER LES YEUX ET LA PEAU 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 Gants a 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 lumi re 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 Utilise
161. manship 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 Powermax Series power supplies which shall be within a period of three 3 years from the date of delivery to you and ii with respect to the torch and leads within a period of one 1 year from its date of delivery to you and with respect to torch lifter assemblies within a period of one 1 year from its date of delivery to you and with respect to laser heads 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
162. n MAX200 Service Manual 1 97 PARTS LIST E A os Refer to page 4 58 for the list of internal hose to from terminations as indicated by the letters above Note Figure 4 4 Power Supply Plasma Gas SA MAX200 Service Manual 4 10 3 96 Plasma Gas SA MAX200 Power Supply Part Item Number 029314 1 004342 2A 005235 2B 005239 3A 006014 3B 006014 3C 006014 4 015131 5 015132 6 015133 7 015134 8 015165 9 015196 10 015510 11 015532 12 015540 13 015570 14 015592 15 015593 16 046067 Description Plasma Gas SA MAX200 Flow restrictor 020 1 4 NPT Switch Pressure 0 90 PSI PS1 Switch Pressure 0 90 PSI PS4 Valve Sol 90 1 4 NPTF Water vi Valve Sol 90 1 4 NPTF Water Valve Sol 90 1 4 NPTF Water V9 Fitting 3 8 tube x 1 4 NPT Fitting 90 3 8 tube x 1 4 NPT Ferrule 3 8 OD Tube Delrin Insert 3 8 OD x 062 w Brass Orifice 032 ID x 1 8 NPT Fitting 3 8 Tube x 1 8 NPT Nipple 1 4 x Cl Hex Street elbow 1 4 Tee 1 8 Reducer Bushing 1 4 x 1 8 Cross 1 4 Street Tee 1 4 Tubing 3 8 OD Blu Air Brake Note Length of tubing includes interconnections not shown this drawing For a complete listing of internal hosing and hosing lengths see MAX200 Power Supply Internal Hosing later in this section MAX200 Service Manual Designator PARTS LIST 2 Pp WH NON OAH AH mb N 4 11 2 00 PARTS LIST Center Wall Left Side Fig
163. n injure eyes and burn skin Wear correct eye and body protection Noise can damage hearing Wear correct ear protection and others when the switch is depressed Wear correct eye and body protection NE PAS ENLEVER CET AVIS DO NOT REMOVE THIS MARKING 010298 Rev TLF Hypertherm Plasma Systems 1 7 8 99 SAFETY WARNING LABEL 1 Cutting sparks can cause explosion This warning label is affixed to some power supplies It is oe important that the operator and maintenance technician 1 1 Keep flammables away from cutting understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on 1 2 Keep a fire extinguisher nearby and the label have a watchperson ready to use it 1 3 Do nat cut on any closed containers 2 The plasma arc can cause injury and burns 2 1 Turn off power before disassembling torch 2 2 Do not hold the material near cutting path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Use ventilating fan to remove
164. nnect switch off and unplugging the power supply unit 2 Using a Phillips head screwdriver remove top access panel 2 side access panels and front and rear access panels 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 to identify parts and part numbers 4 If no damage is apparent plug in the power supply unit and apply power by turning on the main disconnect Switch 5 For a 200 208 240 480 or 600 volt power supply measure the voltage at TB1 between L1 U L2 V and L3 W See Figure 3 1 item 5 Refer to wiring diagram supplied with manual if required The voltage between any 2 of the 3 points at TB1 should be equal to the supply voltage 200 208 240 480 or 600 VAC If there is a problem at this point disconnect main power and check connections power cable and fuses or circuit breaker at line disconnect switch Repair or replace any defective components For a 400 volt CE power supply measure the voltage between the U V and W studs on the EMI filter Refer to Appendix A Also refer to wiring diagram supplied with manual if required The voltage between any 2 of the 3 studs should be equal to the supply voltage 400 VAC If there is a problem at this point disconnect main power and check connections power cable and fuses or circuit b
165. normally open switch that is closed when a flow greater than 5gpm is sensed When FS1 is closed the COOLANT FLOW LED extinguishes Check coolant hoses and connections for leaks Repair and or replace defective component s if necessary Volume of hosing from supply gas to power supply is too small in diameter Increase D of supply hose Valves V1 V2 and V3 not getting 120VAC from Control Board PCB7 On PCB7 check to see if D5 and D33 are illuminated See Figure 3 16 for location of D5 and D33 If these LEDs are not illuminated check pins connectors and associated wiring from REC2 of Power Distribution Board to REC2 and REC4 of Control Board If D5 and D33 are lit disconnect receptacles 28 and 29 from V1 and V3 and check for 120VAC from Control Board PCB7 after S1 is in the TEST position See Figure 4 4 for location of V1 and V3 If there is no 120VAC use 013 4 179 wiring diagram and check pins connections and associated wiring from V1 and V3 to REC1 of PCB7 If wiring is O K replace Control Board PCB7 3 21 1 97 MAINTENANCE Problem All status indicators extinguished switch to TEST plasma gas flow present but no shield gas flow All status indicators extinguished switch from TEST to RUN but gases continue to flow The green POWER ON indicator is illuminated the START command is given and DC ON indicator is illuminated but there is no high frequency and no pilot arc 3 22 Possible Causes
166. ntorcha EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS El arco de plasma puede cortar a trav s de guantes y de la piel con rapidez Mant ngase alejado de la punta de la antorcha No sostenga el metal junto al trayecto de corte Nunca apunte la antorcha hacia Ud mismo o hacia otras personas Protecci n para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles ultravioleta e infrarrojo que pueden quemar los ojos y la piel Utilice protecci n para los ojos de conformidad con los c digos locales o nacionales aplicables Col quese protectores para los ojos gafas o anteojos protectores con protectores laterales y bien un casco de soldar con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco N mero del cristal Corriente del arco AWS EE UU ISO 4850 Hasta 100A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Mas de 400 A No 14 No 14 LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS OJOS Y EN LA PIEL Protecci n para la piel Vista ropa de protecci n para proteger la piel contra quemaduras causadas por la radiaci n ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro de combusti n retardada y que cubra todas las partes expuestas Pantalones sin dobladillos para impedir que recojan chispas y escorias
167. o B4 L3 aes B4 al pS 84 aol Is Px pe a 2 ed E 1 1 BS pore I 380 VAC Ee I zs 1 I I 1 I I 1 had X amp n 14 400 I ae ca 575 I xn OVAC l i un 600VAC 1 y LH E T 1 LH 46 64 7 p d E 1 418 UI LEN in I Ll 1 208VAC 71 b red u 11 200 71 nh Boo I 4 1 I 1 k Ims es un 4 20 l H 4 gl al I 1 I I I L PE m L PE 5 m L 4 PE 2 MM 2 1 T2 Lod 220 VAC I Y 600 VAC 1 4 20 Lod p 7777 200vAC E rmm 1 240 A 575 VAC J 14 4 240vac 4 380 trT44 208 774 A 400VAC 3 IE 2 gt gt 415 VAC 12 158 28 ola a S r LE B A MATERIAL DRAWN BY DATE BC 5 9 96 e mus Y 60020 000 APP BY DATE Y Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES TOLERANCES ARE ELEC GAS SCHEM MAX200 THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 4 005 ITEM NO DRAWING NO FILE NAME PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 520 013179 013 2 179 013179B7 SON SHARP EDGES BREAK SHARP EDGES
168. ol Programmable V C Cov DR PR V C Top Cov DR PR V C Bottom Panel Rear PR V C Fuse 3 8 Amp 313 375 Fuseholder REM V C Transf mer DR PR SR V C Bracket Mtg DR PR V C Encl Assy PR V C PL HT400 PR V C MDL FR Flg HT400 DR PR V C MDL Fr FR HT400 DR PR ST V C Mal LS FR HT400 DR PR ST V C RS Filter PNL PCB SA PR V C Receptacle Shell 13 9 Size Pin 20 24 AWG Recp CPC 17 16 Standard Sex Term 22 18 250 FEM QC Insul Term 22 18 FEM QC Insul Term 22 18 6 Ring Uninsul Term 22 18 25 MAL QC Insul PC BD Assy Opto Iso Terminal PC HHS 2022C PC BD Assy PR V C Heatsink DR PR SR V C Capacitor 2600 UF 15VDC IC LM340AK 5 0 Terminal PC HHS 2022C Terminal PC CAM PC BD Assy Rem Volt Disp PC BD Assy Rem Curr Disp Figure 5 3 Designator 1FU 029089 7RECP 6RECP 2PC 041085 PARTS LIST 4 55 PARTS LIST Figure 4 23 Inductive IHS Control Module MAX200 Service Manual PARTS LIST Inductive IHS Control Module Part Item Number Description Designator Qty 053016 Control Module IND IHS HT400 1 002095 Encl Control Module UW IHS 1 2 006021 Valve SOL 75 1 4 NPTF 1SOL 1 3 008073 Terminal Strip 16 1TB 1 4 008071 Strain Relief 1 2 X 375 500 1 5 008175 Receptacle Shell Size 13 9 14RECP 1 6 008176 Pin 20 24 AWG 7 7 008177 Grommet HHS 91107 1 8 008186 Socket 20 24 AWG 8 9 008210 Receptacle 11 4 15RECP 16RECP 2 10 009041 Filter AC 1
169. onnections to Power Supply MAX200 Service Manual 3 37 MAINTENANCE 5 Holding one end of the the torch lead pull the sheath 9 off of the torch lead 6 Cut the tape every 18 inches that holds the torch leads together 7 Remove the lead 1 6 requiring repair or replacement Replacement 1 Replace the repaired or replacement lead with the other leads 2 Ensure the lead lengths 1 6 at both ends are in accordance with those called out in Figure 3 5 3 Tape the leads together every 18 inches 4 Slide the sheath 9 over the torch lead ends and pull the sheath until it approximates the length requirements called out in Figure 3 5 5 Tape both ends of the sheath to the torch lead 6 Slide the shrink tubing 8 over each end of the sheath Heat the shrink tubing until it tightly bonds around the sheath and torch lead 7 Connect the torch lead to the power supply 8 Connect the torch lead to the torch 3 38 MAX200 Service Manual MAX200 Rev 1 90 Hand Torch Lead Set Assemblies 5 3 029309 023326 024194 024192 023013 P G 023013 029310 023327 024195 024193 023199 023199 The following parts common to both hand torch lead assemblies 6 047032 7 020536 8 046026 9 024197 9 024198 Part Number Description Hand Torch Lead 25 Ft Lead Pilot Shield Gas 25 Ft blue Lead Plasma Gas 25 Ft red Lead Cap Sensor 25 Ft gray Cable
170. oolant reservoir is maintained Level switch LS1 is located in the coolant reservoir and will open when it senses that coolant level is too low See Figure 4 13 for location of coolant reservoir and LS1 STATUS O ntervock 0 tRansrormer O LEVEL gt e suievo gt PLASMA GAS O cooLANT TEMP gt 9 Check coolant level If coolant level is adequate disconnect PL23 located near reservoir and check to see if LS1 switch is closed Check connections and associated wiring from PL23 to REC3 of PCB6 See Figure 4 6 for location of PCB6 and Figure 3 2 for location of REC3 Repair and or replace defective component s if necessary 3d SHIELD GAS CAP LED 3d 1 Shield gas pressure too low illuminated This LED will extinguish when shield gas pressure of 70 psi or greater is sensed by PS2 See Figure 4 6 for location of PS2 and Figure 3 14 for gas interconnect diagram STATUS O inTeRLock tRansrormer COOLANT LEVEL SHIELD GAS CAP PLASMA GAS O cooLanT TEMP gt O Check to see that shield gas supply is set to specifications according to the Cut Charttables in Section 4 of MAX200 Instruction Manual 800870 Hand Torch 800980 Machine Torch Verify that all shield gas connections are secure and that there are no leaks in the hosing See Figure 4
171. or operating precautions and warning formats If you need additional assistance or need to order parts call our Customer Service or Technical Service Group at the phone numbers listed in the front of this manual SHOCK HAZARD 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 3 2 MAX200 Service Manual 1 99 MAINTENANCE Routine Maintenance The MAX200 system is designed to require very little regular maintenance under normal use The following torch torch leads torch coolant and power supply routine maintenance checks are suggested to keep your system in top running condition Torch and Torch Leads Always inspect the torch consumable parts and torch main body prior to cutting Worn or damaged parts can cause gas and water leaks which can affect the cut quality Check for pitting and burn marks on the consumable parts and replace if necessary See Changing Consumable Parts in Section 4 of the MAX200 Instruction Manual 800870 Hand Torch or 800980 Machine Torch The torch leads should be
172. os a calor excesivo chispas escorias 0 llamas No emplee nunca martillos llaves otro tipo de herramientas para abrir de golpe la v lvula del cilindro EL RUIDO PUEDE DETERIORAR LA AUDICI N La exposici n prolongada al ruido propio de las operaciones de corte y ranurado puede da ar la audici n Utilice un m todo de protecci n de los o dos aprobado al utilizar el sistema de plasma Advierta a las dem s personas que se encuentren en las cercan as acerca del peligro que supone el ruido excesivo UN ARCO PLASMA PUEDE 2 DANAR TUBOS CONGELADOS Se puede hacer da o a los tubos congelados o se los puede reventar si uno trata de descongelarlos con una antorcha por plasma OPERACION DE MARCAPASOS s Y DE AUD FONOS Los campos magn ticos producidos por las elevadas corrientes pueden afectar la operaci n de marcapasos y de audifonos Las personas que lleven marcapasos y audifonos deberan consultar a un m dico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magn ticos Mantenga el cable de trabajo y la manguera de la antorcha a un lado lejos del cuerpo Dirija la manguera antorcha lo m s cerca posible del cable de trabajo No envuelva el cable de trabajo ni la manguera de la antorcha en su cuerpo Mant ngase tan lejos de la fuente de energ a como sea posible 1b 6 11
173. oth halves of the handle press together and secure with the six 6 screws 3 46 MAX200 Service Manual MAINTENANCE Torch Main Body Lead Insulator Figure 3 9 PAC200T Torch Assembly MAX200 Service Manual 3 47 MAINTENANCE PAC200T E Torch Lead Assembly Removal and Replacement Note To change length of torch lead assemblies see Increase or Decrease PAC200 Torch Lead Length on page 3 50 Press the OFF O pushbutton switch on the power supply and place the wall mounted disconnect box switch to OFF before working on the torch or torch leads Removal To disconnect the PAC200T E torch lead assembly from the MAX200 proceed as follows see Figure 3 10 1 Disconnect the torch COOLANT RETURN lead red w red band for 25 leads blue w red band for extended leads from the bulkhead adapter 2 Disconnect the torch COOLANT SUPPLY lead blue w green band from the bulkhead adapter 3 Disconnect the SHIELD GAS lead grey w blue band for 25 leads blue for extended leads from the high frequency coil 4 Disconnect the PLASMA GAS lead red from adapter 2 This connection is left hand threaded it loosens clockwise cw direction 5 Disconnect the CAP SENSE lead grey from adapter 1 6 Disconnect the shielded PLASMA START SWITCH LEADS red and black from terminal block TB2 Note The 90 hand torch lead assemblies are not interchangeable with the PAC200T E lead assembly Replacement 1 Connect the tor
174. oval and Replacement of Machine Torch procedure on page 3 40 Replacement 1 Connect the torch lead to the power supply by reversing directions in steps 1 5 of the above Removal procedure 2 Connect the torch lead to the torch by referring to the Replacement of Machine Torch procedure on page 3 40 Note 3 42 1 99 When using the MAX200 machine torch with extended torch leads 100 125 or 150 feet be aware that the 40A consumable parts cannot be used There is also a slight chance that the following conditions could occur during cutting with extended torch leads over 75 feet High ambient operating temperature or high volume production cutting may increase the heat load on the torch cooling system enough to cause the system to shutdown If this occurs allow the system to cool down Reduce the ambient temperature if possible or the cutting arc on time The gas pressure response time will increase at the torch at preflow plasma on and plasma off This may reduce consumable life The user may have to increase the lead in of the cut and or increase the time between successive cuts There may be a slight incidence of the torch misfiring due to the high frequency energy from the start circuit being dissipated MAX200 Service Manual MAINTENANCE PILOT SHIELD GAS TORCH COOLANT CAP SENSOR HOSE HOSE BLUE SUPPLY HOSE GRAY BLUE W GREEN BAND PLASMA GAS HOSE WORK CABLE RED TORCH COOLANT RETURN H
175. ower supply PAC200T 65 Gouging Torch and Torch Lead Part Number Description 020908 Torch Main Body 029865 Leads SA PAC200T E 25 ft torch to power supply PAC200T 65 Cutting Torch and Torch Lead Part Number Description 020907 Torch Main Body 029865 Leads SA PAC200T E 25 ft torch to power supply MAX200 Service Manual PARTS LIST 4 31 PARTS LIST 4 32 020446 020448 020688 020485 Shield Retaining Nozzle Swirl Ring Electrode Cap 020605 020604 020616 020617 o Bee 220021 920607 020415 i i 120547 020608 020611 020689 i i i 020615 Figure 4 14 MAX200 Rev 1 Hand Torch Consumable Parts MAX200 Service Manual MAX200 Rev 1 Hand Torch Consumables See Figure 4 14 Plasma Gas Shield Gas Air Air O Air H35 N Ny Air MAX200 Rev 1 Hand Torch Consumable Parts Kit 028414 MAX200 Service Manual 40 020446 020423 020448 020423 020688 020423 200 gouging 020485 020423 200 020446 020423 020605 020604 100 020448 020423 020616 020617 200 100 020602 020423 020448 020423 Part Numbers Nozzle Type Retaining Amps Cap Electrode 200 100 020608 020611 020689 020615 020608 020611 020607 020607 020613 020607 020607 020607 200 gouging 020485 020423 x 020446 020423 020608 020607 x 020446 020423 020608 020607 Part Number 0
176. p support bracket 4 Turn power to the MAX200 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 corresponding fuse F3 or was blown replace the chopper module If there is no 280 VDC input check input to bridge for shorts Also check contactor CON1 connections and associated wiring to the contactor Repair and or replace defective component s if necessary 5 If voltage from step 4 is 280 VDC and corresponding fuse is not blown check the CH1 chopper output at TB1 by putting the positive lead of the voltmeter at the WORK terminal 48A output cable and negative lead at the TORCH 39A output cable Check the CH2 output using the same procedure used checkout CH1 See Figure on page 3 32 6 Turn the system on and press the START command After the START command has been given check the voltage If the output from each chopper at these points is 280 VDC then choppers are OK 7 If the chopper does not output 280 VDC check to see if LED1 logic power light is on If LED1 is not on 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 on and LED3 is red when enabled fault condition then make sure that JP9 is s
177. pair 075365 Screws 8 028717 PAC200T E Torch Leads Ext 100 1 100 ft 029866 Leads SA PAC200T E 25 1 029593 Leads MAX200 Hand Torch XT 50 CTRSC 1 029867 Leads SA PAC200T E XBT PS 25 1 001313 Box Torch Leads Ext 2 pair 075365 Screws 8 028718 PAC200T E Torch Leads Ext 125 1 125 ft 029866 Leads SA PAC200T E 25 1 029593 Leads MAX200 Hand Torch XT 50 CTRSC 1 029594 Leads MAX200 Hand Torch XT 50 PS End 1 001313 Box Torch Leads Ext 2 pair 075365 Screws 8 028719 PAC200T E Torch Leads Ext 150 1 150 ft 029866 Leads SA PAC200T E 25 1 029593 Leads MAX200 Hand Torch XT 50 CTRSC 2 029867 Leads SA PAC200T E XBT PS 25 1 001313 Box Torch Leads Ext 3 pair 075365 Screws 8 See page 4 83 for detail 4 82 MAX200 Service Manual Trigger Torch 25 Foot Lead Assembly Torch to Extension Box Part Number z 3 029866 024376 024379 023714 023716 023717 047203 005094 024197 015036 10 015049 11 015208 12 074067 13 046065 O1 Figure 4 39 029866 Leads SA PAC200T E Torch to Extension Box 25 MAX200 Service Manual Description Leads SA PAC200T E Torch Ext Box 25 Hose 200T E Cap Sensor Torch Box Hose Assy 3 16 Red LH A 25 1 Cable 200T E Water Cooled Blue Cable 200T E Water Cooled Red Cable 200T E Shield Gas Torch Box Cable 16 1 Pair Push Button Switch Torch Sheath MAX200 Hand Torch Leads 25 UN Right Han
178. pertherm Syst mes plasma Seccion 1b SEGURIDAD En esta seccion Reconocimiento de informaci n de seguridad T a 1b 2 Siga las instrucciones de seguridad 1b 2 Los cortes pueden provocar incendios o explosiones 1b 2 El choque el ctrico puede provocar la muerte iii 1b 3 Electricidad est tica puede da ar tablillas de circuito su 1b 3 Humos t xicos pueden causar lesiones o 1b 4 El arco de plasma puede causar lesiones y 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en 1b 5 Seguridad de toma a U 1b 5 Seguridad de los equipos de gas comprimido is 1b 6 Los cilindros de gas pueden explotar si est n da ados 1b 6 El ruido puede deteriorar la audici n siennes 1b 6 Operaci n de marcapasos de aud fonos siens 1b 6 Un arco plasma puede da ar tubos 1b 6 Etiquetas d AV ia 1b 7 Hypertherm Sistemas plasma 1b 1 8 06 SEGURIDAD A RECONOCIMIENTO DE Mantenga su maquina en buenas condiciones de INFORMACION DE SEGURIDAD funcionamiento La realizaci n de modificaciones no autorizadas a la maquina puede comprometer la Los s mbolos que se muestran en esta secci n se utilizan seguridad y la vida util de la maquina para ident
179. power supply cable shielding recommendations Connect power cable Connect one end of the power cable to the EMI filter first and then connect the other end to the line disconnect switch Power Supply 1 Locate the EMI filter on the top rear of the power supply see Figure a 1 EMI Filter OT Strain Relief 4 P a Figure a 1 200 Power Supply with EMI Filter Side View b 2 MAX200 Service Manual APPENDIX B ELECTROMAGNETIC COMPABILITY EMC 2 Unscrew the four filter cover screws and remove cover to access input voltage connections at TB1 see Figure a 2 m lo ia 9 9 Filter I gt Ed TB1 Figure a 2 200 Power Supply with EMI Filter Cover Off Top View 3 Insert the power cable through the strain relief see Figure a 1 4 Connect leads L1 to U L2 to V and L3 to W terminals of TB1 see Figure a 3 Ensure that all connections are tight to avoid excessive heating 5 Connect the ground lead to terminal marked PE at TB1 see Figure a 3 MAX200 Service Manual b 3 1 97 APPENDIX B ELECTROMAGNETIC COMPABILITY EMC L 3 3 3 110191510
180. proper precautions when handling printed circuit boards STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards Hypertherm Plasma Systems 1 3 8 06 SAFETY The plasma arc by itself is the heat source used for cutting Accordingly although the plasma arc has not been identified as a source of toxic fumes the material being cut can be a source of toxic fumes or gases that deplete oxygen Fumes produced vary depending on the metal that is cut Metals that may release toxic fumes include but are not limited to stainless steel carbon steel zinc galvanized and copper In some cases the metal may be coated with a substance that could release toxic fumes Toxic coatings include but are not limited to lead in some paints cadmium in some paints and fillers and beryllium Gases produced by plasma cutting vary based on the material to be cut and the method of cutting but may include ozone oxides of nitrogen hexavalent chromium hydrogen and other substances if such are contained in or released by the material being cut Caution should be taken to minimize exposure to fumes produced by any industrial process Depending upon the chemical composition and concentration of the fumes as well as other factors such as ventilation there may be a risk of physical illness such as birth defects or cancer It is the
181. que et la concentration des vapeurs ainsi que d autres facteurs comme la ventilation il peut y avoir un risque de maladie physique comme des malformations ou le cancer Il incombe au propri taire du mat riel et du site de v rifier la qualit de l air dans le secteur l on utilise le mat riel et de s assurer que la qualit de l air sur les lieux de travail r pond aux normes et r glementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT Le niveau de qualit de l air dans tout lieu de travail d pend des variables propres au site comme Type de table humide s che sous l eau Composition du mat riau fini de la surface et composition des rev tements Volume de mat riau enlev Dur e du coupage ou du gougeage Dimensions volume d air ventilation et filtration de la zone de travail quipement de protection individuelle Nombre de syst mes de soudage et de coupage en fonctionnement Autres proc d s du site qui peuvent produire des vapeurs Si les lieux de travail doivent tre conformes aux r glements nationaux ou locaux seuls les contr les OU les essais effectu s au site peuvent d terminer si celui ci se situe au dessus ou au dessous des niveaux admissibles Pour r duire le risque d exposition aux vapeurs liminer tout rev tement et solvant du m tal avant le coupage Utiliser la ventilation d extraction locale pour liminer les vapeurs
182. r 1 REC2 REC1 1 1 06 4 D5 12VDC Start 08 Transfer D31 Mach Motion Delay D33 12VDC DE A Ln Figure 3 15 PCB7 Control Board MAX200 D32 Auto Stop Service Manual Section 4 PARTS LIST In this section 4 2 Front Wall Outside MAX200 Power Supply 4 5 Control Panel SA MAX200 Power Supply 4 7 Base Plate MAX200 Power Supply n 4 9 Plasma Gas SA 200 Power Supply iii 4 11 Center Wall Left Side MAX200 Power 4 13 Center Wall Right Side MAX200 Power 4 15 Front Wall Inside MAX200 Power 4 17 Chopper SA Front Wall Inside Left MAX200 Power Supply sisi 4 19 Chopper SA Front Wall Inside Right MAX200 Power 4 21 Rear Wall Inside MAX200 Power 4 23 Spark Gap Assembly MAX200 Power Supply iii 4 25 High Frequency and I O PCB MAX200 Power 4 27 Rear Wall Outside MAX200 Power
183. r des affiches ou des panneaux 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 travail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s 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 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 S assurer que toutes les connexions sont bien serr es pour viter la surchauffe Hypertherm Syst mes plasma 1a 5 5 02 SECURITE 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 con us pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder
184. r 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 6 07 Proper disposal of Hypertherm products Hypertherm plasma cutting systems like all electronic products may contain materials or components such as printed circuit boards that cannot be discarded with ordinary waste It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes In the United States check all federal state and local laws In the European Union check the EU directives national and local laws For more information visit www hypertherm com weee In other countries check national and local laws Hypertherm TABLE OF CONTENTS Electromagnetic Compatibility EMC LUE LE PR iii Section 1 SAFETY 1 1 Recognize safety information 1 2 Follow Er Alte E 1 2 Cutting can Cause fire Or explosSiOn tnt tenetis niente mania tan a inst sae 1 2 Electric
185. rallel resistors R6 When the torch is sufficiently close to the workpiece the arc is transferred to the workpiece Once the transferred arc is established relay CR1 opens stopping the pilot arc The controls for shutting off the pilot arc and the high frequency generator come from Control PCB7 3 6 MAX200 Service Manual Sequence of Events MAINTENANCE On the following pages is a detailed flow chart outlining the sequence of events during proper MAX200 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 J lt gt lt gt y Preparation Off page Connector MAX200 Service Manual 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 entry from another page to the flowchart MAINTENANCE Push ON button PB1 24VAC relay CR1 240VAC relay CR3 on PCB6 stay open status indicators remain illuminated Correct interlock problem 110V relay CR2 on PCB6 closes
186. reaker at line disconnect switch Repair or replace any defective components continued on page 3 15 MAX200 Service Manual 3 13 8 98 MAINTENANCE 1 PC Board PCB6 2 Linkboard 3 Fuse F1 F2 4 Contactor 1 5 Terminal Block 1 Transformer 1 26 D N mnc aum Aa TN Primary 3 Phase AC Power Cable Figure 3 1 200 Initial Checks 3 14 MAX200 Service Manual 8 9 MAINTENANCE Figure 3 2 Power Distribution PCB6 6 Measure voltage at power distribution board PCB6 Figure 3 1 item 1 Look on the board for fuses F1 through F4 Figure 3 2 Measurements between each fuse and chassis ground should be as follows F1 24VAC F2 120 F3 240 F4 120VAC If voltages are not present or incorrect at 1 or more of these points disconnect power and troubleshoot PCB6 fuses and associated pins connectors and wiring between power distribution board connector REC1 and transformer secondary T1 Figure 3 1 item 6 Also check main power fuses F1 and F2 Figure 3 1 item 3 and associated wiring and connections between T1 and L1 and L2 Repair or replace any defective components MAX200 Service Manual 3 15 8 99 MAINTENANCE Troubleshooting The troubleshooting section is presented by following normal operational sequence Before troubleshooting for specific problems be sure that unit passes Initial Checks as outlined earlier in this section
187. record the voltage off of the meter It should read 1 100th of the first reading Example 130VDC at positive and negative terminals should read 1 3VDC between pins 3 amp 4 If the second reading is not 1 100th of the first reading check pins connectors and associated wiring between REC1 of PCB5 and REC2 of PCB7 MAX200 Service Manual 3 33 6 94 MAINTENANCE MAX200 Rev 1 90 Hand Torch Removal and Replacement To remove and replace the hand torch main body from the torch lead perform the following procedure and see Figure 3 3 Removal 1 Remove the nine 9 screws securing the two handle halves and separate 2 Remove the torch switch from the handle switch holder and allow to hang freely 3 On the larger leads use a 3 8 open end wrench to hold the torch body fittings and a 1 2 open end wrench to turn the torch lead fittings On the smaller leads use a 5 16 open end wrench to hold the torch body fittings and a 7 16 open end wrench to turn the torch lead fittings Turn the torch lead fittings counterclockwise ccw to loosen the connections Note that the red lead fitting is reverse threaded and must be turned in the opposite direction clockwise 4 Remove the torch main body Replacement 1 Connect the torch leads to the replacement torch main body Thread the torch main body fittings and the torch lead fittings together clockwise cw Use the size wrenches called out in the Removal procedure above Note that the red
188. responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations TOXIC FUMES CAN CAUSE INJURY OR DEATH The air quality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of cutting or gouging Size air volume ventilation and filtration of the work area Personal protective equipment Number of welding and cutting systems in operation Other site processes that may produce fumes If the workplace must conform to national or local regulations only monitoring or testing done at the site can determine whether the site is above or below allowable levels To reduce the risk of exposure to fumes Remove all coatings and solvents from the metal before cutting Use local exhaust ventilation to remove fumes from the air Do not inhale fumes Wear an air supplied respirator when cutting any metal coated with containing or suspected to contain toxic elements Assure that those using welding or cutting equipment as well as air supplied respiration devices are qualified and trained in the proper use of such equipment Never cut containers with potentially toxic materials inside Empty and properly clean t
189. ribution Board Check pins connectors and associated wiring for good continuity Check for 120VAC at PL31 PL2 and REC2 on Power Distribution Board see Figure 3 2 for location of REC2 are not seated well Check pins connectors and associated wiring for good continuity Repair or replace if necessary MAX200 Service Manual Problem 3a 3b MAX200 Service Manual The green POWER ON pushbutton switch PB1 is pressed the fans are operating but the green POWER ON indicator does not illuminate INTERLOCK LED illuminated STATUS O inTeRLock 0 tRansrormer COOLANT LEVEL SHIELD GAS CAP PLASMA GAS O TEMP gt O TRANSFORMER LED illuminated STATUS O ntervock tRansrormer COOLANT LEVEL gt e suievo gt PLASMA GAS O cooLant TEMP gt MAINTENANCE Possible Causes and Solutions 3 1 3 2 3 3 Pushbutton PB1 was not held down long enough Press and hold PB1 for a minimum of five seconds Relay CR1 on the Power Distribution Board is defective Check that CR1 switches when POWER ON pushbutton is pressed See Figure 3 2 for location of CR1 If CR1 is defective desolder CR1 and replace One or more of the STATUS LEDs remains illuminated indicating a fault condition The following is a guide to troubleshooting
190. ros de gas pueden explotar si est n da ados u 1b 6 El ruido puede deteriorar la audici n se AAA Aaaa te tenente tente tentent tente tenente tente tenente 1b 6 Operaci n de marcapasos de aud fonos I I 1b 6 Un arco plasma puede da ar tubos congelados essent tenente tenente tete tenente tenete tennis 1b 6 Etiquetas de adVvertercla a aa rto ertet didt E HERR ERR anand mine aan ne ain CREE RES REALE EXERCERE GER ES 1b 7 Section 2 INTRODUCTION amp SPECIFICATIONS Generals eset rn o ELI MIL uetus EUN E OR SE Product Specifications tnt rene a reb a a Du MAX200 Power Supplies MAX200 CE irit iia sai caria enm 2 4 PAC200T 90 4 65 Cutting PAC200E 65 Gouging MAX200 Rev 1 90 Hand Torches sss 2 5 MAX200 Rev 1 Machine Torch EE 2 5 Switch Remote SR Contra e iia 2 5 Digital Remote DR Control inner 2 6 Programmable Remote PR Control cinc 2 6 Initial Height Sensing Water Muffler d ev nda dada car d Section MAINTENANCE a 3 1 INTO GU CONS rr P 3 2 ROUTINE MAlBteratie8 laca 3 3 Torch and Torch Lead iii aia 3 3 Torch Coolant Power Supply Theory of Operation Chopper Power Supply inner aaae Q ike a ain a Q
191. s rayons de l arc peuvent br ler les yeux et 1 5 Mis la masse 6ta a 1 5 S curit des bouteilles de gaz comprim viii ta 1a 6 Les bouteilles de gaz comprim peuvent exploser en cas de dommages ss 1a 6 Le bruit peut provoquer des probl mes auditifs sn 1a 6 Pacemakers et proth ses auditives sn 1a 6 Un arc plasma peut endommager les tuyaux gel s iii 1 6 Enquetes da Seo nD ida 1 7 Seccion 1b SEGURIDAD Reconocimiento de informaci n de seguridad situer Siga las instrucciones de seguridad ttt rn suis Los cortes pueden provocar incendios o explosiones El choque el ctrico puede provocar la muerte sense Electricidad est tica puede da ar tablillas de circuito seen Humos t xicos pueden causar lesiones o muerte IIIa tnter tenente tenente tente tenente tentent teens El arco de plasma puede causar lesiones y quemaduras sn Los rayos del arco pueden producir quemaduras en los ojos y en la piel MAX200 Service Manual TABLE OF CONTENTS Seguridad d toma a tetracaine A e ei dE cri er dedi 1b 5 Seguridad delos equipos de gas LUIS 1b 6 Los cilind
192. seconds before arc fires Relay dry contacts Auxiliary 24VAC 1 amp 1X1 pins 21 22 cable lugs 77 76 Notes 1X1 designates connector on rear of power supply Lug numbers designate wire numbers on end of Interface cable These functions are available only on MAX200s equipped with Torch Height Control option Note that resistor R150 and capacitor C78 are connected in series across the contacts In some cases one lead of R150 must be cut from the control PC board as the R C circuit may provide enough current flow to maintain machine motion input to cutting machine Note that resistor R155 and capacitor C79 are connected in series across the contacts In some cases one lead of R155 must be cut from the control PC board as the R C circuit may provide enough current flow to maintain machine motion input to cutting machine Figure 4 24 Machine Interface Cable Diagram 2 of 2 4 60 MAX200 Service Manual PARTS LIST D A YS YAMS Ajddng lqeO D A 66 4 19 y 002 ZEEETO 10H OVAOZL y 091 Leeezo 021 4 001 055550 IVAOZL wez y 9 10H couse Sis MIN OVA PIIUS 9 H 5 PISIUS M X p snun dos dOS 6 ais 45 1uBi H 1 45 GOS
193. should require little maintenance if proper setup and operation procedures as outlined in instruction manuals 800870 MAX200 Hand Torch and 800980 MAX200 Machine Torch are followed If a problem does arise this section will familiarize qualified service personnel with the proper operation of the MAX200 system and will provide guides to troubleshoot problems that may occur during operation Isolation of a problem at a modular level is the intent of this section PC board component level troubleshooting is not addressed unless the component is easily isolated and easily replaced After a routine maintenance section a general theory of operation for the chopper power supply and high frequency circuits followed by a detailed sequence of events flowchart are presented so that service personnel can gain knowledge of proper MAX200 operation An initial checks procedure is then given followed by a troubleshooting guide and test procedures to aid in servicing the MAX200 system Finally procedures to remove and replace the torch and torch leads are given It is assumed that the service personnel performing the troubleshooting testing are high level electronic service technicians that have worked with high voltage electro mechanical systems Knowledge of final isolation troubleshooting techniques is also assumed In addition to being technically qualified maintenance personnel must perform all testing with safety in mind Refer to the Safety section f
194. tank prior to startup More coolant may be required if lead lengths were increased If you have increased torch lead length from 50 feet or under to 75 feet or over see Adjusting Plasma Gas page 3 53 3 50 MAX200 Service Manual MAINTENANCE suonoS uuo21 lul YOO 2 eJnDiJ 4 6 33 AlddNS H3MOd S 33S SNOILO3NNOO xog 8712000 1008 590970 1 91 6 101e nsu pee P 9 pee ELELOO 1X3 Spe97 4210 xog 06 40 1986808 Sy Aiddns 1emod s aun9 l4 335 01 1xg spe 1 SNOILO3NNO2 l 9 38NDIW 335 xog 1 9 S909t0 1 9986 0 49L 6 1ol nsul pee 1 3 01 4210 10020 5 1 695750 2 1olelnsul 1 2 15100 Spee 4210 xog 06 569650 speo 1899 3 51 MAX200 Service Manual MAINTENANCE 015036 UN Right Hand A Male Brass 015208 Adapter 5 Male X 5 Male Brass 015049 UN Left Hand A Male Brass Figure 3 12 Extension Connectors 3 52 MAX200 Service Manual MAINTENANCE Adjusting Plasma Gas If you have increased torch lead length from 50 feet or under to 75 feet or over the plasma gas pressure must be re adjusted to accommodate the extra torch lead length 1 At the front panel of the MA
195. tema local de escape para eliminar los humos Utilice un ventilador para eliminar los humos Los rayos del arco pueden producir quemaduras en los ojos y en la piel Utilice un sombrero y gafas de seguridad Utilice protecci n para los o dos y abr chese el bot n del cuello de la camisa Utilice un casco de soldar con el filtro de sombreado adecuado Proteja su cuerpo completamente Antes de trabajar en la m quina o de proceder a cortar capac tese y lea las instrucciones completamente No retire las etiquetas de advertencia ni las cubra con pintura Hypertherm Sistemas plasma Section 2 SPECIFICATIONS In this section 2 2 Product Specification S 2 3 MAX200 Power Supplies u u aria iia 2 3 200 PowerS upplieSu rs u y as 2 4 PAC200T 90 amp 65 Cutting PAC200E 65 Gouging MAX200 Rev 1 90 Hand TOrGhies lu deniers a 2 5 MAX200 Bev 1 Machine laa satan ad 2 5 Switch Remote SR VIC CODnlOL 5 Su ada 2 5 Digital Remote DR V C COntrol male lien 2 6 Programmable Remote Control a 2 6 Inttial Height SOMSING erret A is 2 6 E 2 6 MAX200 Service Manual 2 1 2 96 SPECIFICATIONS General MAX200s are normally shipped from the factory configured for mil
196. the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations 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 1 2 11 98 Hypertherm Plasma Systems SAFETY Le JN Touching live electrical parts can cause a fatal shock or severe burn Operating the plasma system completes an electrical circuit between the torch and the workpiece The workpiece and anything touching the workpiece 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
197. ur 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 s curit 79 lt 2 On doit prendre les pr cautions qui s imposent quand on manipule les circuits imprim s Hypertherm Systemes plasma L LECTRICIT STATIQUE PEUT ENDO
198. ure 4 5 Power Supply MAX200 Service Manual 4 12 PARTS LIST Center Wall Left Side MAX200 Power Supply Part Item Number 1 001230 2 004261 3 004262 4 004334 5A 007022 5B 007022 6 007024 7 008945 8A 008317 8B 008317 9 075137 10 075166 11 075194 12 075092 13 075241 14 075136 15 075216 16 075192 17 008245 Description Panel MAX200 Center Bar Lift MAX100 amp 80 Plate Lift MAX100 amp 80 Busbar MAX200 Shunt Shunt 100A 100mv Shunt 100A 100mv Shunt 200A 100mv Fuseholder 100A Fuse Semiconductor 125A 250V Fuse Semiconductor 125A 250V 3 8 16 X 1 1 4 Hex S Z Hexnut 3 8 16 S Z Lkwshr 3 8 Splitlock M S 10 32 X 1 2 PH Pan M S 1 4 20 X 1 2 SL IHW Hhdcap 3 8 16 X 3 4 Hex S Z Flwshr 5 16 Lkwshr 1 4 Splitlock Bushing 7 8 hole X 11 16 ID Designator N 5 5 0 UD O A 8 200 Service Manual 4 13 4 is T KT PARTS LIST Refer to page 4 58 for the list of internal hose to from terminations as indicated by the letters above Note Figure 4 6 Power Supply Center Wall Right Side MAX200 Service Manual 4 14 3 96 PARTS LIST Center Wall Right Side MAX200 Power Supply Part Number Description Designator Qty 1 001230 Panel MAX200 Center 1 2 008551 Fuse 7 5 Amp 600V F1 1 2 008709 Fuse 20Amp 500V F1 1 3 008551 Fuse 7 5 Amp 600V F2 1
199. use skin irritation Ingestion Oral LD 50 rat as reported for 100 Benzotriazole is 560 mg Kg Inhalation Mists are harmful eye contact Causes eye irritation skin contact Can cause skin irritaion MAX200 Service Manual a 3 MSDS Hypertherm Torch Coolant CODE Page2ol4 SECTION 4 FIRST AID MEASURES Ingestion Never give anything by mouth to an unconscious person Give several glasses of water If vomiting is not spontaneous induce vomiting Keep airway clear Get medical attention Inhalation If affected remove from exposure Restore breathing Keep warm and quiet Get medical attention Eye Contact Immediately flush eye with cool running water Remove contact lenses if applicable Continue flushing with water for at least 15 minutes Get immediate medical attention Skin Contact Wash with soap and water If irritation develops or persists get medical attention Note to Physician Treatment based on judgment of the physician in response to reactions of the patient SECTION 5 FIRE FIGHTING MEASURES limits Extinguishing media Product is an aqueous solution Use Carbon Dioxide Dry Chemical Foam special fire fighting Full protective equipment including self contained breathing apparatus should be used During emergency conditions overexposure to decomposition products may cause a health hazard Symptoms may not be immediately apparent Get medical attention procedures Fire and explosion hazards Water b
200. utting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 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 Hypertherm Plasma Systems WARNING LABEL This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described AX WARNING Protect yourself and others Read and under stand this marking SAFETY AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Disconnect power source before servicing Couper l alimentation avant d effectuer le d pann ge Disconnect power source before disassembly of Couper l alimentation avant de d monter la torche the torch Utiliser exclusivement les torches indiqu es dans le Use torches specified in the instruction manual manual d instructions This plasma cutting machine must be connected Le raccordement au r seau de cette machine de to power source in accordance with applicable coupage arc plasma doit tre comforme aux codes electrical codes de l lectricit pertinents Plasma arc cutting can be injurious to operator Le coupage arc plasma comporte des risques pour and persons in the work area Befor
201. ve See if D4 illuminates during cut sequence If D4 does not illuminate and voltage division and CR3 are O K replace PCB10 3 29 1 97 MAINTENANCE Test Procedures 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 Hypertherm Technical Services Department at 1 800 643 0030 Arc Transfer Test Procedure The transfer of arc refers to the arc being made between the electrode 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 and the signal is sent to the Control Board PCB7 To check for proper functioning of the arc transfer sensing system perform the following procedure 1 Observe D8 on PCB7 see Figure 3 16 and see if it lights after main contactor closes see sequence flowchart earlier in this section If it does not light continue to next step If it does light return to Troubleshooting section 2 Disconnect PL12 from CS1 see Figure 4 12 for location of CS1 and check for 12VDC between pins 1 amp 2 If there is 12VDC go to step 5 3 If there is no 12VDC power down and check connectors pins and associated wiring between PL12 and REC2 of PCB7 Repair and or replace defectiv
202. vent tre endommag s ou clater si l on essaie de les d geler avec une torche plasma 1a 6 11 98 PACEMAKERS ET T PROTH SES AUDITIVES Les champs magn tiques produits par les courants a haute tension peuvent affecter le fonctionnement des protheses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un m decin avant de s approcher d un lieu s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques 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 Hypertherm Syst mes plasma Etiquette de s curit SECURITE Cette tiquette est affich e sur la source de courant est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit AX WARNING Protect yourself and others Read and under stand this marking AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Disconnect power source before servicing Couper l alimentation avant d effectuer le d pann ge Disconnect power source before disassembly of Couper l alimentation avant
203. ventilaci n y filtraci n del lugar de trabajo Equipo de protecci n personal N mero de sistemas de soldar y cortar en la operaci n Otros procesos del lugar que pueden producir humo Si el lugar de trabajo debe cumplir reglamentos nacionales o locales solamente el monitoreo o las pruebas que se hacen en el lugar pueden determinar Si el sitio est encima o debajo de los niveles permitidos Para reducir el riesgo de exposici n a humo Quite todos los recubrimientos y solventes del metal antes de cortar Use ventilaci n extractora local para quitar humo del aire No inhale el humo Use un respirador con fuente propia de aire cuando corte cualquier metal recubierto con o sospechado de contener elementos t xicos Garantice que aqu llos usando equipo de soldar o cortar al igual que aparatos de respiraci n con aire propio de aire est n capacitados y entrenados en el uso apropiado de tal equipo Nunca corte recipientes con materiales potencialmente t xicos adentro Primero vac e y limpie el recipiente adecuadamente Monitoree o compruebe la calidad del aire en el sitio como fuera necesario Consulte con un experto local para realizar un plan al sitio para garantizar la calidad de aire seguro 1b 4 8 06 Hypertherm Sistemas plasma SEGURIDAD Antorchas de encendido instantaneo El arco de plasma se enciende inmediatamente despu s de activarse el interruptor de la a
204. vice Hypertherm Shanghai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service 1 19 07 France Representative office 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 Italia 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 Technical Service 00 800 49 73 7843 Tel Technical Service Hypertherm Japan Ltd 801 Samty Will Building 2 40 Miyahara 1 Chome Yodogawa ku Osaka 532 0003 Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax HYPERTHERM BRASIL LTDA Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114 000 Guarulhos SP Brasil 55 11 6409 2636 Tel 55 11 6408 0462 Fax EMC Introduction Hypertherm s CE marked equipment is built in compliance with standard EN60974 10 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN60974 10 may not be adequate to compl
205. wer Supply Introduction The MAX200 plasma unit uses a chopper control circuit to stabilize the DC output current of the system The chopper is a switching circuit that is AC activated and outputs a square wave with the peak value being equal to its DC input 283 VDC in the case of the MAX200 Circuit Description The following is a description of the operation of the chopper section of the MAX200 power supply See wiring diagram 013 4 179 as well as component figures in the Parts List section for reference Snubber Section The snubber section supplies 283VDC to the chopper PCBs Incoming AC voltage enters dual snubber PCBs PCB1 PCB3 and becomes rectified to DC through diodes D1 D6 Varistors MOV1 2 and MOV3 limit transient voltage spikes Capacitors C1 C6 are charged to 283VDC Bleeder resistors R7 and R8 allow capacitors C1 C6 to discharge when the unit is not in use Chopper Section Chopper modules PCB2 and PCB4 are powered by 14VAC from T3 and T4 Current control which controls pulse duration duty cycle of the choppers is selected from Voltage Current V C Remote or thumbwheel switch This information is on pins 5 and 6 of REC1 on the chopper PCBs A longer pulse duration yields a higher output current and a shorter pulse duration yields a lower output current The chopper module generates a square wave of output current at the input DC voltage 283V at an operating frequency of16KHZ The output of th
206. x 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 ou ces instructions ne seraient pas suivies correctement Les messages de PRECAUTION 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 Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur a proximit loigner 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 utiliser un systeme 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
207. yocur Conditions to avoid Not applicable SECTION 11 TOXICOLOGICAL INFORMATION Carcinogenicity THIS PRODUCT CONTAINS A KNOWN OR SUSPECTED CARCINOGEN x THIS PRODUCT DOES NOT CONTAIN ANY KNOWN OR ANTICIPATED CARCINOGENS ACCORDING TO THE CRITERIA OF THE NTP ANNUAL REPORT ON CARCINOGENS AND OSHA 29 CFR 1910 Z Other effects Acute Not determined Not determined MAX200 Service Manual a 5 15 MSDS Hypertherm Torch Coolant CODE 4 SECTION 12 ECOLOGICAL INFORMATION Biodegradability Considered biodegradable Not biodegradable BOD COD Value Not established Ecotoxicity As reported for 100 Benzotriazole Bluegill Sunfish 96 hr Tlm 28mg l Minnow 96hr Tlm 28mg l Trout 96 hr LC 50 39mg l Algae 96hr 50 15 4mg l Daphina magna 48 hr LC 50 141 6 SECTION 13 DISPOSAL CONSIDERATIONS Waste disposal method Waste material must be disposed of in accordance with national local legislative requirements RCRA Classification Classification Non Non Hazardous Ap SECTION 14 TRANSPORT INFORMATION DOT Classification A 1 SECTION 15 REGULATORY INFORMATION REGULATORY STATUS Benzotriazole e GermanwGk 04 SECTION 16 OTHER INFORMATION NFPA Classification BLUE Health hazard __ Flammabilit o YELLOW WHITE Special hazard Information contained in this MSDS refers only to the spec

MAX200 Service Manual - Rapid Welding and Industrial Supplies Ltd

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