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Operator Manual - Air

1. Location of fuses F1 and F2 LI IT IL I m n o 55 e p e Ge A A SIS l werten enim g E pO E io ee ale og ame Gr CR Sam E T e fi HOI er wA Se el oo Le ell O Des b Se gt S9 gt C e e e O Hall o g Si eye ets o z z C Lx J Figure a 1 F1 and F2 Fuse Location powermax900 Operator Manual a 1 STANDARDS INDEX APPENDIX B STANDARDS INDEX The Standards Index contains a list of publications dealing with plasma arc cutting equipment safety practices 1 10 11 12 13 14 15 16 ANSI Standard Z49 1 Safety in Welding and Cutting obtainable from the American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 NIOSH Safety and Health in Arc Welding and Gas Welding and Cutting obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 OSHA Safety and Health Standards 29FR 1910 obtainable from the U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 Standard for Men s Safety Toe Footwear obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z
2. 15 06 1 00 f E 1 38 Figure 2 4 PAC125M Torch with Dimensions 2 4 powermax9g0o Operator Manual SPECIFICATIONS S MARK The Powermax900 conforms to C standard EN50192 The mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The hand torches must have shielded consumable parts to maintain S mark compliance powermax900 Operator Manual 2 5 SPECIFICATIONS IEC SYMBOLS USED Direct Current DC c Alternating current AC Plasma cutting torch Sr AC input power connection The terminal for the external protective earth conductor mE COHM E An inverter based power source N Anode work clamp Temperature switch 0 i Pressure switch M Plasma torch in the TEST position cooling and cutting gas exiting nozzle l Power is on O Power is off Ei Volt amp curve drooping characteristic 2 6 powermax900 Operator Manual Section 3 SETUP In this section Upon Ee EE 3 2 RE EEN 3 2 HOiSting e e lun CT 3 3 Voltage COMMGUIATIONS EE 3 4 Power ee EE 3 6 Power CONS ee EE 3 6 208 240 480 600V Power Supplies 3 6 200 230 400V Power Supplies ss 3 6 Single Phase and Three Phase Power Configurations 3 7 Single Phase esten rro a ect m ve e ated 3 7 ThreesPhase Non GE
3. Sick Red Black Figure 3 15 Machine Interface Cable and Signals powermaxgo0 Operator Manual 313 SETUP Arc Voltage If arc voltage is necessary for activating a torch height control the customer must supply an 18AWG single pair unshielded cable rated for 300V or greater All work must be performed following applicable national or local codes A WARNING A SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures 1 Disconnect power from the power supply 2 Remove the screws that attach the power supply cover to the chassis Remove the cover 3 Feed the cable through the strain relief at the rear of power supply See Fig 3 16 Strain Relief Feed the arc voltage cable through and route it to the machine interface board Figure 3 16 Feeding Arc Voltage Cable to Machine Interface Board 208 240 480V power supply shown 4 Find the machine interface board on the top of the unit near the Powermax900 control board and connect the arc voltage cable as shown in Fig 3 17 EME ARC VOLTAGE torch height control START Output ull arc voltage XFER 300VDC maxi
4. Machine Swirl Gouging Shield Electrodes Ring PAC125 120608 120600 120573 120576 Torch Gouging SS 9 O Ring 044016 120578 Deflector 55A 120303 120600 120574 Non Shielded Extended d LET oe 120606 C 35A J Figure 4 5 Consumables Description of Consumables e Shielded Shielded nozzle allows the torch tip to be dragged directly on the workpiece e Gouging For metal removal without cutting Use for weld removal or setup Nozzle shield may be placed directly on the workpiece e Non Shielded Extended For increased visibility and access for special applications The nozzle is not shielded Maintain a torch to work distance of approximately 1 8 3 mm when cutting above 40A to avoid accelerated consumable parts wear In the European community do not use the non shielded extended consumables with the hand torch powermax900 Operator Manual 4 7 OPERATION Cutting 4 8 Do not fire the pilot arc into the air needlessly doing so causes a significant reduction of the nozzle and electrode life Start cutting from the edge of the workpiece Fig 4 6 When cutting make sure that the sparks are coming out of the bottom of the workpiece If they are spraying on top of the workpiece you are moving the torch too fast or you do not have sufficient power to fully penetrate the workpiece Hold the torch lightly on the metal or just off the metal Holding the torch firmly to the workp
5. 004704 edo Ring Gutcha 075339 WEE Screws P S 4 X 1 2 PH RND S B 120577 Nozzle PAC125 55A Shield 19060 T re Shield PAC121T 120600 uet etude Cap Retaining PO Dina Torch Main Body with Switch PAC125T DAD NG istos ioe O Ring BUNA 90 Duro 614X 070 129352 EE Torch Lead 25 ft 7 6 m 129353 ish wee cia ceto HEISE Torch Lead 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown j Used only in 083066 iie Used only in 083067 Note See page 5 8 or 5 9 for detail of consumable parts Torch Torch Lead Pushbutton 129352 25 ft 7 63 m Switch 129353 50 ft 15 25 m 128284 Gutcha Ring 004764 LA Spring 027254 Safety Trigger 002244 Torch Main Body w Switch 120570 044016 Figure 5 5 PAC125T Torch Assembly and Leads 5 10 powermax900 Operator Manual 9 99 MAINTENANCE PARTS PAC125M Torch Assembly and 14 ft 4 3 m Lead 083069 w pigtail 083073 no pigtail PAC125M Torch Assembly and 25 ft 7 6 m Lead 083068 w pigtail 083072 no pigtail PAC125M Torch Assembly and 35 ft 10 6 m Lead 083070 w pigtail 083074 no pigtail PAC125M Torch Assembly and 50 ft 15 2 m Lead 083071 w pigtail 083075 no pigtail Part Number Description AAA ret Electrode Air 120576 sn Ring Swirl T20619 W Sleeve Machine Torch PAC125M 0200620 etti d Sleeve Torch Position PAC121 125M 129939 iios Deed Torch Lead w pigtail 14 ft 4 3 m AAA EE
6. 33 1 34 24 03 05 Fax 33 1 34 25 09 64 Italy Via Torino 2 20123 Milan Italy Tel 39 02 725 46 312 Fax 39 02 725 46 400 The Netherlands Burg Haverkampstraat 13 7091 CN Dinxperlo Holland Tel 31 315 655866 Fax 31 315 655886 ELECTROMAGNETIC COMPATIBILITY EMC INTRODUCTION Hypertherm s CE marked equipment is built in compliance with standard EN50199 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 may not be adequate to completely eliminate 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 plasma 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 casesthis remedial action may be as simple as earthing the cutting circuit see Earthing of Workpiece In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be re
7. 5 11 PAC125M Torch Assembly and 35 ft 10 6 m Lead 083070 w pigtail 083074 no pigtail 5 11 PAC125M Torch Assembly and 50 ft 15 2 m Lead 083071 w pigtail 083075 no pigtail 5 11 Powermax900 Field Upgrade Kits and Optional Parts 5 12 POWER SUPPLIES 208 240 480V 1F 3F 60 HZ us 5 12 POWER SUPPLIES 200 230 400V 1F 3F 50 60 HZ cooooocccccconoccccccconcccnoncnnccnnnnanncnnnannnnnnnnann cnc nnnnnes 5 12 POWER SUPPLPIES 4DOV CE SF S0 HZ eie edu b 5 13 e PuIedlesglll a 1 STANDARDS INDEX a 2 AERATION MANIFOLD isis a 3 powermax9 go Operator Manual v 9 99 TABLE OF CONTENTS ILLUSTRATIONS Figure 2 1 Powermax900 Hand Plasma Cutting System nnee 2 2 Figure 2 2 Powermax900 Power Supply with Dimensions 2 3 Figure 2 3 PAC125T Torch with Dimensions crece te eee ennemie 2 4 Figure 2 4 PAC125M Torch with Dimensions ern ret diet rte rene kn AXE een nds 2 4 Figure 3 1 Powermax900 Power Supply Hoisting Setup 3 3 Figure 3 2 eg TEE 3 4 Figure 3 3 200V or 208V Configuration sr 3 5 Figure 3 4 230V or 240V Configuration
8. Pr vention des explosions Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s Ne pas couper de r cipients contenant des mati res combustibles 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 et potentiellement explosifs Conserver l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de m thane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasma d argon hydrog ne ou de m thane AVERTISSEMENT D tonation de l hydrogene 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 08 99 HYPERTHERM Syst mes plasma SECURITE de y LES CHOCS ELECTRIQUES PEUVENT ETRE FATALS Toucher une pi ce lectrique sous tension peut provoquer Installer et mettre la terre l quipement sel
9. 120602 120600 120577 120573 120576 Torch Se Material Thickness Arc Arc Recommended Pierce ga or in mm Current Voltage Travel Speed Delay i i A V ipm mm min S D oe woe jaja EA SIN NUN US D pe pm om p pom D pee psp RR IR LL A II rn So wem Pa fo pu as eme x Rp Tom EN Recommended travel speeds are 10 20 slower than maximum These slower speeds will produce optimum cut quality A WARNING A E The voltage between the tip of the torch and the workpiece will exceed 113VDC if shielded consumable parts are not installed in the torch If using the 400V CE power supply the hand torch must be operated with shielded parts to maintain the S mark and CE low voltage compliance for hand held applications See Section 5 Consumable Parts For CE Compliance for a list of CE consumable parts This requirement does not apply to machine torch applications E lt POWEFMAXY00 Operator Manual OPERATION CUT CHART 35A CONSUMABLES Use 35 amp consumables on thin material to obtain maximum consumable life a narrow kerf width and to minimize the heat affected zone The following recommended settings are for mechanized cutting Torch to work distance is 1 16 inch 1 6 mm for all cuts Deflector Retaining Cap Nozzle Electrode Swirl Ring PAC125 120303 120600 120606 120574 120576 Torch lt p Arc Recommended Pierce I RS Voltage Trave
10. 3 5 Figure 3 5 400V or 480V Configuration sr 3 5 Figure 3 6 Power Cord Preparation 3 6 Figure 3 6a Power Cord Preparation CE sise 3 6 Figure 3 7 Single Phase Power 3 7 Figure 3 8 Three Phase Power Non CE sise 3 7 Figure 3 9 Three Phase GE POWer accionada or ae ae eb er 3 8 Figure 3 10 Proper Work Clamp Connection ss 3 9 Figure 3 11 Recommended Three Stage Air Filtration System 3 10 Figure 3 12 Rear Panel Gas Supply Connection to Filter 3 11 Figure 3 13 ON OFF Pendant Connection issue 3 12 Figure 3 14 Aligning the Machine Torch with Square 3 13 Figure 3 15 Machine Interface Cable and Signals 3 13 Figure 3 16 Feeding Arc Voltage Cable to Machine Interface Board 3 14 Figure 3 17 Machine Interface Board Connections for Arc Voltage ooooooonocccccnnocociccnananccnnanancnnn 3 14 Figure 4 1 Powermax900 Controls and Indicators cnn nano cnn nnnnrnnccnnnns 4 2 Figure 4 2 Powermax900 Operating Indicators and Adjustments 4 3 Figure 4 3 Proper Work Clamp Connection is
11. Figure 3 1 Powermax900 Power Supply Hoisting Setup powermax900 Operator Manual 3 3 SETUP VOLTAGE CONFIGURATIONS A WARNING A SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch in OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures The 400V CE Powermax900 power supplies are shipped to operate at 400 volts and do not require any voltage configuration change The 208 240 480V Powermax900 power supplies are shipped to operate at 240 volts The 200 230 400V Powermax900 power supplies are shipped to operate at 400 volts To operate at an alternate voltage remove the rear panel and configure the wires and jumpers on TB2 and TB3 as shown on the facing page Notes When switching to the 400 or 480V configuration secure unused link box jumper in the clip located in the link box e f using the 600V transformer option kit configure the 36 Powermax900 for 480V Fig 3 5 See also Power Cords later in this section Remove screws to remove panel Figure 3 2 Rear Panel 3 4 powermax900 Operator Manual 200V or 208V Figure 3 3 200V or 208V Configuration Figure 3 4 230V or 240V Configura
12. Steel 1 Adapter 1 8 NPT to 1 4 Hose 1 Lubricant Silicone 1 4 Oz Tube 1 5 8 powermax900 Operator Manual 9 99 MAINTENANCE PARTS Consumable Configurations Shield Retaining Cap Nozzle Electrode Swirl Ring PAC125 120601 120600 120577 120573 120576 Torch Shielded wow 0 0 c Retaining Cap Nozzle Electrode Swirl Ring PAC125 120602 120600 120577 120573 120576 Torch Shielded Machine Torch A i 55A Cutting 9 e 5 amp 2 yp Shield Retaining Cap Nozzle Electrode Swirl Ring PAC125 120608 120600 120607 120573 120576 Torch Shielded 55A Gouging e 6 ED Figure 5 3 Shielded Consumable Configurations Deflector Retaining Cap Nozzle Electrode Swirl Ring PAC125 120303 120600 120578 55A 120574 120576 Torch Unshielded NE Deflector Retaining Cap Nozzle Electrode Swirl Ring PAC125 120303 120600 120606 35A 120574 120576 Torch Unshielded NOE Figure 5 4 Unshielded Consumable Configurations In CE countries use unshielded consumables only in machine torch applications powermax900 Operator Manual 5 9 9 99 MAINTENANCE PARTS PAC125T Torch Assembly and 25 ft 7 6 m Lead 083066 PAC125T Torch Assembly and 50 ft 15 2 m Lead 083067 Part Number Description 001288 ton t Handle PAC121 125T 022 at ere naine Safety Trigger PAC121 125T 128284 ceo eue Kit Switch Repair 1205798 tiun rence Electrode Air 120570 A a Ring Swirl 027254 ME Trigger Spring PAC121 125T
13. cc 5 4 Technical Questions interessante 5 7 A 5 8 Consumable Parts Kiss aida 5 8 Hand Consumable Parts Kit 5 8 Machine Consumable Parts Kit 5 8 Consumabl Parts Kit CE idees unes ds 5 8 Consumable Configurations 5 9 PAC125T TOFChASSSmbly es dd eet tees gd ausi Ee 5 10 PAGI25M Torch Assembly nai ia 5 11 Powermax900 Field Upgrade Kits and Optional Parts 5 12 Power Supplies 208 240 480V 5 12 Power Supplies 200 230 400V 5 12 Power Supplies 400V CE inner 5 13 powermax900 Operator Manual 5 1 9 99 MAINTENANCE PARTS INTRODUCTION This section contains information for simple maintenance and troubleshooting A brief parts list is also included For higher level troubleshooting see Technical Questions later in this section ROUTINE MAINTENANCE Bowl Draining and Filter Element Cleaning Moisture coming out of the torch can cause the torch to sputter and hiss If there is moisture purge the lines If moisture builds up in the bowl of the filter at the rear of the power supply drain the bowl and clean the filter element 1 Shut off the gas supply and disconnect the gas supply hose from the filter assembly before proceeding Remove
14. obtainable from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 ANSI Standard Z88 2 Practices for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 Canadian Electrical Code Part 1 Safety Standards for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Rexdale Ontario Canada M9W1R3 powermax900 Operator Manual APPENDIX C AERATION MANIFOLD AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM Introduction When plasma arc cutting aluminum at the water table surface or below water free hydrogen gas may be generated by the cutting process The high temperature of the plasma process causes disassociation of oxygen and hydrogen from the water in the water table The hot aluminum which has a high affinity for oxygen then combines with the oxygen leaving free hydrogen An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the floor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Figure c 1 Make an Aeration Manifold with two inch 50 mm PVC tubing with one inch 25 mm Distribution Lines connected to it Drill 1 8 inch 3 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distribution lines and install the lines so that oxygen is delivered to all parts of the cutting area Conne
15. s asseoir ou se coucher sur une surface de s curit mouill e ni la toucher quand on utilise le systeme Avant d enlever le capot du syst me ou de la source de plasma courant couper l alimentation lectrique Attendre ensuite S isoler de la surface de travail et du sol en utilisant des 5 minutes pour que les condensateurs se d chargent tapis isolants secs ou des couvertures assez grandes Ne jamais faire fonctionner le syst me plasma sans que pour viter tout contact physique avec le travail ou le sol les capots de la source de courant ne soient en place S il s av re n cessaire de travailler dans ou pr s d un Les raccords expos s de la source de courant sont endroit humide proc der avec une extr me prudence extr mement dangereux Installer un sectionneur avec fusibles appropri s Lors de l installation des connexions attacher tout d abord proximit de la source de courant Ce dispositif permet la prise de terre appropri e l op rateur d arr ter rapidement la source de courant en Chaque syst me plasma Hypertherm est concu pour tre cas d urgence utilis uniquement avec des torches Hypertherm En cas d utilisation d une table eau s assurer que cette sp cifiques Ne pas utiliser des torches inappropri es qui derni re est correctement mise la terre pourraient surchauffer et pr senter des risques pour la s curit LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES Le coupage peut produire
16. 480 600V Power Supplies Input Phase Input Recommended Power Cord Gauge Size AWG Voltage Current ln lt 10 ft 10 25 ft 25 50 ft 50 100ft 100 150 ft A 200 230 400V Power Supplies Input Phase Input Recommended Power Cord Gauge Size mm Voltage Current I 3m 3 7 5m 7 5 15m 15 30m 30 45m I m 4 E 4 5 114 mm 4 Bd 4 75 120 mm 4 jJ 3 5 89 mm 3 75 95 mm 2 L3 10 Ground Ground All wires 1 turn A 7 through toroid J L1 L2 L3 Figure 3 6 Power Cord Preparation Non CE Figure 3 6a Power Cord Preparation CE 3 6 powermax900 Operator Manual SETUP SINGLE PHASE AND THREE PHASE POWER CONFIGURATIONS All Powermax900 power supplies except the 400V CE and 600V power supplies can operate from either a single phase or three phase input The 400V CE 230V CE and 600V power supplies operate only from a three phase input Power cords must meet the specifications described earlier in this section Follow applicable local or national wire color conventions See also EMC Compatibility and Mains Supply on page i for further CE compliance recommendations A WARNING A SHOCK HAZARD Always turn off power unplug cord from wall and wait
17. 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Remove the rear panel Fig 3 2 and connect the power cable to terminal block TB1 as shown in the figures below Connect the ground wire to the stud marked above the terminal block Single Phase Conductor ine U Black or Brown Neutral Line V White or Blue Ground Green or Green Yellow Figure 3 7 Single Phase Power Three Phase Non CE Brown or Black NEEN Figure 3 8 Blue or White Jr Three Phase Power Black or Red DER PARA Non CE Green Yellow or Green powermax900 Operator Manual 3 7 SETUP Three Phase CE O O Note See also EMC Compatibility and Mains Supply on page i for further power supply cable shielding recommendations Green Yellow Black Blue for CE compliance Brown Se Figure 3 9 e Three Phase CE Power POWER REQUIREMENTS Line Voltage Disconnect Box Use a line disconnect box for each power supply This disconnect box allows the operator to turn the power supply off quickly in an emergency situation The switch should be
18. Section 3 10 2 Consumables are worn See Operating Tips in Section 4 TECHNICAL QUESTIONS If you are unable to fix the problem with your Powermax900 by following this basic troubleshooting guide or if you need further assistance 1 Call your distributor or an authorized Hypertherm repair facility 2 Call the nearest Hypertherm office listed in the front of this manual 3 See the Powermax900 service manual for wiring diagrams higher level troubleshooting and more parts list information powermax900 Operator Manual 5 7 9 99 MAINTENANCE PARTS PARTS Consumable Parts Kits Hand Consumable Parts Kit 128287 Part Number Description Quantity Box Consumable Parts 1 Electrode 3 Electrode Extended 1 Nozzle 55A Shielded 3 Nozzle Pipe Saddle Extended 1 Nozzle Gouging 1 Shield 55A 1 Shield Gouging 1 Deflector 1 Nipple 1 8 NPT QDisc Steel 1 Reducer 1 4 FPT X 1 8 NPT Brass 1 Lubricant Silicone 1 4 Oz Tube 1 Description Quantity Box Consumable Parts 1 Electrode 3 Electrode Extended 3 Nozzle 55A Shielded 3 Nozzle 35A Extended 3 Shield PAC125M Machine Torch 1 Deflector 1 Nipple 1 8 NPT QDisc Steel 1 Reducer 1 4 FPT X 1 8 NPT Brass 1 Lubricant Silicone 1 4 Oz Tube 1 Description Quantity Box Consumable Parts 1 Electrode Air 3 Nozzle 55A Shielded 3 Nozzle Gouging 1 Shield Gouging 1 Shield 55A 1 Nipple 1 8 NPT QDisc
19. Torch Lead w pigtail 25 ft 7 6 m 1299405 ient cei nette Torch Lead w pigtail 35 ft 10 6 m 129944 certes Torch Lead w pigtail 50 ft 15 2 m 1299438 tage detinet Torch Lead no pigtail 14 ft 4 3 m 129942 rete te eee Torch Lead no pigtail 25 ft 7 6 m 129944 inttr Torch Lead no pigtail 35 ft 10 6 m 129945 4 eee Torch Lead no pigtail 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown 027599 stet tie dites Snap Ring T2057 Rara Nozzle PAC125 55A Shield 120602 Aere rege Shield PAC121M Machine Torch OO ertet Te Cap Retaining A O teneis Torch Main Body w Switch PAC125M 0440 LEE O Ring BUNA 90 Duro 614X 070 Note See page 5 8 or 5 9 for detail of consumable parts Torch Main Body w Switch 120583 Snap Ring O Ring Torch 044016 Position Sleeve 020620 Torch Sleeve O Ring 120613 044016 On Off Pendant not part of machine torch assembly See Powermax900 Field Upgrade Kits and Optional Parts later in this section for part numbers Torch Lead 129339 with pigtail 14 ft 4 3 m 129338 with pigtail 25 ft 7 6 m 129340 with pigtail 35 ft 10 6 m 129341 with pigtail 50 ft 15 2 m 129343 no pigtail 14 ft 4 3 m 129342 no pigtail 25 ft 7 6 m 129344 no pigtail 35 ft 10 6 m 129345 no pigtail 50 ft 15 2 m Pigtail Figure 5 6 PAC125M Torch Assembly and Leads powermax900 Operator Manual 5 11 9 99 MAINTENA
20. duty cycle or the amount of time the pilot or plasma arc can remain on in minutes within a 10 minute period is affected by many factors When the current is set at 55 amps the Powermax900 has a 50 duty cycle at a temperature of 40 C 104 F At these conditions the plasma arc can remain on 5 minutes out of every 10 minutes without causing the tempera ture sensors to disable the unit The duty cycle increases to 10096 at a temperature of 40 C 104 F when the current is set below 39 amps To avoid performance deterioration of the Powermax900 input voltage should be within 1096 of the specified system line voltage setting COMMON CUTTING FAULTS The workpiece is not totally penetrated Causes can be The current is too low The cut speed is too high The torch parts are worn The metal being cut is too thick The work clamp is not properly attached to the workpiece e Dross forms on the bottom of the cut Causes can be 4 14 The cutting speed is too slow The torch parts are worn The metal being cut is too thick The current is too low powermax900 Operator Manual Section5 MAINTENANCE PARTS In this section SSSR Ped 5 2 Routine Maintenance tn in ane Noa ation 5 2 Bowl Draining and Filter Element Cleaning 5 2 Removal Cleaning and Replacement of the Cooling Air Filter 5 3 Basic Troubleshootihg Ext
21. on the filter bowl for other safety warnings Air Supply Quality The cylinder or shop compressed air supply must be clean dry and oil free If air supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Additional Air Filtration Use a three stage coalescing filtration system as shown in Fig 3 11 when site conditions introduce moisture oil or other contaminants into the air line Water particle filter Oil filter Oil vapor filter From air To supply Powermax900 Figure 3 11 Recommended Three Stage Air Filtration System Nitrogen Quality Nitrogen must be supplied to the Powermax900 at 99 995 purity If the purity level of the nitrogen is too low cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Note These conditions also occur if there are leaks in the gas supply hoses or connections The nitrogen supply can be compressed gas cylinders or liquid containers 3 10 powermax900 Operator Manual SETUP GAS SUPPLY CONNECTION Use a 3 8 inch ID inert gas hose to connect the gas supply air or nitrogen to the filter at the rear of the power supply To connect the hose to the power supply install a 1 8 NPT nipple or adapter to the filter block as shown in Fig 3 12 Apply liquid pipe sealant to the threads to ensure a leak free installation A nipple and adapters are included with the consuma
22. prot ger les autres personnes de la lumi re et de la r verb ration Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux MISE LA MASSE ET LA TERRE Cable de retour Bien fixer le cable de retour ou de masse la pi ce couper ou la table de travail de facon 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 1a 4 08 99 HYPERTHERM Systemes plasma 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
23. the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl Gas supply hose connection Filter element Filter Bowl Cap Figure 5 1 Filter Assembly Unscrew the filter bowl Unscrew the filter element See Powermax900 Field Upgrade Kits and Optional Parts later in this section for part number information Clean the filter element with alcohol then blow it out with air from the inside of the filter element Clean the bowl with household soap only Replace the filter element and filter bowl Reconnect the gas supply hose powermax900 Operator Manual MAINTENANCE PARTS Removal Cleaning and Replacement of the Cooling Air Filter Powermax900 systems are normally shipped without air filters If your Powermax900 has the air filter option the filter will need periodic cleaning Excessively dirty or dusty environments can block the cooling air filter if installed and cause the power supply to overheat and shut down WARNING SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures 1 Turn the Powermax900 pow
24. 0 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 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 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 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 Hypertherm Plasma Systems 1 5 SAFETY Hypertherm Plasma Systems Section 1a SECURITE Cette section comprend IDENTIFIER LES CONSIGNES DE S CURIT es 1a 2 SUIVRE LES INSTRUCTIONS DE S CURIT 1a 2 LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION 1a 2 LES CHOCS LECTRIQUES PEUVENT ETRE FATALS iii 1a 3 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES ii 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRULURES ei E d e REM E a 1a 4 LES RAYONS DE L ARC PEUVENT
25. 2 Electric Shock Can 1 3 Cutting Can Produce Toxic FUMES tvn Ep titer eddie epe oaa ep nn uS een 1 3 Plasma Arc Can Cause Injury and Bums 1 4 Are Rays Can Burn Eyes and Skins eae o c tete Ee ee e p oA 1 4 G OUNOINO SACL ois ec ctn o e UE 1 4 Compressed Gas Equipment Safety cooooonononnnnnccnnnnnnnnnnonononannnncnnnnnnnnonononnnnnnnns 1 5 Gas Cylinders Can Explode if Damaged 1 5 Noise Can Damage Hearing cic eee A d e eo er aos 1 5 Pacemaker and Hearing Aid Operation sn 1 5 Additional Safety Information ss 1 5 Hypertherm Plasma Systems 1 1 8 99 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
26. 4 4 Figure 4 4 PAC125T Torch Safety Trigger Operation 4 5 Figure 4 5 e Ein CO 4 7 Fig re 4 6 Starting a Culata Else ertet bati bearer Fol PM rarest 4 8 Figure 4 7 Cutting s Gel sooo eege titio ie anis 4 9 Figure 4 8 Dragging the torches tes st a esta 4 9 Figure 4 9 4 PIGTCINQ dant e o ones eee ntm dee dceorevdt ed betta ide tov tint ss 4 10 testa 4 11 Figure 5 1 Filter Assembly Lien at A 5 2 Figure 5 2 Air Filter R Moval rasta he eR RES MR ere Eech ed ed 5 3 Figure 5 3 Shielded Consumable Configurations 5 8 Figure 5 4 Unshielded Consumable Configurations sen 5 8 Figure 5 5 PAC125T Torch Assembly and Leads 5 9 Figure 5 6 PAC125M Torch Assembly and Leads ono nano no nann no rnnnnanns 5 10 Figure a 1 and F2 Fuse Loca ON deser a 1 Figure c 1 Aeration Et EE c 1 vi powermax900 Operator Manual Section 1 SAFETY In this section Recognize Safety Information ne 1 2 Follow Salely InsitfCcllOriS E 1 2 Cutting Can Cause Fire or Explosion 1
27. 49 2 Fire Prevention in the Use of Cutting and Welding Processes obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 Welding and Cutting Containers Which Have Held Combustibles obtainable from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA Standard 70 1978 National Electrical Code obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 CSA Standard W117 2 Code for Safety in Welding and Cutting obtainable from the Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada NWSA booklet Welding Safety Bibliography obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances
28. 55A STANDARD CONSUMABLES usines 4 12 GUT CHART 35A CONSUMABLES e iae t e ee Hed dani EU RESI Meli EK ee eet 4 13 COMMON CUTTINE FAULTS ES c p Mm 4 14 SECTION 5 MAINTENANCE PARTS sisissiccesscssscesicacccaccsceussacnsnsecsonssceteesecsseeivasesasviorsseeseres 5 1 INTRODUCTION ER 5 2 ROUTINE MAINTENANCE i ctt coc EE re Re coc e ed kde ade ERU AD RR et e ve er emma RES 5 2 Bowl Draining and Filter Element Cleaning ss 5 2 Removal Cleaning and Replacement of the Cooling Air Filter 5 3 BASIC TROUBLESHOOTING sich cases desse coca eax DOR D UE EU RO sae Casas E QE ERG ne 5 4 TECHNICAL QUESTIONS pectet e oq eode td 5 7 PARTS oda ue peo Pateat a 5 8 iv powermax900 Operator Manual 9 99 TABLE OF CONTENTS Consumable Parts ls ica gsc eggs ed wa Pert itu e eal Zoe ge gees 5 8 Consumable Parts Kit CE 128289 cocos tale 5 8 Consumable CONTIGUOS esses atr ee rS EROR E ERR OON DOR ies a aad eee UAR dt de 5 9 PAC125T Torch Assembly and 25 ft 7 6 m Lead 083066 0ooccccocoocccccococccononancccnnnnnancncnnnnnnnnnnnnns 5 10 PAC125T Torch Assembly and 50 ft 15 2 m Lead 083067 5 10 PAC125M Torch Assembly and 14 ft 4 3 m Lead 083069 w pigtail 083073 no pigtail 5 11 PAC125M Torch Assembly and 25 ft 7 6 m Lead 083068 w pigtail 083072 no pigtail
29. BR LER LES YEUX ET LA PEAU 1a 4 MISE A LA MASSE ET LA TERRE 1a 4 S CURIT DES BOUTEILLES DE GAZ COMPRIM mms 1a 5 LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES AN o decae a la 1a 5 LE BRUIT PEUT PROVOQUER DES PROBL MES AUDITIFS 1a 5 PACEMAKERS ET PROTH SES AUDITIVES ne 1a 5 HYPERTHERM Syst mes plasma 1a 1 08 99 SECURITE IDENTIFIER LES CONSIGNES A DE SECURITE Les symboles indiqu s dans cette section sont utilis s pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce soit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et Suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE SECURITE Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non autoris es sur la machine peuvent engendrer des probl mes de s curit et raccourcir la dur e d utilisati
30. ES OU DES BR LURES 1a 4 MISE LA MASSE ET LA TERAE sore eee ec t e eb a et od 1a 4 LES RAYONS DE L ARC PEUVENT BR LER LES YEUX ET LA PEAU 1a 4 S CURIT DES BOUTEILLES DE GAZ COMPRIM 1a 5 LE BRUIT PEUT PROVOQUER DES PROBL MES AUDITIES 0occcocococcoccoconcncconnnnnncnnnononononancnnnnnss 1a 5 PACEMAKERS ET PROTH SES AUDITIVES 0oooooccoccocooonococonnnncnnnnnonnnnnnonnnncnnnnnnn nan nnnnnn conan 1a 5 LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES 1a 5 SECTION 2 SPECIFICATIONS 2 1 INTRODUCTION CRF Re saan as ae saad nee SLOT 2 2 SPECIEIGATIONS a stetit teet Nds on ge 2 3 Power Supply 2 3 PC 2ST OG zc NER 2 4 PAGT25T Hand Weu EE 2 4 PAC125M Machine Torch Assembly reco eie epar exei cura isset e Ed 2 4 Iesch giele USE EE 2 6 SECTION 3 SEHR 3 1 UPON RECEIPT EEN 3 2 CLAIM 3 2 HOISTING REQUIREMENT Sie iid rete ae cde o Da teo ten t wae 3 3 powermax900 Operator Manual iii TABLE OF CONTENTS VOLTAGE CONFIGURATIONS An 3 4 POWER RO RABBIT ter Rate AERA ii 3 6 POWERDOROS oeste eie dd AL t EE 3 6 208 240 480 600V Power Supplies iii 3 6 200 230 400V Power SUDDIIBS 3 1 d sed
31. ESHOOTING Problem 1 The ON OFF power switch is set to ON but the fan does not operate and the POWER ON LED is not illuminated 2 The POWER ON LED is illuminated but the GAS PRESSURE LED is not illuminated 3a The POWER ON LED is illuminated the LINE VOLTAGE LED is disabled white and the torch is disabled 9 99 ON OFF Power Switch Cause Solution 1 1 The power cord is not plugged into the power receptacle Plug in the power supply 1 2 The disconnect power switch is not set to ON or there is no power available to the disconnect power switch box Turn the power ON at the main power panel or at the disconnect power switch box 1 3 A fuse is blown See Appendix A Changing Fuses 2 1 The gas supply is turned OFF or not connected to the power supply Verify that the gas is turned on and connected to the power supply 2 2 Gas pressure is too low Set gas supply pressure to 90 psi 6 2 bar Verify that there are no leaks in the gas supply line 3a 1 Power supply voltage links are incorrect See voltage configuration settings in Section 3 3a 2 Line voltage is extremely low The following table represents the operating range of the Powermax900 power supplies Have an electrical technician check incoming power powermax900 Operator Manual Problem 3b The POWER ON LED is illuminated the LINE VOLTAGE LED is blinking yellow and the torch is disabled 3c T
32. Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields or a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays Lens Shade AWS USA ISO 4850 No 8 No 11 No 10 No 11 12 No 12 No 13 No 14 No 14 Arc Current Up to 100A 100 200 A 200 400 A Over 400 A O GROUNDING SAFETY Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to an earth ground in accordance with appropriate national or local electrical codes Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat e Flame retardant clothing to cover all exposed areas e Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light e Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to
33. NCE PARTS Powermax900 Field Upgrade Kits and Optional Parts Part Number Description 028714 ee id On Off Pendant with Lead 25 ft 7 6 m Also comes standard with most machine torch system configurations See note below A eie On Off Pendant with Lead 50 ft 15 2 m 128062 ica esci ss On Off Pendant with Lead 75 ft 23 m 128316 ies Kit Powermax900 Power Unit Wheels 1289143 itr Kit Powermax900 Pilot Arc Controller 12824 Matas tiritas Kit Powermax900 Machine Interface 208 240 480V 128242 Kit Powermax900 Machine Interface 200 230 400V 128286 Kit Powermax900 Machine Interface 400V CE 028907 ide Ron dress Work Cable 50 ft 15 2 m A muntis Kit Powermax900 Cooling Air Filter O 11079 ntm Filter Element 129019 RE Jumper Powermax900 Link Box 128312 be a Kit Powermax900 600V Conversion 1283139 assueti mee Kit Powermax900 CE 230V Conversion 008809 EE Fuse 1A 600V 13 32 X 1 1 2 Slo Used on 208 240 480V power supplies DOI acciona ds Fuse 1A 500V 10mm X 38mm Slo Used on 200 230 400V and 400V CE power supplies E rare Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits 024548 osse DOR Leather Cable Covers 25 ft 7 6 m 109008 usan Toroid Used only on 400V CE power supply linecord assemblies POWER SUPPLIES 208 240 480V 10 36 60 HZ Part For With Pilot Arc With Machine Number Tor
34. RESSURE GAUGE Pull the REGULATOR CAP out Push the GAS TEST switch in Turn the REGULATOR CAP while still holding in the GAS TEST switch After adjustment to 70 psi 4 8 bar release the GAS TEST switch Push the REGULATOR CAP back in Note If using 50 ft 15 2 m torch leads adjust pressure to 75 psi 5 bar 5 Adjust the AMPS knob to the desired setting See Cut Chart later in this section if necessary powermax900 Operator Manual 4 3 9 99 OPERATION 6 Attach the work clamp securely to the workpiece Do not attach it to the portion that will fall away Figure 4 3 Proper Work Clamp Connection WARNING The PAC125 torches are instant on torches These torches produce a plasma arc immediately after the torch start switch closes Always hold the hand torch away from your body as a precaution against accidental torch firing Be aware of this hazardous potential Failure to do so can result in serious bodily injury 7 The Powermax900 is now ready to operate When you are ready to cut place the tip of the torch at the edge of the workpiece Pull the trigger to start the arc See PAC125T Safety Trigger Operation later in this section for proper operation of the safety trigger 8 Move the torch slowly across the workpiece The arc will transfer from the torch to the work piece Move the torch in the desired direction at a speed which will ensure good cut quality See Cutting instructions and the Cut Chart later in this sec
35. SSURE LED When illuminated indicates that the gas pressure is within operating limits e GAS TEST Switch When pushed in allows the operator to view and adjust the pressure setting e AMPS Output Adjustment Knob Adjusts output current between 20 and 55 amps e Pressure Regulator Regulates input gas pressure to power supply e Pressure Gauge Indicates gas pressure at power supply es ON I OFF 0 Power Switch Activates the power supply and its control circuits LINE GAS GAS VOLTAGE TEMP PRESSURE TEST Pressure Gauge Pressure Regulator Figure 4 1 Powermax900 Controls and Indicators 42 POWErMaX900 Operator Manual 9 99 OPERATION OPERATING INSTRUCTIONS A WARNING Before operating this system read the Safety section of this manual thoroughly 1 Ensure that the work environment and your clothing meet the safety requirements outlined in the Safety section 2 Follow the instructions in the Setup section Verify that the input gas supply pressure is set to 90 psi 6 2 bar 3 At the rear of the power supply set the power switch to the ON I position The POWER ON GAS PRESSURE and LINE VOLTAGE LEDs should illuminate green The TEMP LED should remain extinguished GAS TEST POWER ON AMPS PRESSURE GAUGE REGULATOR REGULATOR CAP Figure 4 2 Powermax900 Operating Indicators and Adjustments 4 Adjust the gas pressure REGULATOR to read 70 psi 4 8 bar on the P
36. acsececcaccaecarecsarsatcatsecateteateseereates 1 4 COMPRESSED GAS EQUIPMENT SAFETY 1 4 ADDITIONAL SAFETY INFORMATION torii tee e rene teorie RO EE etn Feo ee e eens 1 4 NOISE CAN DAMAGE HEARING 1 4 GAS CYLINDERS CAN EXPLODE IF DAMAGED 0ocoocococccococonoconononnonconcnnonnonnonnnncnnonnnn non onrannnnnnnnninnss 1 4 GROUNDING SAFETY 1 A 1 5 PLASMA ARC CAN CAUSE INJURY AND BURNS 1 5 PACEMAKER AND HEARING AID OPERATION 1 5 SECTION 1a S CURIT lt 1a 1 IDENTIFIER LES CONSIGNES DE 866 1a 2 SUIVRE LES INSTRUCTIONS DE S CURIT seen rentrer rennes 1a 2 LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION 1a 2 DANGER AVERTISSEMENT PR CAUTION ener terrere tette re nnn 1a 2 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 1a 3 LES CHOCS LECTRIQUES PEUVENT tre fatale 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSUR
37. an be pulled back and the torch can fire 4 Release the safety to return to the Safety On position shown in step 1 Figure 4 4 PAC125T Torch Safety Trigger Operation powermax900 Operator Manual 4 5 OPERATION OPERATING TIPS Changing Consumable Parts WARNING A SHOCK HAZARD Always turn off power and unplug cord from wall before changing consumable parts If power supply is directly connected to a line disconnect switch place line disconnect switch in OFF position Do not rely on the cap on sensor switch to remove power It is provided strictly for safety backup In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Changing the consumable parts requires no tools 1 Shut off the power supply 2 Unscrew the retaining cap and the remaining parts will come apart easily When you unscrew the retaining cap you will hear a click This click is a microswitch cap on sensor switch that disables the power supply if it is plugged in 3 Check the shield if applicable for external signs of wear The shield should be clean and clear of metal debris The gas holes along the edge of the shield should not be blocked with debris The center hole should not have any nicks or gouges and should show no signs of arcing activity 4 Unscrew the shield Inspect the gas holes from the inside The holes should be
38. ble parts kit CAUTION Never use Teflon tape when installing the nipple or adapters Bits of tape can break off and enter the air line and harm the pressure regulator pressure switch and valve 1 8 NPT Nipple or adapter Gas Supply Hose Connection Filter Figure 3 12 Rear Panel Gas Supply Connection to Filter TORCH LEAD CONNECTION To connect the PAC125T or PAC125M torch lead to the power supply 1 Align the connector key plugs on the torch lead with the connector receptacle key slots on the power supply and push in until the pins seat 2 Turn the connector securing ring 1 4 turn to the left to ensure that the securing ring threads and the connector receptacle threads are aligned prior to tightening 3 Turn the connector securing ring to the right to tighten Note The PAC121 torches used with the Powermax800 and other Hypertherm products cannot be connected to the Powermax900 power supply SETuP PAC125M ON OFF Pendant Connection A sitim Do not connect cutting machine interface START signal if using the ON OFF pendant See page 3 13 To connect the on off pendant lead to the PAC125M machine torch pigtail 1 Align the pendant lead connector key plug with the connector receptacle key slot on the pigtail and push in until pins seat 2 Turn the connector securing ring to the right to tighten Torch Lead To Powermax900 On Off Pendant power supply Machine To
39. ce must be of the 4 wire type with a green yellow wire for protec tive earth ground It must comply with local electrical requirements e Refer to the Standards Index in the Appendix section for other electrical codes WORK CABLE AND CLAMP The work clamp must be attached to the workpiece to perform plasma cutting Ensure that the work clamp and the workpiece make good metal to metal contact Attach the work clamp as close as pos sible to the area being cut to reduce exposure to electric and magnetic fields EMF Do not attach the work clamp to the portion of the workpiece to be cut away See Fig 3 10 Figure 3 10 Proper Work Clamp Connection powermax900 Operator Manual 3 9 SETUP GAS SUPPLY REQUIREMENTS The gas supply for the Powermax900 can be either air or nitrogen Air can be supplied as shop compressed air or cylinder compressed air Nitrogen can be supplied from compressed gas cylinders or liquid containers A high pressure regulator on either type of supply must be used and must be capable of delivering the following 360 scfh 6 scfm 170 l min at a pressure of 90 psi 6 2 bar to the filter on the power supply The filter is mounted at the rear of the Powermax900 power supply See Fig 3 12 WARNING A Do not allow the gas inlet pressure to the filter on the power supply to exceed 120 psi 8 2 bar The plastic filter bowl is rated for 150 psi 10 3 bar and may explode if this pressure is exceeded See the label
40. ch Type Control Interface 083063 Hand No No 083076 Hand Yes No 083077 Machine No Yes 083078 Machine Yes Yes POWER SUPPLIES 200 230 400V 10 30 50 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 083065 Hand No No 083082 Hand Yes No 083083 Machine No Yes 083084 Machine Yes Yes Note Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations 5 12 powermax900 Operator Manual 9 99 POWER SUPPLIES 400V CE 36 50 HZ Part For With Pilot Arc Number Torch Type Control 083064 Hand No 083079 Hand Yes 083080 Machine No 083081 Machine Yes MAINTENANCE PARTS With Machine Interface No No Yes Yes Note Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations powermax900 Operator Manual 5 13 9 99 MAINTENANCE PARTS 5 14 powermax900 Operator Manual APPENDIX A CHANGING Fuses In the event that the Powermax900 was configured incorrectly for the incoming power fuses F1 and or F2 may have blown to protect the power supply A WARNING A SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other co
41. clear of metal debris If the gas holes are blocked by debris try to open them by pushing a pin through each one from the outside of the shield to the inside If the shield is still good screw it back on to the retaining cap If it is damaged replace it with a new one 5 Inspect the nozzle for damage or wear If the hole in the nozzle is worn or oval shaped replace the nozzle 6 Inspect the electrode If the center of the electrode has a pit more than 1 16 inch 1 6 mm deep replace it 7 Inspect the swirl ring It should be clean and the holes along the side should not be plugged If the swirl ring is damaged replace it with a new one 8 Inspect the O ring on the torch It should be lubricated and undamaged If it is dry lubricate it with a thin film of the lubricant provided in the consumable parts kit If it is damaged replace it 9 Replace the parts as shown in Fig 4 5 Each part fits in only one direction so you cannot put the parts in backwards Also the torch will not fire if the parts are improperly assembled 10 When the nozzle electrode and swirl ring are properly in place replace the retaining cap and shield or deflector When the retaining cap is tightened the microswitch will click indicating that the torch is again ready for operation Plug the power supply back in 46 POWErmax900 Operator Manual OPERATION a Shields N 120691 Retaining Cap Nozzles 120600 120577 Hand Shielded 120602 OH
42. coeno denda 3 7 gt CE 3 8 Power Requirements EE 3 8 Line Voltage Disconnect BOX 3 8 Grounding GE Uu ET CH 3 9 Work Gable and Clamp ideo iia Pert etna eu Dua pe er RARE EXTR et tt MA IEEE 3 9 Gas Supply Requirements ss 3 10 Cylinder or Shop Compressed Air Supply ccccccccnccccnonncccccnnnnncnnnnnnonnnanononos 3 10 Additional AIF Filtration EE 3 10 Nitrogen EE 3 10 Eelere WEE 3 11 Qoo NE eio NRI Dm 3 11 PAC125M ON OFF Pendant Connection oooonccccnnccccccccnnnonnnnnccncnnnnnccnnonnnnns 3 12 PAC125M Torch ON OFF Switch Connection Data 3 12 PACT25M Torch le EE 3 12 Machine Interface with PAC125M 3 13 hiemes EU hee tr ES 3 14 SETuP UPON RECEIPT 1 Verify that all parts and items on your order have been received Alert your distributor if any parts or items are damaged or missing 2 Inspect the power supply for any physical damage that may have occurred during shipping If there is evidence of damage refer to the Claims section below All communications regarding this equipment must include the model number and serial number located on the back of the Powermax900 3 Before setting up and operating the Powermax900 read the Safety section of this manual CLAIMS Claims for damage du
43. con us pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz contenu dans chaque tuyau Se r f rer aux codes locaux ou nationaux en vigueur LES BOUTEILLES DE GAZ COMPRIME PEUVENT EXPLOSER 4H EN CAS DE DOMMAGES ne Les bouteilles de 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 enco
44. ct the manifold to a shop air line Set a pressure regulator to obtain a steady stream of bubbles Aeration Manifold e o o o e e o J Distribution Lines Regulated air in Figure c 1 Aeration Manifold powermax900 Operator Manual 1 powermax900 Operator Manual
45. des vapeurs et des gaz toxiques Ne pas couper des m taux peints ou contenant des qui r duisent le niveau d oxyg ne dans l air et peuvent mati res toxiques comme le zinc galvanis le plomb le provoquer des blessures voire la mort cadmium ou le b ryllum moins que la zone de travail Conserver le poste de coupage bien a r ou utiliser un Soit tr s bien ventil e et que l op rateur porte un masque masque respiratoire homologu respiratoire Les rev tements et m taux contenant ces Ne pas proc der au coupage pr s d endroits o mati res peuvent produire des vapeurs toxiques lors du s effectuent le d graissage le nettoyage ou la coupage vaporisation Certains solvants chlor s se d composent Ne jamais couper de r cipients pouvant contenir des sous l effet des rayons ultraviolets et forment du mati res inflammables avant de les avoir vid s et phosg ne nettoy s correctement HYPERTHERM Syst mes plasma 1a 3 08 99 SECURITE Torches a 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 ray
46. duced 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 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 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 fillering of the mains supply Consideration should be given t
47. ed to the workpiece or the work clamp is broken Connect or repair the work clamp 7 2 Work clamp is not making good metal to metal contact Clean area where clamp contacts the workpiece 7 2 The workpiece is too far away from the torch Move the torch head closer 1 8 1 4 8 6 mm maximum distance to the workpiece and start the torch again powermax900 Operator Manual MAINTENANCE PARTS Problem Cause Solution 8 The arc blows out but re ignites when the 8 1 There are faulty consumable parts torch switch is depressed Inspect and change the consumable parts if necessary See Operating Tips in Section 4 8 2 The gas pressure is incorrect Adjust the gas pressure Incoming gas pressure is 90 psi 6 2 bar at a flow of 360 scfh 170 l m Pressure at unit in TEST mode is 70 psi 4 8 bar for lead length of 25 feet 7 6 m and 75 psi 5 bar for lead length of 50 feet 15 2 m See Operating Instructions in Section 4 to adjust gas pressure if necessary 8 3 The gas filter at the rear of the supply contains excessive moisture Drain the filter bowl and clean the filter See Routine Maintenance earlier in this section 9 The arc sputters and hisses 9 1 The gas filter at the rear of the supply contains excessive moisture Drain filter bowl and clean filter See Routine Maintenance earlier in this section 10 Cut quality is not good 10 1 Power supply voltage links are incorrect See voltage configuration settings in
48. er supply provides constant current output variable from 20 to 55 amps for optimum performance on all thicknesses of metal up to 5 8 16 mm thick At 55 amps the Powermax900 can also cut metals up to 7 8 22 mm thick and will sever metals up to 1 1 8 29 mm thick Air is the primary plasma gas providing low operating cost combined with high speed performance Cylinder air or shop air can be used as long as it is clean dry and oil free When properly set and maintained the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality The Powermax900 can also cut with nitrogen when extended electrode life is a priority This instruction manual provides information for the user to set up and operate the system and perform limited maintenance on the power supply This manual also provides a detailed list of safety practices so that the system can be safely operated and maintained READ THE SAFETY SECTION Section 1 FIRST The Powermax900 service manual provides higher level troubleshooting and a more complete parts list Figure 2 1 Powermax900 Hand Plasma Cutting System Single phase 208 240 480V power supply shown See Section 5 for part numbers and descriptions of other Powermax900 power supplies 2 2 powermax900 Operator Manual SPECIFICATIONS SPECIFICATIONS Power Supply Rated Open Circuit Voltage OCV U Rated Outp
49. er switch to the OFF 0 position unplug the power cable from the wall receptacle and disconnect the gas supply 2 Remove the screws that secure the power supply cover to the chassis 3 Remove the cover and remove the cooling air filter from the clips by sliding the filter to the left and then up Fig 5 2 See Powermax900 Field Upgrade Kits and Optional Parts later in this section for part number information Cooling Air Filter x SOO d Ke ee Ss di d 2 ee NNN d E HN OC REA 6 X NONO I I ONU E e se ESS MARO Oe d RRR KG Se SE 5 di 0 Se d ES RS Es etn s Gs di d d ee dy d 000 Re ne d 220 e eS 2 d 05 d Ge E de de SS x eS di x x eS de ge d ARAN ES E 9 gt Figure 5 2 Air Filter Removal 4 Clean the air filter with either soap and water or with low pressure compressed air 5 Replace the dry filter in the power unit with the wire mesh facing the fan 6 Replace and re fasten the power supply cover with the existing screws powermax900 Operator Manual 5 3 MAINTENANCE PARTS BASIC TROUBL
50. ermax900 Operator Manual E t 7 t 4 e EN m n m oom F Po MCU pus LIU n powermaxgoo e e gt AN 2 3 10 98 SPECIFICATIONS Ee Gas Quality Air Gas Quality Nitrogen Gas Inlet Pressure Gas Flow Power Supply pressure regulator setting PAC125 TORCHES Maximum 55A Cutting Capacity PAC125T Maximum 55A Cutting Capacity PAC125M Maximum 39A Cutting Capacity PAC125M Maximum current at 5096 duty cycle Gouging Capability metal removal rate Weight PACT2 Tian Weight PAC125M PAC125T Hand Torch Assembly 65 pounds 30 kg without wheels 72 pounds 33 kg with wheels 128 pounds 58 kg for 600V and 230V CE power supplies Air or Nitrogen Clean dry oil free 99 995 pure 90 psi 6 2 bar 360 scfh 6 scfm at 90 psi 170 l min at 6 2 bar supplied to power supply pressure regulator 70 psi 4 8 bar flowing 7 8 22 mm 50 duty cycle 1 2 13 mm 50 duty cycle 3 8 9 5 mm 100 duty cycle 55 amps 6 3 pounds 2 9 kg hr 4 5 pounds 2 kg with 25 ft 7 6 m lead 7 pounds 3 2 kg with 50 ft 15 m lead 7 pounds 3 2 kg with 25 ft 7 6 m lead 9 5 pounds 4 3 kg with 50 ft 15 m lead Go 8 72 8 50 gt i vu TOUT gt Figure 2 3 PAC125T Torch with Dimensions PAC125M Machine Torch Assembly
51. es Do not substitute other torches which could overheat and present a safety hazard CUTTING CAN PRODUCE TOXIC FUMES Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death Keep the cutting area well ventilated or use an approved air supplied respirator Do not cut in locations near degreasing cleaning or spraying operations The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation Do not cut metal coated or containing toxic materi als such as zinc galvanized lead cadmium or Hypertherm Plasma Systems beryllium unless the area is well ventilated and the operator wears an air supplied respirator The coatings and any metals containing these elements can produce toxic fumes when cut Never cut containers with potentially toxic materials inside they must be emptied and properly cleaned first This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer SAFETY PLASMA ARC CAN CAUSE INJURY AND BURNS Instant On Torches Plasma arc comes on immediately when the torch switch is activated The plasma arc will cut quickly through gloves and skin 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
52. excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve 9 PACEMAKER AND HEARING NOISE CAN DAMAGE 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 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 doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada NFPA Standard 51B Cutting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 0221
53. he POWER ON LED is illuminated the LINE VOLTAGE LED is continuous yellow and the torch is working 3d The LINE VOLTAGE LED is continuous red power supply is disabled powermax900 Operator Manual MAINTENANCE PARTS Cause Solution Note To avoid performance deterioration of the Powermax900 input voltage should be within 10 of the specified system line voltage setting System Lower Limit Line Voltage Upper Limit 164VAC 200VAC 235VAC 170VAC 208VAC 239VAC 189VAC 230VAC 270VAC 197VAC 240VAC 276VAC 328VAC 400VAC 470VAC 393VAC 480VAC 552VAC 510VAC 600VAC 690VAC 3b 1 Power supply voltage links are incorrect See voltage configuration settings in Section 3 3b 2 Line voltage is too low Line voltage is less than 20 of nominal Have an electrical technician check incoming power 3c 1 Power supply voltage links are incorrect See voltage configuration settings in Section 3 3c 2 Line voltage is too low Line voltage is between 15 and 20 below nominal Have an electrical technician check incoming power 3d 1 Line voltage is too high Line voltage is greater than 15 of nominal Have an electrical technician check incoming power 3d 2 Torch cap is not engaging microswitch Verify that the torch consumables are installed correctly and that a click is heard when the retaining cap is screwed down 3d 3 Trip circuit is defective See Technical Questions on page 5 7 3d 4 There is a control board failure Tur
54. iece causes the shield or nozzle to stick and makes smooth cutting difficult The arc transfers to the workpiece once the torch is within 1 4 inch 6 mm of the workpiece Pulling the torch through the cut is easier than pushing it Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line Fig 4 8 By lightly dragging the shield or nozzle on the workpiece you can maintain a steady cut For straight line cuts use any straight edge as a guide When cutting thin material reduce the amps until you get the best quality cut To cut circles use a template or a radius cutter attachment Fig 4 7 Figure 4 6 Starting a Cut powermax900 Operator Manual OPERATION Figure 4 7 Cutting a Circle Figure 4 8 Dragging the Torch powermax900 Operator Manual 4 9 OPERATION Piercing e Hold the torch so that the nozzle is approximately 1 16 inch 1 6 mm away from the workpiece before firing the torch This method maximizes the life of the nozzle e Hold the torch at an angle to the workpiece away from yourself then slowly rotate it to an upright position This is particularly important when cutting thicker material Make sure that the torch is pointed away from you and the people around you to avoid any danger from sparks and hot metal Fig 4 9 This method permits the hot metal to escape to one side rather than splashing back against the nozzle This will protect the operator from the sparks and exte
55. l Speed Delay 2 V ipm mm min S Le p m funeste cm sme sme oe 5 dcus SES Que a fes ve oe om oe BRUN AE SU ARTE HER Recommended travel speeds are 10 20 slower than maximum These slower speeds will produce optimum cut quality Cut Chart Notes The Cut Charts on these pages are optimized to provide the best cut angle least dross and best cut surface finish Remember that cut charts are intended to provide a good starting point for each different cutting assignment Every cutting system requires fine tuning for each cutting application to the materials on site in order to obtain optimum cut quality powermax900 Operator Manual 4 13 OPERATION Cut Chart Notes continued Maximum recommended mechanized cutting capacity 1 2 13 mm See page 4 7 or Section 5 for additional consumable parts Compressed air or nitrogen must be available to the power supply filter pressure regulator at a flow rate of 360 scfh 6 scfm 170 l min at a pressure of 90 psi 6 2 bar The dynamic flowing pressure when operating is 70 psi 4 8 bar If torch leads are 50 ft 15 2 m the dynamic pressure when operating is 75 psi 5 bar If the pressure to the power supply falls below 40 psi 2 8 bar the torch will go out After several minutes of running the torch retaining cap may become hot to touch To cool it push in and hold the GAS TEST switch until the cap cools down The
56. llic components Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes willincrease the risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC TC26 sec 94 and IEC TC26 108A CD Arc Welding Equipment Installation and Use Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications WARRANTY Genui
57. located on a wall near the power supply and should be easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses according to the power requirements listed below Input Input Current Recommended Voltage Phase 6 6 kw Output Slow Blow Fuse Size 200 VAC 1 57 amps 70 amp 208 VAC 1 55 amps 70 amp 230 VAC 1 50 amps 70 amp 240 VAC 1 47 amps 60 amp 400 VAC 1 33 amps 40 amp 480 VAC 1 28 amps 35 amp 200 VAC 3 33 amps 40 amp 208 VAC 3 32 amps 40 amp 230 VAC 3 29 amps 35 amp 230 VAC CE 3 31 amps 40 amp 240 VAC 3 28 amps 35 amp 400 VAC 3 18 amps 25 amp 400 VAC CE 3 18 amps 25 amp 480 VAC 3 15 amps 20 amp 600 VAC 3 12 amps 20 amp 3 8 powermax900 Operator Manual SETUP GROUNDING REQUIREMENTS To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax900 must be properly grounded e The power supply must be properly grounded through the power cord according to your national or local electrical codes The power supply chassis is electrically conductive and can present a shock hazard if it is not properly grounded through the line voltage disconnect box Single phase service must be of the 3 wire type with a green or green yellow wire for protective earth ground It must comply with local electrical requirements Do not use a 2 wire service Refer to Grounding in the Safety section Three phase servi
58. mum Signal not available on rear panel connector ARC VOLTAGE Figure 3 17 Machine Interface Board Connections for Arc Voltage 3 14 powermax900 Operator Manual Section 4 OPERATION In this section Controls Ree te 4 2 Operating Instructions 5 oer eid eet 4 3 Pilot Arc Controller OPIO stunt 4 4 PAC125T Safety Trigger Operation 4 5 Ope rating TPS E 4 6 Changing Consumable Parts 4 6 E ul EE 4 8 PICKING AA TE 4 10 GOUT pee ME 4 11 Cut Chart 50A Standard Consumables 4 12 Gut Chart 35A Consumibles oci nes Db VERA Foie ae a hades 4 13 CommonsGutting Faults sen ln clack sees 4 14 powermax900 Operator Manual 4 1 10 96 OPERATION CONTROLS AND INDICATORS e Green POWER ON LED When illuminated indicates that all control circuits are activated the torch safety interlock is satisfied and the system is ready for operation e Green LINE VOLTAGE LED When illuminated green indicates that the AC line voltage is within proper operating limits If dis abled white or if illuminated or blinking any other color see Basic Troubleshooting in Section 5 e Yellow TEMP LED When illuminated indicates that the power supply temperature has exceeded operating limits Green GAS PRE
59. n power supply off and then on If problem persists see Technical Questions on page 5 7 5 5 9 99 MAINTENANCE PARTS Problem 3e The LINE VOLTAGE LED is blinking red and the power supply is disabled 4 The power supply shuts off after it turns on 5 The fuse on the incoming power line fails during cutting 6 The POWER ON LED is illuminated the TEMP LED stays illuminated and the torch will not fire 7 The arc does not transfer 9 99 Cause Solution 3e 1 There is an internal torch failure Replace the torch 4 1 The torch is not connected to the power supply Connect the torch to the power supply 4 2 The retaining cap is loose Tighten the retaining cap 4 3 The torch is defective See Technical Questions on page 5 7 4 4 Power supply voltage links are incorrect See voltage configuration settings in Section 3 4 5 Line voltage is too high See table on previous page 5 1 The power supply has exceeded the capacity of the fuse Check the fuse for proper amperage rating See Power Requirements in Section 3 Check power cable for a short circuit or loose connection 6 1 One of the internal thermostat switches has opened due to overheating Leave power supply on to allow fan to cool power supply down then shut down and restart Clean internal air filter if installed See Removal Cleaning and Replacement of the Cooling Air Filter earlier in this section 7 1 The work clamp is not connect
60. nd the life of the nozzle e When the pierce is complete proceed with the cut 2 Rotate the torch to an upright position Figure 4 9 Piercing POWEFMAXY00 Operator Manual OPERATION Gouging The Powermax900 can be used for gouging mild steel by using the optional gouging nozzle and gouging shield To gouge e Always wear full protection Awelding helmet with at least a 8 lens shade Welding gloves Awelding jacket The arc is fully exposed and will cause serious burns if the skin is not covered e Install the gouging nozzle and shield just as you would install a standard cutting nozzle and shield See Changing Consumable Parts earlier in this section e Adjust the air pressure to 50 55 psi 3 4 3 8 bar with air flowing from the torch Note that this is lower than the cutting pressure e Start a transferred arc by holding the torch pependicular to the workpiece As soon as the arc transfers tilt the torch approximately 45 from the surface to be gouged and feed into the gouge Multiple passes or wearing may be necessary to gouge wider and deeper sections See Fig 4 10 2 Feed into the gouge Figure 4 10 Gouging OPERATION CUT CHART 55A STANDARD CONSUMABLES The following recommended settings are for mechanized cutting at 55 amps Torch to work distance for the following cut charts is 1 16 inch 1 6 mm for all cuts Shield Retaining Cap Nozzle Electrode Swirl Ring PAC125
61. ne 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 GENERAL HYPERTHER M Inc warrants that Products shall be free from defects in materials and workman ship under proper and normal use for which such Equipment is recommended for a period of two 2 years except only with respect to the Torch for which the warranty period shall be one 1 year from the date of its delivery to you HYPERTHERM at its sole option shall repair replace or adjust free of charge any Products covered by this warranty which shall be returned with HYPERTHERM s prior authorization which shall not be unreasonably withheld properly packed to HYPERTHER M s place of business in Hanover New Hampshire all costs insurance and freight prepaid and which examination proves not to be free from defects in materials and workman ship HYPERTHERM shall not be liable for any repairs replacements or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with HYPERTHERM s written consent This warranty shall not apply to any Product which has been mishandled incorrectly installed modified or assembled by you or any other person HYPER THERM shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable war
62. o 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 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 powermax900 Operator Manual 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 at the same time The operator should be insulated from all such bonded meta
63. o rai 3 6 SINGLE PHASE AND THREE PHASE POWER CONFIGURATIONS eee 3 7 Single NAGS qe T 3 7 Three Phase Non 6 3 7 USS PSCC Bat aa a ager er ie ne ery a otros genet oe a on Graal 3 8 POWER REQUIREMENTS cdta tilda ane odes 3 8 Line Voltage Disconnect BOX 3 ee re SERE AR NO ERE ERAT ni Rte rene 3 8 GROUNDING REQUIREMENT S tuat ee ete ein keep 3 9 WORK CABLE AND CLAMP eebe pte enne ee untur aoa OL EE Me pese 3 9 GAS SUPPLY REQUIREMENT S rait deg EE 3 10 Air SUN Bliss 3 10 Additional Air Filtration 3 10 Nitrogen Quality er 3 10 GAS SUPPLY CONNECTION sienne deed A et Peto qud a 3 11 TORGH LEAD CONNECTION 3 11 PAC125M ON OFF Pendant Connection iii 3 12 PAC125M Torch ON OFF Switch Connection Data 3 12 Se Eeer ln EE 3 12 MACHINE INTERFACE WITH PAGT25M WEE 3 13 Arc VONAGE e 3 14 SECTION 4 OPERATION 4 1 CONTROLS AND INDICATORS a ete ep o tio wmm edet uisu a eae PR 4 2 OPERATING INSTRUCTIONS curia etum ton ds ted dud Ana 4 3 Pilot Arc Controller Option ico tre HR IRURE Ir pt 4 4 PAGI2ST Safety Trigger OP RATION dee persa e eei open er ac EHE eS Paden epa itd 4 5 OPERATING TIPS reee p RSR ne nn nn P pa ap dr aoc das oto 4 6 Changing Consumable E 4 6 CUINA EP 4 8 PICKING ices Seas EE 4 10 le 4 11 CUT CHART
64. on de l quipement DANGER AVERTISSEMENT PR CAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSE MENT 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 o 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 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 syst me plasma Lors de l utilisation d oxyg ne comme gaz plasma un syst me de ventilation par aspiration est n cessaire
65. on les un choc lectrique fatal ou des br lures graves instructions du pr sent manuel et conform ment aux La mise en fonctionnement du syst me plasma ferme un codes lectriques locaux et nationaux circuit lectrique entre la torche et la pi ce couper La Inspecter fr quemment le cordon d alimentation primaire pi ce couper et tout autre l ment en contact avec cette pour s assurer qu il n est ni endommag ni fendu pi ce font partie du circuit lectrique Remplacer imm diatement un cordon endommag Un Ne jamais toucher le corps de la torche la pi ce couper c ble d nud peut tuer ou l eau de la table eau pendant le fonctionnement du Inspecter et remplacer les cables de la torche qui sont syst me plasma us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du Pr vention des chocs lectriques coupage Laisser la pi ce couper en place ou sur la Tous les syst mes plasma Hypertherm utilisent des hautes table de travail le c ble de retour connect lors du tensions pour le coupage souvent de 200 400 V On doit coupage prendre les pr cautions suivantes quand on utilise le Avant de v rifier de nettoyer ou de remplacer les pi ces syst me plasma de la torche couper l alimentation ou d brancher la prise Porter des bottes et des gants isolants et garder le corps de courant et les v tements au sec Ne jamais contourner ou court circuiter les verrouillages Ne pas se tenir
66. ons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d crans lat raux ou 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 E U ISO 4850 Jusqu a 100 A N 8 N 11 100 200 A N 10 Ne 11 12 200 400 A Ne 12 N 13 Plus de 400 A N 14 N 14 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 LES RAYONS DE L ARC PEUVENT BR LER LES YEUX ET LA PEAU Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Pr parer la zone de coupage afin de r duire la r verb ration et la transmission de la 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
67. 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 hazards WARNING safety messages precede related instruc tions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instruc tions in this manual that may result in damage to equipment if not followed correctly CUTTING CAN CAUSE FIRE OR EXPLOSION Fire Prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they 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 WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtu
68. powermax900 Plasma Arc Cutting System Operator Manual IM 308 P N 803080 Revision 1 September 1999 beginning with serial number 900 010000 Hypertherm Inc Hanover NH USA http www hypertherm com email info hypertherm com Copyright 1999 Hypertherm Inc All Rights Reserved HYPERTHERM and POWERMAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Offices Worldwide Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA Tel 603 643 3441 Main Office Fax 603 643 5352 All Departments Tel 800 643 9878 Technical Service Tel 800 737 2978 Customer Service email info hypertherm com General Information email service hypertherm com Technical Customer Services Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 European Technical Support Organization ETSO Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm U K 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 France 10 All e de l Isara F 95000 Cergy Pontoise France Tel
69. protect others from flash and glare Warn others not to watch the arc Use placards or signs Input Power Besure to connect the power cord ground wire to the ground in the disconnect box e f installation of the plasma system involves connect ing the power cord to the power supply be sure to connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating Hypertherm Plasma Systems COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease SAFETY Gas cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accor Use only correct gas cylinders regulators hoses and fittings designed for the specific application Maintain all compressed gas equipment and associ ated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes dance 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
70. ranty period specified herein above THE FOREGOING SHALL CON STITUTE THE SOLE REMEDY TO DISTRIBU TORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF ITS WAR RANT Y PATENT INDEMNITY Except only in cases of Products not manufac tured 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 agrees to indemnify protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their custom ers because of the use in or about the construction or operation of Equipment or any design system formula combination article or material which infringes or alleges to infringe on any patent or other right Distributors shall notify HYPERTHERM promptly upon learning of any action or threatened action in connection with any such alleged in fringement and each party may appoint its own counsel for any such action or threatened action DISCLAIMER OF OTHER WARRANTIES HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR OTHERS INCLUDING WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANT ABILITY OR FITNESS FOR A PARTICULAR PURPOSE EITHER EXPRESS OR IMPLIED EXCEPT AS PROVIDED HEREIN This warranty is in lieu of any and all
71. rch Pigtail Figure 3 13 ON OFF Pendant Connection PAC125M Torch ON OFF Switch Connection Data The PAC125M torch lead is supplied with a pigtail so that the on off pendant may be used If you want to use a different on off switch configuration note that the wiring configuration to the 3 socket female receptacle on the pigtail is as follows PAC125M Torch Alignment Mount the machine torch perpendicular to the workpiece in order to get a vertical cut Use a square to align the torch at 0 and 90 as shown in Fig 3 14 3 12 powermax900 Operator Manual SETUP Figure 3 14 Aligning the Machine Torch with Square MACHINE INTERFACE WITH PAC125M Signals for arc transfer and start are available on power supplies that have the machine interface option The machine interface option is also available as an upgrade kit A WARNING A Do not connect cutting machine interface START signal if using an ON OFF pendant e Plug the machine interface cable into the connector on the rear panel See Fig 3 15 to connect the machine interface cable to the cutting machine Green Black Red Black Signal START start plasma XFER start machine motion Output Normally open 24VAC open circuit voltage Normally open Dry contact closure when arc at START terminals transfers 120VAC maximum at machine Requires dry contact closure to activate interface CT MEME or switching device Rear panel sockets ee 14
72. res Keep flames and sparks away from the torch when using methane or argon hydrogen plasma When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen deto nation Refer to the Appendix section of this manual for aeration manifold details WARNING Hydrogen Detonation with Aluminum Cutting Hypertherm Plasma Systems SAFETY ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause a fatal shock or severe burn 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
73. ring shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance call Customer Service listed in the front of this manual or your authorized Hypertherm distributor Claims for defective or missing merchandise If any of the merchandise is defective or missing call your authorized Hypertherm distributor If you need additional assistance call Customer Service listed in the front of this manual 3 2 powermax900 Operator Manual SETUP HOISTING REQUIREMENTS If the power supply must be hoisted read the Warning first and follow this procedure See Fig 3 1 WARNING The Powermax900 power supply weighs up to 135 pounds 61 kg Do not hoist the power supply by one handle it is not designed to support the weight of the power supply Failure to heed this warning could result in personal injury and damage to the power supply 1 Usea hoisting strap rated for 4x the full weight 2 Ensure the power supply cover is secured prior to hoisting 3 Route strap between both handles as shown in Fig 3 1 4 Bring the strap ends together over the center of the power supply and connect them to the hoisting machine 5 Hoist and lower the power supply slowly and smoothly avoid jerking motions Hoisting Machine Approved hoisting strap keep as vertical as possible Cover in place
74. tion 400V or 480V Get Box Figure 3 5 400V or 480V Configuration powermax900 Operator Manual SETUP 3 5 SETUP POWER CORD PLUGS All 208 240 480V power supplies are shipped with a single phase power cord and plug To operate as a three phase unit the user must obtain a power cord and plug that is certified by national or local electrical codes The plug should be connected to the power cord by a licensed electrician All 200 230 400V and 400V CE power supplies are shipped with a three phase power cord and no plug The user must obtain a plug that is certified by national or local electrical codes The plug should be connected to the power cord by a licensed electrician POWER CORDS If the power cord needs to be changed use the tables below to choose the proper wire size for the appropriate length cord Note that the input current used to determine the cord size is l In the U S use a 3 conductor SO type cord for single phase and a 4 conductor SO type cord for three phase power supplies In other countries use cords that are certified by national or local codes Prepare the power cord wires as shown in Fig 3 6 for non CE power supplies or Fig 3 6a for CE power supplies Note that all 4 wires must loop through the toroid in the CE power supply Cap or tin the conductor leads and use a 10 terminal on the ground wire The cord should be installed only by a licensed electrician 208 240
75. tion 9 When the cut is finished release the trigger to extinguish the arc The arc will also extinguish when transfer to the workpiece is no longer sensed 10 The torch will continue to release gas after the arc is extinguished This gas postflow will con tinue for approximately 15 seconds but can be halted by quickly depressing and then releasing the trigger To reinitiate the arc while in postflow press and hold the trigger Pilot Arc Controller Option In power supplies with the pilot arc controller option the torch will return to a pilot arc after finishing a cut if the torch switch remains pressed After a short delay the pilot arc will then extinguish if no arc transfer is sensed The pilot arc controller option is especially useful if you are cutting expanded metal See Powermax900 Field Upgrade Kits and Optional Parts in Section 5 for part number information OPERATION PAC125T Safety Trigger Operation The PAC125T safety trigger torch allows operators to safely handle the torch before and after the cut and to minimize the possibility of accidental torch firing The safety trigger is easy to operate Follow the steps below 6 Safety On position In this position the trigger cannot be pulled back and the torch cannot fire 2 To fire the torch start pushing the safety forward Do not pull back on the trigger until the safety reaches the Safety Off position 3 Safety Off position In this position the trigger c
76. untries follow appropriate local or national safety procedures 1 Turn the Powermax900 power switch to the OFF 0 position unplug the power cable from the wall receptacle and disconnect the gas supply See warning above 2 Remove the screws that secure the power supply cover to the chassis 3 Remove the cover and find F1 and F2 power fuses Fig a 1 4 Remove and check the fuses Replace if necessary Fuse part number 008809 for 208 240 480V power supplies Fuse part number 008958 for 200 230 400V and 400V CE power supplies 5 Replace the power supply cover 6 Be certain that a licensed electrician verifies incoming power and configures the Powermax900 appropriately See voltage configurations in the Setup section beginning on page 3 4 7
77. urus en cas d exposition au bruit HYPERTHERM Syst mes plasma 9 PACEMAKERS ET S e PROTHESES AUDITIVES Les champs magn tiques produits par les courants haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un m decin avant de s approcher d un lieu o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques Garder loin de soi et du m me c t du corps le c ble 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 c ble de retour autour du corps Se tenir le plus loin possible de la source de courant 1a 5 08 99 SECURITE 1a 6 HYPERTHERM Syst mes plasma 08 99 Section 2 SPECIFICATIONS In this section fe dee e ele ett pcc 2 2 leide CN 2 3 A HET 2 3 PAGI2S ee 2 4 PAC125T Hand Torch Assembly EE 2 4 PAC125M Machine Torch Assembly 2 4 ER TEE 2 5 SYmbolS US 2 6 powermax900 Operator Manual 2 1 SPECIFICATIONS INTRODUCTION The Powermax900 plasma cutting system uses an inverter power supply to provide a smooth DC output voltage producing excellent cut and gouge quality on mild steel stainless steel aluminum and other metals The Powermax900 pow
78. ut Current l Rated Output Voltage U Duty Cycle X 9 40 C Ambient temperature duty cycle Apparent Input Power 5 Input Voltage U Input Current I 6 6 kw Output a titer pet qae Dimensions and Weight 10 4 300 VDC 20 55 amps 120 VDC 50 1 55A U 120V 100 1 39A U 120V for the 208 240 480V power supplies See data tag on power supply for more information on duty cycle Power supplies will operate between 14 and 104 F 10 and 40 C Power supplies operated in an ambient temperature above 86 F 30 C may show some decrease in duty cycle 12 5kVA U L 208V 55A 240V 47A 480V 28A 16 50 60 Hz 208V 32A 240V 28A 480V 15A 36 50 60 Hz 200V 57A 230V 50A 400V 33A 16 50 60 Hz 200V 33A 230V 29A 400V 18A 36 50 60 Hz 230V CE 29A 400V CE 18A 36 50 60 Hz 600V 12A 36 60 Hz 23 1 590 mm 10 4 260 mm without wheels 15 3 390 mm with wheels 19 6 500 mm without wheels 23 7 620 mm with wheels 27 7 700 mm for 600V power supply 23 1 d Ee C 255 Figure 2 2 Powermax900 Power Supply with Dimensions pow
79. warranties express or implied by law or otherwise and Distributors are not authorized to give any other warranty purport ing to be binding upon HYPERTHERM upon resale of Products to their customers IN NO EVENT shall HYPER THERM be liable for inciden tal or consequential damages or injury to the person or property of anyone by reason of any defect in any Equipment sold hereunder 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 incidental or consequential injury to persons or property dam age by reason of any code violation or poor work practices powermax900 Operator Manual TABLE OF CONTENTS CONTENTS ELECTROMAGNETIC COMPATIBILITY i VaN dn EE EE i SECTION 1 SRA ei muc eens ieee EE D neat 1 1 RECOGNIZE SAFETY INFORMATION 1 2 FOLLOW SAFETY INSTRUCTIONS s nues a a rn DU Tr i o a e CN 1 2 CUTTING CAN CAUSE FIRE OR EXPLOSION 1 2 ELECTRIC SHOCK CAN KIEL etico 1 2 CUTTING CAN PRODUCE TOXIC FUMES 1 3 ARC RAYS CAN BURN EYES AND SKIN c ccscesceceeceecescecceccecsececcess
80. you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process 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 enclo sure 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 torch

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