Hypertherm MAX200 Instruction Manual
Machine torch
plasma arc
cutting system
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- Instruction manual (182 pages) ,
- Product configuration manual (14 pages) ,
- Field service bulletin (10 pages)
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Summary of Contents for Hypertherm MAX200
- Page 1 MAX200 ® Machine Torch Plasma Arc Cutting System Instruction Manual 800980 – Revision 15 EN50199 EN60974-1...
- Page 2 800980 Rev 14 to 15 Changed Page Description 5/10/02 3.21 Added part numbers for cable lengths 25 ft-200 ft Call-outs for ends of cable changed. Power supply end was 1X4, changed to 1X2. DR/PR end 3.27 was 5X1, changed to 5X2. 4.6 &...
- Page 3 Changed Page Description 800980 Rev 12 to 13 7/99 Cover New Revision Title Page New Revision Added plumbing/electrical code statement to warranty page 1.1-1.6 New safety section 1a.1-1a.6 New French safety section Added pre-installation for plumbing/electrical codes Added hard plumbing statement Shifted text from page 3-4 Revised coolant mixture 3.22...
- Page 4 Page Changed Description 800980 Rev 11 to 12 Cover New Revision Title Page New Revision Revised duty cycle rating Added 073036 & 073039 power supply 3.31 Removed P/N reference 3.33 Removed P/N reference 3.41 Revised water muffler install options 4.10-4.46 Added 120667 electrode, revised motion delay and notes General correction 5.11...
- Page 5 Changed troubleshooting (second problem) 6.04 Removed word "red" in second & third problem descriptions 6.05 Removed word "red" in first problem description d.03 Changed reference from 220-380-415V CE to 400V CE 8 sheets MAX200 wiring diagram format change 013-2-179 Rev K...
- Page 6 200-003654 Revision 15 – June, 2002 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2002 Hypertherm, Inc. All Rights Reserved Hypertherm and Command THC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries...
- Page 7 63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm (S) Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel...
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Page 8: Electromagnetic Compatibility (Emc
The size of the surrounding area to be Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety, nor connected to earth ing place. -
Page 9: Warranty
Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty. -
Page 10: Table Of Contents
Étiquette de sécurité ...............................1a-6 Section 2 SPECIFICATIONS..........................2-1 General ..................................2-2 Product Specifications ..............................2-2 MAX200 Power Supplies ..........................2-2 MAX200 CE Power Supplies ...........................2-3 MAX200 Machine Torch...........................2-4 Section 3 SETUP ..............................3-1 Claims and Technical Questions ..........................3-3 Pre-Installation ................................3-3 Air and Gas Supply Requirements ...........................3-4 Air Supply.................................3-4... - Page 11 Work Clamp ..............................3-16 Machine Torch System Installations ......................3-19 Install the MAX200 without THC Option......................3-19 Install the MAX200 with THC Option......................3-23 Install the MAX200 with IHS Option .......................3-31 Adjust the Torch Position ..........................3-40 Install the Water Muffler Option........................3-41 Section 4 OPERATION ............................4-1 Front Panel Controls ..............................4-2...
- Page 12 Consumable Parts Kits ............................6-20 MAX200 Machine Torch Assembly ......................6-21 Machine Torch Lead Assemblies ........................6-24 Section 7 WIRING DIAGRAMS ..........................7-1 MAX200 Electrical Schematic & Block Diagram (013-2-179) ................9 Sheets Coolant System Schematic/Diagram (029-2-313) .....................1 Sheet Appendix A FILTERS ............................a-1 Appendix B PROPYLENE GLYCOL SAFETY DATA ..................b-2...
- Page 13 Compressed Gas Equipment Safety ........................1-5 Gas Cylinders Can Explode If Damaged ........................1-5 Noise Can Damage Hearing .............................1-5 Pacemaker and Hearing Aid Operation ........................1-5 A Plasma Arc Can Damage Frozen Pipes ........................1-5 Additional Safety Information ............................1-5 Warning Label................................1-6 Hypertherm Plasma Systems...
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Page 14: Recognize Safety Information
• Install an aeration manifold on the floor of the water closed container. table to eliminate the possibility of hydrogen • Do not cut containers that have held combustible detonation. Refer to the Appendix section of this materials. manual for aeration manifold details. Hypertherm Plasma Systems 11-98... -
Page 15: Electric Shock Can Kill
• Provide a disconnect switch close to the power grounding conductor first. supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be the operator to turn off the power supply quickly in used only with specific Hypertherm torches. Do not an emergency situation. -
Page 16: A Plasma Arc Can Cause Injury And Burns
Work Table Connect the work table to an earth power cord ground. Fasten the retaining nut tightly. ground, in accordance with appropriate national or • Tighten all electrical connections to avoid excessive local electrical codes. heating. Hypertherm Plasma Systems 5/6/02... -
Page 17: Compressed Gas Equipment Safety
Protection Association, 470 Atlantic Avenue, Boston, MA 02210 Hazardous Substances, American Welding Society 10. OSHA, Safety and Health Standards, 29FR 1910 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98... -
Page 18: Warning Label
Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or cutting. Do not remove or paint over (cover) warning labels. Hypertherm Plasma Systems 8-99... -
Page 19: Section 1A
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............1a-5 Le bruit peut provoquer des problèmes auditifs......................1a-5 Pacemakers et prothèses auditives ........................1a-5 Un arc plasma peut endommager les tuyaux gelés....................1a-5 Étiquette de sécurité ...............................1a-6 Hypertherm Systèmes plasma 1a-1 2/12/01... -
Page 20: Identifier Les Consignes De Sécurité
• Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 Hypertherm Systèmes plasma 2/12/01... -
Page 21: Les Chocs Électriques Peuvent Être Fatals
• Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée. proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm cas d’urgence. -
Page 22: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 5/6/02... -
Page 23: Sécurité Des Bouteilles De Gaz Comprimé
LES TUYAUX GELÉS • Se tenir le plus loin possible de la source de courant. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01... -
Page 24: Étiquette De Sécurité
6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 Hypertherm Systèmes plasma 2/12/01... -
Page 25: Specifications
Section 2 SPECIFICATIONS In this section: General ..................................2-2 Product Specifications ..............................2-2 MAX200 Power Supplies ..........................2-2 MAX200 CE Power Supplies ...........................2-3 MAX200 Machine Torch ...........................2-4 MAX200 Instruction Manual... -
Page 26: General
For better cut quality on metals such as stainless steel, aluminum, and other non-ferrous materials, either nitrogen or argon/hydrogen (Hypertherm recommends a mixture of 35% hydrogen and 65% argon) can be used as the plasma gas. When cutting mild steel, oxygen can also be used as the plasma gas. Shield gases other than air which can be used are nitrogen and carbon dioxide. -
Page 27: Max200 Ce Power Supplies
Depth..............41-1/4" (104 cm) w/o handle 50" (127 cm) w/handle Weight ..............780 pounds Cooling..............Forced Air (Class F) ** MAX200 Power Supply – Machine Torch w/o THC Configuration ** MAX200 Power Supply – Machine Torch w/THC Configuration Gas Requirements: Gas Type/Quality..........Air (compressed)/clean, dry, oil-free Oxygen (liquid)/99.5%... -
Page 28: Max200 Machine Torch
SPECIFICATIONS MAX200 Machine Torch The MAX200 machine torch conforms to the following specifications: Maximum cutting thickness ........2 inches Maximum current at 100% duty cycle ....200 amps Plasma Gas Flow ..........66 scfh (Air), 60 scfh (N ), 70 scfh (H35), 72 scfh (O Shield Gas Flow ...........220 scfh (CO... -
Page 29: Setup
Work Table ..............................3-16 Work Clamp ..............................3-16 Machine Torch System Installations .......................3-19 Install the MAX200 without THC Option......................3-19 Install the MAX200 with THC Option......................3-23 Install the MAX200 with IHS Option .......................3-31 Adjust the Torch Position..........................3-40 Install the Water Muffler Option........................3-41 MAX200 Instruction Manual... -
Page 30: Upon Receipt
SETUP Upon Receipt The MAX200 power supply is shipped mounted to a skid and protected by a heavy carton cover. Before unpacking the unit, inspect the carton for evidence of damage during shipment. 1. Remove all packing material and discard and remove the power supply from the shipping skid. -
Page 31: Claims And Technical Questions
Claims for damage during 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. Claims for defective merchandise – All units shipped from Hypertherm undergo rigorous quality control testing. -
Page 32: Air And Gas Supply Requirements
Air Supply Two different sources of air can be used to supply the plasma and shield gas requirements of the MAX200: cylinder compressed air or shop compressed air. Use an inert gas hose to connect the air supply to the input connection on the filter/pressure regulator mounted on the rear of the power supply. -
Page 33: Adjusting The Filter/Pressure Regulator
Plasma Gas To use liquid nitrogen, liquid oxygen, or argon/hydrogen as the plasma gas, it must be supplied to the MAX200 at these purities: nitrogen, 99.995% and oxygen, 99.5%. The gas supply source can be compressed gas cylinders or liquid containers. -
Page 34: Torch Coolant Requirements
8.5 ppm. If using a conductivity meter to measure water purity, the recommended level is between .5 and 18 µSiemens/cm at 77° F (25° C). 32 °F (0 °C) 10 °F (-12 °C) (mixture resists freezing to this temperature) Propylene Glycol (%) MAX200 Instruction Manual... -
Page 35: Filling The System
1. Ensure the torch lead is connected. Refer to Connect the Torch Lead in this section. Note: Always add coolant with the MAX200 system off. 2. Fill the tank with coolant until the level reaches the bottom of the neck, approximately 2.9 gallons (11liters). -
Page 36: Power Requirements
SETUP Power Requirements A separate line disconnect switch should be provided for each MAX200 power supply. The disconnect box should be sized to the following requirements: Rated Input Input Current @ Recommended Voltage Phase 30 kw Output Fuse Size 200 VAC... -
Page 37: 240/480V Linkboard Configurations
The links must be moved for 240-volt operation. Ensure that the linkboard is configured properly to the appropriate voltage line (see Figure 3-1). WARNING Danger: High Voltage. Line voltage may be present on this linkboard. Disconnect input power before servicing. 240-Volt Configuration 480-Volt Configuration Figure 3-1 Dual Voltage 240/480-Volt Linkboard Configurations MAX200 Instruction Manual... -
Page 38: 220/380/400/415V Transformer T1 And T2 Configurations
Danger: High Voltage. Line voltage is present in the power supply unless disconnected. Always disconnect input power at the line disconnect switch before servicing. * A long # 6 wire is shipped with every unit. Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations (1 of 2) 3-10 MAX200 Instruction Manual... - Page 39 SETUP Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations (2 of 2) MAX200 Instruction Manual 3-11...
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Page 40: Power, Gas, And Torch Lead Connections
To connect the power cable to the MAX200, proceed as follows (see Figure 3-3): 1. Insert the power cable through the strain relief at the rear of the MAX200. Connect the power cable leads to TB1 located at the rear center panel of the right side. -
Page 41: Connect The Air And Gas Hoses
Plasma (Air) and Shield (Air) Hoses MAX200 systems are normally shipped from the factory configured, so that air is supplied to both the PLASMA and SHIELD GAS inlets from a single filter/pressure regulator. The filter is used to maintain a high air purity level. - Page 42 3. Connect the shop-supplied or cylinder-supplied air hose to the input of the filter pressure regulator. Air Supply Hose Plasma Gas Shield Filter/Pressure Supply Hose Air Hose Regulator Figure 3-5 Plasma Gas and Shield Air Connections 3-14 MAX200 Instruction Manual...
- Page 43 SETUP Plasma (Gas) and Shield (Gas) Hoses When gases other than air are used, connect the liquid or compressed bottled gases to the MAX200 as follows (see Figure 3-6): 1. Connect the plasma gas supply hose to the PLASMA gas inlet.
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Page 44: Connect The Torch Lead
(ccw) direction. 5. Connect the cap sensor hose (gray) to the adapter. Connect the Work Cable To connect the work cable to the MAX200, connect the work cable (black) to the bulkhead adapter. (See Figure 3-7.) Grounding To ensure proper operation, personal safety, and to reduce emission of radio frequency interference, the properly... - Page 45 SETUP Figure 3-7 Machine Torch Lead Connections to MAX200 MAX200 Instruction Manual 3-17...
- Page 46 SETUP Figure 3-8 Proper Work Clamp Connection 3-18 MAX200 Instruction Manual...
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Page 47: Machine Torch System Installations
Refer to the following procedures in order to install a machine torch system. Install the MAX200 without THC Option Installing the MAX200 without the THC option requires the user to connect the MAX200 to the cutting machine and to connect the Remote Switch. See Figure 3-9 to make interconnections. - Page 48 SETUP Remote Switch Assembly Machine Interface Cable (Fig. 3-10) Figure 3-9 Machine Torch System Interconnection Diagram without THC Option 3-20 MAX200 Instruction Manual...
- Page 49 023335 50 ft. (15.2 m) 023336 75 ft. (23 m) 023337 100 ft. (30.5 m) 023338 150 ft. (46 m) 023339 200 ft. (61 m) Figure 3-10 MAX200 to Machine Interface Cable Diagram (1 of 2) MAX200 Instruction Manual 3-21...
- Page 50 SHIELD PLASMA STOP-SIG PLASMA STOP-SIG SHIELD * Signals are AC relays. DC relays are available as an option from Hypertherm by ordering kit # 128404. Figure 3-10 MAX200 to Machine Interface Cable Diagram (2 von 2) 3-22 MAX200 Instruction Manual...
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Page 51: Install The Max200 With Thc Option
Connect the interface cable from either the Switch Remote (SR), Digital Remote (DR), or Programmable Remote (PR) receptacle at the rear to the REMOTE V/C - 1X4 receptacle at the rear of MAX200. See Figures 3-12 through 3-14 for cable layouts, cable part numbers and lengths, socket pin configurations, and wire colors and signal names. - Page 52 Cable (Fig. 3-13) PR to Computer Interface Cable (used with PR Remote V/C Option only) (Fig. 3-14) Serial Remote (SR) Digital Remote (DR) Programmable Remote (PR) (shown) Figure 3-11 Machine Torch System Interconnection Diagram with THC Option 3-24 MAX200 Instruction Manual...
- Page 53 25 ft. (7.6 m) 023328 50 ft. (15.2 m) 023329 75 ft. (23 m) 023330 100 ft. (30.5 m) 023331 150 ft. (46 m) 023332 200 ft. (61 m) Figure 3-12 MAX200 to Switch Remote Interface Cable Diagram MAX200 Instruction Manual 3-25...
- Page 54 125 ft (38.1 m) 023350 150 ft (46 m) 023351 200 ft (61 m) 023813 250 ft (76 m) 023577 275 ft (83.6 m) 023818 300 ft (91.5 m) Figure 3-13 MAX200/Digital Remote and Programmable Remote Interface Cable MAX200 Instruction Manual 3-27...
- Page 55 Blk on Wht Spare (Remote Chassis) Shield Wire Shield (Remot Chassis Part No. Length 023098 10 ft (3 m) 023099 25 ft (7.6 m) 023100 50 ft (15.2 m) Figure 3-14 Programmable Remote to Computer Interface Cable Diagram MAX200 Instruction Manual 3-29...
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Page 56: Install The Max200 With Ihs Option
Mount the IHS Control Module on to the cutting machine frame. It must be located within 40 feet of the torch. After mounting the IHS Control Module, the unit is ready to be connected to the MAX200 and the shop air supply. - Page 57 2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now around the plastic torch sleeve. Tighten the bracket. 3. The final torch position adjustment is described on page 3-40. 3-32 MAX200 Instruction Manual...
- Page 58 Shop Air supplied) Remote V/C Option SR-073001 * Cable used depends on Remote V/C option selected DR-073007 ** PR is shown PR-055004** *** Used only with PR Figure 3-15 Machine Torch System Interconnection Diagram with IHS Option MAX200 Instruction Manual 3-33...
- Page 59 25 ft (7.6 m) 023112 50 ft (15 m) 023155 75 ft (23 m) 023113 100 ft (30.5 m) 023114 150 ft (46 m) 023284 200 ft (61 m) Figure 3-16 MAX200 to IHS Interface Cable MAX200 Instruction Manual 3-35...
- Page 60 004085 Nut, Insulating 008145 RECP, 3 Pin Male LEGEND – INDUCTIVE SENSOR END Part No. SOCKET COLOR FUNCTION 005074 Power (+15 VDC) Common Signal Inductive Probe Assembly Figure 3-17 IHS Control Module to Inductive Probe Assembly Interface Cables 3-36 MAX200 Instruction Manual...
- Page 61 4. Route the cable in through the strain relief in order to connect the cable wires to 1TB. 5. Connect the shield drain wire (uninsulated) to 1TB-10 (#S). Be sure the drain wire does not contact the IHS Control Module case. Note that the cable shield is now electrically connected to the MAX200 frame. MAX200 Instruction Manual...
- Page 62 To connect MAX200 machines with the IHS option together with hold interconnecting cables: 1. Pass the hold interconnection cable through the feed-through at the rear of the MAX200. See Figure 3-18 for the cable layout, cable part numbers and lengths, socket pin configurations and wire colors and signal names.
- Page 63 X FT, 047125, Belden #9320–20 AWG, 1 Pair Overall Shielded, CSA Certified Shield Shield Qty 6, 074027 Terminal–Insulated Locking Fork, 22–18 AWG #6: T&B RA2217 LEGEND – MAX200 END LEGEND – OTHER MAX200 END WIRE # COLOR FUNCTION WIRE # COLOR FUNCTION...
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Page 64: Adjust The Torch Position
To adjust the torch, perform the following procedure. WARNING Disconnect all power to the MAX200 before adjusting the torch. Failure to do so could result in eye or bodily injury due to accidental firing or movement of the torch. -
Page 65: Install The Water Muffler Option
The Water Muffler option can be used with the 1.75 inch (44.5 mm) diameter torch bodies only. The 2 inch (51 mm) diameter torch body can not support the Water Muffler option. To install the Water Muffler option, refer to the MAX200 Water Muffler Instruction Manual IM-205 (P/N 802050). MAX200 Instruction Manual... -
Page 66: Operation
Status ................................4-2 Status Indicators Before Startup ........................4-2 Gas...................................4-3 Pre-operation ................................4-4 Operation ..................................4-4 Operating Tips ................................4-5 Changing Consumable Parts ...........................4-5 Cutting Techniques............................4-7 Torch Alignment............................4-7 Cutting................................4-8 Piercing ................................4-8 Common Cutting Faults ..........................4-9 Duty Cycle..............................4-9 Claims and Technical Questions..........................4-9 Cut Charts................................4-10 MAX200 Instruction Manual... -
Page 67: Front Panel Controls
Other fault conditions may also be indicated when the line power is switched on. Correct any other fault conditions before pressing the the POWER ON (I) button. See Troubleshooting in Section 3 of MAX200 Service Manual, IM-162 (801620). MAX200 Instruction Manual... -
Page 68: Gas
SHIELD Machine System without THC POWER STATUS -INTERLOCK DC ON MACHINE DELAY -TRANSFORMER TEST -COOLANT LEVEL -SHIELD GAS/CAP -PLASMA GAS -COOLANT TEMP 6 SEC -COOLANT FLOW PLASMA SHIELD Machine System with THC Figure 4-1 Front Panel Controls MAX200 Instruction Manual... -
Page 69: Pre-Operation
4-5.) 4. Attach the MAX200 work clamp to the workpiece. Do not attach work clamp to the section of the workpiece that will drop off. Make sure that there is good metal-to-metal contact between the work clamp and the workpiece. -
Page 70: Operating Tips
3. Check the shield 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. MAX200 Instruction Manual... - Page 71 12. Install nozzle until finger-tight, then tighten with wrench. Do not overtighten. 13. Replace the retaining cap. Make sure that it is tightened snugly; if it is loose, it can affect the shield gas flow. MAX200 Instruction Manual...
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Page 72: Cutting Techniques
Prior to cutting with a machine torch, ensure that the torch is at right angles to the workpiece to get a clean, vertical cut. Use a square to align the torch. The torch should be aligned at 90° increments (0°, 90°, 180°, and 270°). See Figure 4-2. Figure 4-2 Torch Alignment MAX200 Instruction Manual... -
Page 73: Cutting
Piercing Note: The MAX200 can pierce metals up to a thickness of one (1) inch. • Set the torch-to-work distance (standoff) so that the shield cap is 1/8 inch or more away from the workpiece. (Refer to the Adjust the Torch Position procedure, page 3-40.) •... -
Page 74: Common Cutting Faults
Claims for damage during 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. Claims for defective merchandise — All units shipped from Hypertherm undergo rigorous quality control testing. -
Page 75: Cut Charts
OPERATION Cut Charts The following Cut Charts provide the necessary information in order for the operator using the MAX200 machine torch system to be successful in plasma arc cutting. The Cut Charts are divided into two areas: (1) above water cutting (pages 4-11 through 4-33) and (2) under water cutting, where the water table water is 3"... - Page 76 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1 inch (25 mm) not recommended. MAX200 Instruction Manual 4-11...
- Page 77 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 4-12 MAX200 Instruction Manual...
- Page 78 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1/8 inch (3 mm) not recommended. MAX200 Instruction Manual 4-13...
- Page 79 If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. Production cutting above 1 inch (25 mm) not recommended. 4-14 MAX200 Instruction Manual...
- Page 80 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-15...
- Page 81 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1 inch (25 mm) not recommended. 4-16 MAX200 Instruction Manual...
- Page 82 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. MAX200 Instruction Manual 4-17...
- Page 83 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 4-18 MAX200 Instruction Manual...
- Page 84 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-19...
- Page 85 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 4-20 MAX200 Instruction Manual...
- Page 86 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. MAX200 Instruction Manual 4-21...
- Page 87 H35 Plasma / N Shield This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives maximum thickness cutting capability, minimum dross levels, minimum amount of surface contamination, excellent weldability and excellent cut quality on thicknesses greater than 1/2". On thicknesses less than 1/2", excessive dross levels may be experienced.
- Page 88 Note: Maximum piercing thickness 3/8-inch (10 mm) and IHS recommended. If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-23...
- Page 89 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 4-24 MAX200 Instruction Manual...
- Page 90 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-25...
- Page 91 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1/8 inch (3 mm) not recommended. 4-26 MAX200 Instruction Manual...
- Page 92 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. MAX200 Instruction Manual 4-27...
- Page 93 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 4-28 MAX200 Instruction Manual...
- Page 94 H35 Plasma / N Shield This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives maximum thickness cutting capability, excellent cut quality and excellent weldability. Electrode life is extended when this combination is used.
- Page 95 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 4-30 MAX200 Instruction Manual...
- Page 96 Gas Inlet Gas Inlet TEST Pressure Pressure Pressure (bar) (bar) (bar) (bar) (bar) 3.4-3.5 3.4-3.6 If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. MAX200 Instruction Manual 4-31...
- Page 97 OPERATION Stainless Steel – Gouging • 200 amps H35 Plasma / N Shield Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. 020615 020607 220021 020485 020423 Nozzle Swirl ring Electrode Shield Retaining cap English...
- Page 98 OPERATION Aluminum – Gouging • 200 amps H35 Plasma / N Shield Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. 020615 020607 220021 020485 020423 Nozzle Swirl ring Electrode Shield Retaining cap English Plasma Gas Pressure...
- Page 99 Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 4-34 MAX200 Instruction Manual...
- Page 100 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-35...
- Page 101 Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 4-36 MAX200 Instruction Manual...
- Page 102 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-37...
- Page 103 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 4-38 MAX200 Instruction Manual...
- Page 104 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-39...
- Page 105 Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 4-40 MAX200 Instruction Manual...
- Page 106 Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. MAX200 Instruction Manual 4-41...
- Page 107 Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 4-42 MAX200 Instruction Manual...
- Page 108 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. MAX200 Instruction Manual 4-43...
- Page 109 Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 4-44 MAX200 Instruction Manual...
- Page 110 Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. MAX200 Instruction Manual 4-45...
- Page 111 Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1 inch (25 mm) not recommended. 4-46 MAX200 Instruction Manual...
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Page 112: Maintenance
Section 5 MAINTENANCE In this section: Routine Maintenance ..............................5-2 Troubleshooting ................................5-2 Removal and Replacement of Torch.........................5-6 Removal and Replacement of Torch Lead........................5-7 Removal and Replacement of Individual Torch Leads....................5-7 MAX200 Instruction Manual... -
Page 113: Routine Maintenance
Troubleshooting Becoming familiar with the contents of this manual will aid in safely troubleshooting the MAX200 power supply and torch should the need arise. The following procedures will show the user how to locate the most common problems. - Page 114 Refer to Section 4, Operation, Front Panel Controls for interlock indicator descriptions and Status Indicators Before Startup. Cause: Fuse F1 on the power distribution board PCB6 is blown. Solution: Replace fuse F1. Cause: Relay CR1 on the power distribution board PCB6 is defective. Solution: Replace relay CR1. MAX200 Instruction Manual...
- Page 115 If a spark is not observed across the gaps, remove capacitors C7 and C8. If a faint spark is now observed across the gaps, replace T5 and reconnect the capacitors. If a spark is not observed replace C7 and C8. (Always replace the capacitors in pairs). MAX200 Instruction Manual...
- Page 116 The work clamp is not connected or it is broken. Solution: Connect or repair the work clamp. Cause: The torch is cracked. Solution: Replace the torch. Cause: The pilot arc relay CR1 is defective. Check for contacts that are welded shut Solution: Replace relay CR1. MAX200 Instruction Manual...
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Page 117: Removal And Replacement Of Torch
2. Ensure the lead insulator is positioned over the pilot/shield gas lead fitting. 3. Slide the insulating sleeve to the torch main body and screw together. INSULATING SLEEVE TORCH MAIN BODY TORCH LEAD LEAD INSULATOR Figure 5-1 Machine Torch Assembly MAX200 Instruction Manual... -
Page 118: Removal And Replacement Of Torch Lead
6. Holding one end of the the torch lead, pull the shield braid (8) off of the torch lead. 7. Cut the tape (every 18 inches) that holds the torch leads together. 8 Remove the lead (1-5) requiring repair or replacement. MAX200 Instruction Manual... - Page 119 8. Connect the torch lead to the power supply. Refer to the Connect the Torch Lead procedure on page 3-16. 9. Connect the torch lead to the torch. Refer to theTorch Replacement procedure on page 5-6. Figure 5-2 Machine Torch Lead Assembly MAX200 Instruction Manual...
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Page 120: Parts List
PARTS LIST In this section: MAX200 Power Supply .............................6-2 Illustrations/Parts Lists .............................6-2 Recommended Spare Parts...........................6-16 MAX200 Consumables,Torch Assembly and Torch Leads ..................6-18 MAX200 Machine Torch Consumables ......................6-18 Consumable Configurations ...........................6-19 Consumable Parts Kits ............................6-20 MAX200 Machine Torch Assembly .......................6-21 Machine Torch Lead Assemblies ........................6-24... - Page 121 PARTS LIST MACHINE DELAY AMPS 6 SEC Figure 6-1 Power Supply – Control Panel SA, Front MAX200 Instruction Manual...
- Page 122 Thumbwheel 15** 009604 Resistor, variable, 100 K, 1 turn * Power Supplies with THC – 073020, 073021, 073022, 073023, 073024 and 073213 (CE) ** Power Supplies without THC – 073002, 073003, 073004, 073005, 073026 and 073200 (CE) MAX200 Instruction Manual...
- Page 123 PARTS LIST Figure 6-2 Power Supply – Front View MAX200 Instruction Manual...
- Page 124 * Power Supplies with THC – 073020, 073021, 073022, 073023, 073024 and 073213 (CE) ** Power Supplies without THC – 073002, 073003, 073004, 073005, 073026 and 073200 (CE) *** Items not shown in Figure 6-2. Refer to MAX200 Service Manual IM-162 (801620), Section 3, Routine Maintenance to check and replace filter.
- Page 125 PARTS LIST Figure 6-3 Power Supply – Right Side, Front View MAX200 Instruction Manual...
- Page 126 ◊ Connector to thermostat is shown. Thermostat is in transformer. * Power Supplies with THC – 073020, 073021, 073022, 073023, 073024 and 073213 (CE) ** Power Supplies without THC – 073002, 073003, 073004, 073005, 073026 and 073200 (CE) MAX200 Instruction Manual...
- Page 127 PARTS LIST Figure 6-4 Power Supply – Right Side, Rear View MAX200 Instruction Manual...
- Page 128 PCB, power distribution PCB6 008322 Fuse, Amp., 250 VAC * Power Supplies with THC – 073020, 073021, 073022, 073023, 073024 and 073213 (CE) ** Power Supplies without THC – 073002, 073003, 073004, 073005, 073026 and 073200 (CE) MAX200 Instruction Manual...
- Page 129 PARTS LIST Figure 6-5 Power Supply – Left Side, Front View 6-10 MAX200 Instruction Manual...
- Page 130 Fuse, semiconductor, 125 Amp, 250 V 128236 Phase loss detection upgrade kit * Power Supplies with THC – 073020, 073021, 073022, 073023, 073024 and 073213 (CE) ** Power Supplies without THC – 073002, 073003, 073004, 073005, 073026 and 073200 (CE) MAX200 Instruction Manual 6-11...
- Page 131 PARTS LIST Figure 6-6 Power Supply – Left Side, Rear View 6-12 MAX200 Instruction Manual...
- Page 132 Assembly, coil, high frequency 041145 PCB, input/output PCB5 029202 Sensor, current * Power Supplies with THC – 073020, 073021, 073022, 073023, 073024 and 073213 (CE) ** Power Supplies without THC – 073002, 073003, 073004, 073005, 073026 and 073200 (CE) MAX200 Instruction Manual 6-13...
- Page 133 PARTS LIST Figure 6-7 Power Supply – Rear View 6-14 MAX200 Instruction Manual...
- Page 134 Filter, Element 011025 Filter Regulator 011027 Gauge, High Press (for 011025) 002304 Reservoir, coolant 022036 Gauge, liquid level 129618 Level Switch Subassembly, 1/2 NPT 029323 Temp Switch Subassembly, 162 Deg F 006099 Bib drain valve 1/4 NPT MAX200 Instruction Manual 6-15...
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Page 135: Recommended Spare Parts
Coolant Pump SA 029323 Switch, water temperature, 162°F 029326 Switch, level 029361 Switch, flow, 0.5 gpm 028872 Coolant, propylene glycol 30%/ deionized water 70% (standard mixture) 028873 Coolant, propylene glycol 100% * Power Supplies with THC 6-16 MAX200 Instruction Manual... -
Page 136: Recommended Spare Parts
028384 Shielded torch lead, 50 ft. 028773 Shielded torch lead, 60 ft. 028599 Shielded torch lead, 75 ft. 028781 Shielded torch lead, 100 ft. 028782 Shielded torch lead, 125 ft. 028783 Shielded torch lead, 150 ft. MAX200 Instruction Manual 6-17... -
Page 137: Max200 Consumables,Torch Assembly And Torch Leads
PARTS LIST MAX200 Consumables, Torch Assembly and Torch Leads MAX200 Machine Torch Consumables (see figure 6-8) Part Numbers Plasma Gas/ Nozzle Type Retaining Shield Gas (Amps) Shield Nozzle Swirl Ring Electrode Air/Air 020424 120837 020608 020607 220021 020448 120837 020611... -
Page 138: Consumable Configurations
020415 020424 120547 020448 020608 020607 020611 020613 020423 020612 020514 Gouging 220021 020415 020615 020607 020485 020423 120547 020613 Beveling 120258 120259 120833 120260 020423 Water Tube 120257 Figure 6-8 MAX200 Machine Torch Consumable Parts MAX200 Instruction Manual 6-19... -
Page 139: Consumable Parts Kits
Swirl Ring, Air/ Nitrogen 020608 Nozzle, Shield 200A, .086 020604 Swirl Ring, Oxygen 020611 Nozzle, Shield 100A, .059 020613 Swirl Ring, 40A 020688 Shield, MAX200/HT2000 40A 020689 Nozzle, MAX200/HT2000 40A 027055 Lubricant, Silicon, 1/4 Oz. Tube 027194 Wrench, Nozzle, 3/4" 044027 O-Ring 027347... -
Page 140: Max200 Machine Torch Assembly
MAX200 Machine Torch Main Body 020536 Lead insulator 9/16 X 2.5 Tef 044027 O-ring, Buna-N The following consumables are part of the MAX200 Machine Torch Assembly. See Figure 6-8 for details. 020424 Shield, MAX200 Mch 200A 120837 Cap, Nozzle Retaining, MAX200 020608 Nozzle MAX200 200A .086 Air/N2/H35... - Page 141 PARTS LIST MAX200 Machine Torch Assembly with 2" Stainless Steel Torch Body and 2" diameter Sleeve (Optional) Part Item Number Description Qty. 128365 MAX200 Machine Torch Assembly 020041 Sleeve, Insul, MAX200 Mach, 2.0" diameter 120356 MAX200 Machine Torch Main Body 020536 Lead insulator 9/16 X 2.5 Tef...
- Page 142 PARTS LIST MAX200 Machine Torch Assembly with 1.75" diameter Torch Body and 1.75" diameter Sleeve (Optional) Part Item Number Description Qty. 128364 MAX200 Machine Torch Assembly 020431 Sleeve, Insul, MAX200 Mach, 1.75" diameter 120584 MAX200 Machine Torch Main Body 020536 Lead insulator 9/16 X 2.5 Tef...
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Page 143: Machine Torch Lead Assemblies
Cable, Water Cooled, 20 Ft. (blue- green band) 020536 Lead Insulator, 9/16" ID x 2-1/2" 046026 Tubing, 1-1/2" ID Shrink Black 046061 2" ID Tinned Braid 027015 Ring Compress, Shield Torch Lead 004080 Collar, Shield Torch Leads 015090 Clamp, Hose, 1-5/16 - 2-1/4 6-24 MAX200 Instruction Manual... - Page 144 Cable, Water Cooled, 35 Ft. (blue- green band) 020536 Lead Insulator, 9/16" ID x 2-1/2" 046026 Tubing, 1-1/2" ID Shrink Black 046061 2" ID Tinned Braid 027015 Ring Compress, Shield Torch Lead 004080 Collar, Shield Torch Leads 015090 Clamp, Hose, 1-5/16 - 2-1/4 MAX200 Instruction Manual 6-25...
- Page 145 Cable, Water Cooled, 50 Ft. (blue- green band) 020536 Lead Insulator, 9/16" ID x 2-1/2" 046026 Tubing, 1-1/2" ID Shrink Black 046061 2" ID Tinned Braid 027015 Ring Compress, Shield Torch Lead 004080 Collar, Shield Torch Leads 015090 Clamp, Hose, 1-5/16 - 2-1/4 6-26 MAX200 Instruction Manual...
- Page 146 Collar, Shield Torch Leads 015090 Clamp, Hose, 1-5/16 - 2-1/4 Note: Hypertherm does not recommend using torch leads longer than 75 Feet. 100 Ft, 125 Ft. and 150 Ft. leads will cause problems with starting. 028781 Shield Torch Lead, 100 Ft.
- Page 147 PARTS LIST Machine Torch Lead Assemblies (continued) Note: Hypertherm does not recommend using torch leads longer than 75 Feet. 100 Ft, 125 Ft. and 150 Ft. leads will cause problems with starting. Part Item Number Description Qty. 028782 Shield Torch Lead, 125 Ft.
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Page 148: Wiring Diagrams
WIRING DIAGRAMS Introduction This section contains the wiring diagrams for the MAX200 system. When tracing a signal path or referencing with the Parts List or Troubleshooting sections, please be aware of the following format to assist you in understanding the wiring diagrams' organization: •... - Page 149 Push Button, Battery Fuse Normally Open Receptacle Ground Clamp Cap, polarized Relay, Coil Ground, Chassis Cap, non-polarized Relay, Normally Closed Ground, Earth Cap, feed-thru Relay, Normally Open IGBT Circuit breaker Relay, Solid State, AC Inductor Coax shield Relay, Solid State, DC Current Sensor Relay, Solid State, Dry Light...
- Page 150 Time Delay Closed, Switch, Level, Torch Symbols NO/Off Normally Closed Switch, Pressure, Transformer Normally Closed Electrode Switch, Pressure, Transformer, Air Core Normally Open Switch, 1 Pole, 1 Throw Nozzle Transformer Coil Switch, 1 Pole, 2 Throw Triac Switch, 1 Pole, 1 Throw, Shield Center Off VAC Source...
- Page 151 W/THC 073020 240-480/60 073021 600/60 073022 208/60 073023 380-415/50 Unit 15 073024 200/50 Remote Current Control 073193 15X1 Hold Cable 2nd MAX200 System 023340 (Optional control w/Machine I/O Cable) DRAWN BY DATE MATERIAL 5-9-96 CHECKED BY DATE APP. BY DATE...
- Page 152 APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL ±.005 ITEM NO.
- Page 153 APP. BY DATE 2-B2 Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL ±.005 ITEM NO.
- Page 154 DATE APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED ITEM NO. DRAWING NO. FILE NAME 3 PL DECIMAL ±.005...
- Page 155 APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL ±.005 ITEM NO.
- Page 156 DATE APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED ITEM NO. DRAWING NO. FILE NAME 3 PL DECIMAL ±.005...
- Page 157 APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL ±.005 ITEM NO.
- Page 158 APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. ELEC/GAS SCHEM: MAX200 TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL ±.005 ITEM NO.
- Page 159 PLASMA 26psi SHIELD SHIELD 4psi PLASMA CON1 TORCH 70psi NOZZLE GAS FLOW DIAGRAM MAX200 TIMING CHART CON1 MAIN CONTACTOR PLASMA PRE/POST FLOW SOLENOID VALVE SHIELD GAS SOLENOID START XFER STOP POST PLASMA STEP GAS SOLENOID VALVE FLOW CAP-ON-SENSE SOLENOID VALVE...
- Page 160 10-10-91 APP. BY DATE Box-5010 Hanover, NH 03755-5010 603/643-3441 UNLESS OTHERWISE SPECIFIED: DESCRIPTION DIMENSIONS ARE IN INCHES. RSVR SA:MAX200/HT2000 PWR SPLY TOLERANCES ARE: THIS DRAWING AND ALL INFORMATION 2 PL DECIMAL ±.01 ITEM NO. DRAWING NO. FILE NAME CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL ±.005...
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Page 161: Filters
Appendix A FILTERS In this section: Hankison® Centriflex® Filters...........................a-2 Hankison® Aerolescer® Filters..........................a-4 Hankison® Hypersorb® Filters ..........................a-6 Wilkerson Type PC6 Filter/regulator .........................a-8 MAX200 Instruction Manual... -
Page 170: Propylene Glycol Safety Data
Appendix B PROPYLENE GLYCOL SAFETY DATA BENZOTRIAZOLE SAFETY DATA In this appendix: Propylene Glycol Safety Data Section 1 Chemical Product and Company Identification ..........b-2 Section 2 Information on Ingredients ................b-2 Section 3 Hazards Identification..................b-2 Section 4 First Aid Measures ..................b-3 Section 5 Fire Fighting Measures ................... - Page 175 % of Propylene Glycol Figure b-1 Freezing Point of Propylene Glycol Solution...
- Page 179 b-10...
- Page 180 Appendix C AERATION MANIFOLD In this section: Aeration Manifold for Plasma Cutting Aluminum.......................c-2 Introduction...............................c-2 Making an Aeration Manifold - Figure c-1......................c-2 MAX200 Instruction Manual...
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Page 181: Appendix Caeration Manifold
Connect the manifold to a shop air line. Set a pressure regulator to obtain a steady stream of bubbles. Aeration Manifold Distribution Lines Regulated air in Figure c-1 Aeration Manifold MAX200 Instruction Manual... - Page 182 Appendix D ELECTROMAGNETIC COMPABILITY (EMC) In this section: EMC Introduction ..............................d-2 General ..................................d-3 Power Cable ................................d-3 Connect Power Cable ...............................d-3 Power Supply ..............................d-3 Line Disconnect Switch ............................d-5 EMI Filter Parts List ..............................d-6 MAX200 Instruction Manual...
- Page 183 Safety critical equipment, for example as possible and should be positioned guarding of industrial equipment. close together, running at or close to the e. Health of the people around, for floor level. example the use of pacemakers and hearing aids. MAX200 Instruction Manual...
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Page 184: General
Connect one end of the power cable to the EMI filter first and then connect the other end to the line disconnect switch. Power Supply 1. Locate the EMI filter on the top rear of the power supply (see Figure d-1). Strain Relief EMI Filter Figure d-1 MAX200 Power Supply with EMI Filter – Side View MAX200 Instruction Manual... - Page 185 Filter Figure d-2 MAX200 Power Supply with EMI Filter Cover Off – Top View 3. Insert the power cable through the strain relief (see Figure d-1). 4. Connect leads L1 to U, L2 to V, and L3 to W terminals of TB1 (see Figure d-3). Ensure that all connections are tight to avoid excessive heating.
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Page 186: Line Disconnect Switch
ON. This indicator is a warning that there is line voltage at the filter even if the ON (1) pushbutton on the MAX200 power supply has not been pressed. As a common safety practice, ALWAYS verify that the line disconnect switch is in the OFF position before installing, disconnecting or servicing in this area. -
Page 187: Emi Filter Parts List
Bushing: 1.97 ID X 2.5 Hole Black-Snap 008610 Strain Relief: 1-1/2NPT 1.5ID 2-Screw 029316 TB1 Input-Power SA: 200/2000/4X00/HD 109036 Filter: 60A 440VAC 3PH 2-Stage Electronic 109040 Filter Mounting Bracket for 109036 Figure d-4 MAX200 EMI Filter Parts MAX200 Instruction Manual...
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