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Summary of Contents for Hypertherm powermax1100
- Page 1 ® Plasma Arc Cutting System Operator Manual 802730 Revision 1 EN50199 EN50192...
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Page 2: Operator Manual
July, 1999 Hypertherm, Inc. Hanover, NH http://www.hypertherm.com email:info@hypertherm.com © Copyright 1999 Hypertherm, Inc. All Rights Reserved Hypertherm, HyDefinition, HT, HyLife, LongLife, MAX, PAC and Powermax are trademarks of Hypertherm, Inc., and may be registered in the United States and/or other countries... - Page 3 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)
- Page 4 LECTROMAGNETIC OMPATIBILITY EMC INTRODUCTION e. Health of the people around, for Cutting Cables example the use of pacemakers and The cutting cables should be kept as The 230/400V CE power supply has been hearing aids. short as possible and should be built in compliance with standard f.
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Page 5: Warranty
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... -
Page 6: Table Of Contents
ABLE OF ONTENTS ELECTROMAGNETIC COMPATIBILITY .................. i WARRANTY ..........................ii SECTION 1 SAFETY ......................1-1 About Notes, Cautions & Warnings ..................1-2 Safety Instructions ........................ 1-2 Eye Protection ........................ 1-2 Skin Protection ........................ 1-2 Toxic Fume Prevention....................1-2 Fire Prevention ........................ 1-2 Electric Shock Prevention .................... - Page 7 ABLE OF ONTENTS SECTION 3 SETUP ......................3-1 Upon Receipt ........................3-2 Claims ..........................3-2 Hoisting Requirements ......................3-3 Voltage Configurations ......................3-4 Power Cords - 208/240/480V, 200/230/400V and 600V Power Supplies ......3-5 Power Cords - 230/400V CE Power Supplies ..............3-6 Changing the Strain Relief Sleeve ..................
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Page 8: Section 1 Safety
Be aware of anything touching the workpiece. The workpiece is part this hazard, which has potential for of the electrical circuit. serious bodily injury. HYPERTHERM Plasma Systems 5-98... -
Page 9: Eye Protection
– Install protective screens or curtains to reduce ultraviolet transmission. Electric Shock Prevention All Hypertherm plasma systems use high Skin Protection voltage (up to 300 VDC) to initiate the plasma • Wear protective clothing to protect against burns arc. Take the following precautions when... -
Page 10: Explosion Prevention
(CSA) or applicable national or local codes. • Examine hoses at regular intervals for leaks, wear, loose connections or other hazard. • Never use a cylinder that leaks or is physically • Replace hose that is damaged in any way. damaged. HYPERTHERM Plasma Systems 5-98... -
Page 11: Grounding
• Coil any excess hose and place it out of the way to the retaining cap is loosened. prevent damage and to eliminate the danger of • Each Hypertherm plasma system is designed to be tripping. used only with specific Hypertherm torches. Do not... -
Page 12: Section 1A Sécurité
Se référer à l’annexe du manuel pour plus de • Ne pas couper de récipients contenant des matières renseignements sur les collecteurs d’aération. combustibles. HYPERTHERM Systèmes plasma 1a-1 10/6/98... - Page 13 • 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.
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Page 14: Mise À La Masse Et À La Terre
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. HYPERTHERM Systèmes plasma 1a-3 4/9/99 10/6/98... - Page 15 • Faire passer le faisceau de la torche le plus près possible du câble de retour. • Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. • Se tenir le plus loin possible de la source de courant. 1a-4 HYPERTHERM Systèmes plasma 10/6/98 10/16/98...
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Page 16: Specifications
PECIFICATIONS Section 2 SPECIFICATIONS In this section: Introduction ...................... 2-2 Specifications ....................2-3 Power Supply ....................2-3 PAC135 80A Torches ..................2-4 PAC135T Hand Torch Assembly..............2-5 PAC135M Machine Torch Assembly ............2-5 S Mark ......................2-5 IEC Symbols Used ................... 2-6 Operator Manual... -
Page 17: Introduction
80 amps, for optimum performance on all thicknesses of metal up to 3/4 inch (20 mm) thick. At 80 amps, the Powermax1100 can cut metals up to 1 inch (25 mm) thick and will sever metals up to 1-1/4 inch (32 mm) thick. -
Page 18: Specifications
PECIFICATIONS SPECIFICATIONS Power Supply Rated Open Circuit Voltage (OCV) (U ) ....280-320 VDC Rated Output Current (I ) ........30–80 amps Rated Output Voltage (U ) ........140 VDC Duty Cycle (X) @ 104° F (40° C) ......50% (I =80A, U =140V) 100% (I... -
Page 19: Pac135 80A Torches
19.6" (498 mm) (498 mm) Figure 2-2 Powermax1100 Power Supply Dimensions PAC135 80A TORCHES Maximum 80A Cutting Capacity (PAC135T) ....1" (25 mm) @ 50% duty cycle Recommended 80A Cutting Capacity (PAC135T) ..3/4" (20 mm) @ 100% duty cycle Maximum 80A Cutting Capacity (PAC135M) ..... -
Page 20: Pac135T Hand Torch Assembly
55° Figure 2-4 PAC135M Torch with Dimensions MARK The Powermax1100 conforms to standard EN50192. The S 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. -
Page 21: Iec Symbols Used
PECIFICATIONS IEC SYMBOLS USED Direct Current (DC) Alternating current (AC) Plasma cutting torch AC input power connection The terminal for the external protective (earth) conductor An inverter-based power source Anode (+) work clamp Temperature switch Pressure switch Plasma torch in the TEST position (cooling and cutting gas exiting nozzle) Power is on Power is off Volt/amp curve, "drooping"... -
Page 22: Setup
ETUP Section 3 SETUP In this section: Upon Receipt ....................3-2 Claims ....................... 3-2 Hoisting Requirements ..................3-3 Voltage Configurations..................3-4 Power Cords - 208/240/480V, 200/230/400V and 600V Power Supplies ..3-5 Power Cords - 230/400V CE Power Supplies ..........3-6 Changing the Strain Relief Sleeve .............. -
Page 23: Upon Receipt
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. If you need additional assistance, call Customer Service at 1 800 643 0030 in the U.S. and Canada, or your authorized Hypertherm distributor. -
Page 24: Hoisting Requirements
In the event that the power supply has to be hoisted, follow the steps below. WARNING The Powermax1100 power supply weighs up to 100 pounds (45 kg) when fully configured with torch, torch leads and wheels. The fully configured 600V power supply weighs nearly 200 pounds (91 kg). -
Page 25: Voltage Configurations
The 208/240/480V Powermax1100 power supplies are shipped to operate at 480 volts. The 200/230/400V and 230/400V CE Powermax1100 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 below. -
Page 26: Power Cords - 208/240/480V, 200/230/400V And 600V Power Supplies
ETUP POWER CORDS - 208/240/480V, 200/230/400V and 600V POWER SUPPLIES The 208/240/480V and 200/230/400V power supplies are shipped without a power cord. Use the tables below to choose the proper wire size for the appropriate length cord. 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. -
Page 27: Power Cords - 230/400V Ce Power Supplies
ETUP POWER CORDS - 230/400V CE POWER SUPPLIES The 230/400V CE power supply is shipped with a power cord. If the three-phase power cord length needs to be changed, use the table below to choose the proper wire size for the appropriate length. Use a 4-conductor "HAR"... -
Page 28: Single-Phase And Three-Phase Power Configurations
ETUP SINGLE-PHASE AND THREE-PHASE POWER CONFIGURATIONS All Powermax1100 power supplies except the 230/400V CE and 600V power supplies can operate from either a single-phase or three-phase input. The 230/400V CE and 600V power supplies operate only from a three-phase input. -
Page 29: Power Cord Plugs
GROUNDING REQUIREMENTS To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the Powermax1100 must be properly grounded through the power cord according to your local or national 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. -
Page 30: Work Cable And Clamp
GAS SUPPLY REQUIREMENTS The gas supply for the Powermax1100 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. -
Page 31: Gas Supply Connection
Figure 3-12 Recommended Three-Stage Air Filtration System Nitrogen Supply Quality Nitrogen must be supplied to the Powermax1100 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. -
Page 32: Torch Lead Connection
ETUP TORCH LEAD CONNECTION To connect the torch lead to the power supply: 1. Align the connector key plug on the torch lead with the connector receptacle key slot on the power supply and push in until the pins seat. The top of the torch connector is marked "TOP". 2. -
Page 33: Machine Interface With Pac135M
ETUP Torch - (typical) 0° 90° Figure 3-14 Aligning the Machine Torch with Square MACHINE INTERFACE WITH PAC135M Signals for arc transfer, start, and arc voltage are available on power supplies that have the machine interface option. WARNING Do not connect the cutting machine interface START signal if using an ON/OFF pendant! •... -
Page 34: Arc Voltage
Figure 3-16 Location of Arc Voltage Cable Strain Relief 4. Route the cable to the machine interface board located on the top of the power supply near the Powermax1100 control board. Connect the arc voltage cable as shown in Fig. 3-17. Tighten the strain relief. -
Page 35: Operation
PERATION Section 4 OPERATION In this section: Controls and Indicators ................... 4-2 Operating Instructions ..................4-3 Pilot Arc Controller (Optional) ..............4-4 PAC135T Safety Trigger Operation ............. 4-5 Operating Tips ....................4-6 Changing Consumable Parts ..............4-6 Cutting ......................4-8 Piercing ..................... -
Page 36: Controls And Indicators
• ON (I)/OFF (0) Power Switch Activates the power supply and its control circuits. LINE ON (I)/OFF (0) Power Switch VOLTAGE TEST TEMP PRESSURE POWER AMPS Pressure Gauge Pressure Regulator Figure 4-1 Powermax1100 Controls and Indicators Operator Manual Operator Manual... -
Page 37: Operating Instructions
GAS TEST POWER ON AMPS PRESSURE GAUGE REGULATOR REGULATOR Figure 4-2 Powermax1100 Operating Indicators and Adjustments 4. Adjust the gas pressure REGULATOR to 65 psi (4.5 bar): • Pull the REGULATOR CAP out • Push the GAS TEST switch in •... -
Page 38: Pilot Arc Controller (Optional)
Failure to do so can result in serious bodily injury. 7. The Powermax1100 is now ready to operate. When you are ready to cut, place the tip of the torch at the edge of the workpiece. Pull back on the trigger switch to start the arc. See PAC135T Safety Trigger Operation later in this section for proper operation of the safety trigger. -
Page 39: Pac135T Safety Trigger Operation
PERATION PAC135T Safety Trigger Operation Safety On position. In this position the trigger cannot be pulled back, so that the torch cannot be accidentally fired. Start pushing the safety forward. Do not pull back on the trigger now; wait until the safety reaches the Safety Off position as shown in step 3. -
Page 40: Operating Tips
PERATION OPERATING TIPS Changing Consumable Parts WARNING 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 to OFF position. Do not rely on the cap-on sensor circuit to remove power. It is provided strictly for safety backup. - Page 41 PERATION Shielded - 80A, 40A Nozzle Machine Shield Retaining Cap 120476 - 80A 120516 120483 - 80A Electrode Swirl Ring PAC135T 120473 120474 Torch Nozzle Hand Shield Retaining Cap 120515 - 40A 120475 120520 - 40A O-Ring 026020 Extended Nozzle Deflector Retaining Cap Electrode...
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Page 42: Cutting
PERATION Cutting • Do not fire the pilot arc into the air needlessly—doing so causes a significant reduction of the nozzle and electrode life. • If arc transfer to the workpiece does not occur within 5 seconds, the pilot arc will shut off. Re- lease the torch trigger and press it again to reset the pilot arc timer. - Page 43 PERATION Figure 4-7 Cutting a Circle Figure 4-8 Dragging the Torch Operator Manual...
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Page 44: Piercing
PERATION Piercing • Hold the torch so that the tip is approximately 1/16 inch (1.6 mm) away from the workpiece before firing the torch. This method maximizes the life of the nozzle. • Hold the torch at an angle to the workpiece away from yourself, pull back on the trigger and slowly rotate the torch to an upright position. -
Page 45: Gouging
The Powermax1100 can be used for gouging mild steel by using the optional gouging nozzle and gouging shield. • Always wear full protection: - A welding helmet with at least a #8 lens shade – Hypertherm recommends using a #10 lens shade when gouging - Welding gloves - A welding jacket The arc is fully exposed and will cause serious burns if the skin is not covered. -
Page 46: Cut Chart - 80A Standard Consumables
PERATION CUT CHART - 80A STANDARD CONSUMABLES The following recommended settings are for mechanized cutting. Torch-to-work distance is 1/16 inch (1.6 mm) for all cuts. Shield Retaining Cap Nozzle Electrode Swirl Ring 120516 120483 - 80A 120476 - 80A 120473 120474 Recommended Material... -
Page 47: Cut Chart - 40A Consumables
PERATION CUT CHART - 40A CONSUMABLES Use 40-amp consumables on thin material to obtain a narrower 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. Shield Retaining Cap Nozzle... -
Page 48: Common Cutting Faults
The duty cycle, or the amount of time the pilot or plasma arc can remain “on” in minutes within a 10- minute period, is affected by many factors. When the current is set at 80 amps, the Powermax1100 has a 50% duty cycle at a temperature of 104°... -
Page 49: Maintenance/Parts
Consumable Parts Kits ................5-9 PAC135T Torch Assembly ................ 5-10 PAC135M Torch Assembly ................5-11 Powermax1100 Field Upgrade Kits and Optional Parts ......5-12 Power Supplies - 208/240/480V ..............5-12 Power Supplies - 200/230/400V ..............5-12 Power Supplies - 230/400V CE ..............5-12... -
Page 50: Introduction
AINTENANCE ARTS 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 in the torch can cause the torch to sputter and hiss. If moisture is present, purge the gas lines. -
Page 51: Removal, Cleaning And Replacement Of The Cooling Air Filter
In other countries, follow appropriate local or national safety procedures. 1. Turn the Powermax1100 power switch to the OFF (0) position, unplug the power cord, or turn off the wall receptacle, and disconnect the gas supply. -
Page 52: Basic Troubleshooting
3.1 Power supply voltage links are incorrect. LINE VOLTAGE LED is illuminated. See voltage configuration settings in Section 3. 3.2 Line voltage is too low. The following table represents the operating range of the Powermax1100 power supplies. Have an electrical technician check incoming power. Operator Manual... - Page 53 AINTENANCE ARTS Cause / Solution Problem Note: When the power supply operates at the Lower Limit, the line voltage LED will illuminate and the power supply will function with some performance degradation. At -20% of the System Line Voltage, the line voltage LED will illuminate but the torch will not function.
- Page 54 AINTENANCE ARTS Cause / Solution Problem 8. The arc does not transfer after 5 seconds. 8.1 The 5-second time-out for the pilot arc has occurred. Press the torch start button again. 8.2 The work clamp is not connected or it is broken.
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Page 55: Technical Questions
If you are unable to fix the problem with your Powermax1100 by following this basic troubleshooting guide or if you need further assistance: 1. Call your distributor. He will be able to help you, or refer you to an authorized Hypertherm repair facility. -
Page 56: Parts
AINTENANCE ARTS PARTS PAC135 Consumable Parts Shielded - 80A, 40A Nozzle Machine Shield Retaining Cap 120476 - 80A 120516 120483 - 80A Electrode Swirl Ring 120473 120474 Nozzle Hand Shield Retaining Cap 120515 - 40A 120475 120520 - 40A Extended Nozzle Deflector Retaining Cap... -
Page 57: Consumable Parts Kits
AINTENANCE ARTS Consumable Parts Kits Hand Consumable Parts Kit (128148) Part Number Description 120473 ....Electrode, PAC135 120517 ....Electrode, PAC135 Extended 120476 ....Nozzle, PAC135, 80A 120509 ....Nozzle, PAC135 Gouging 120518 ....Nozzle, PAC135 Extended 120475 ....Shield, PAC135 Hand 120510 .... -
Page 58: Pac135T Torch Assembly
AINTENANCE ARTS PAC135T Torch Assembly and 25 ft (7.6 m) Lead - 085001 PAC135T Torch Assembly and 50 ft (15.2 m) Lead - 085061 Index No. Part No. Description Qty. 002287 Handle Assembly: PAC135T w/screws 001615 Handle, PAC135T 075497 #6 X 5/8 Pillips Head, Pan Head 002299 Safety Trigger Assembly, PAC135T 005212... -
Page 59: Parts
AINTENANCE ARTS PAC135M Torch Assembly and 14 ft (4.3 m) Lead - 085062 PAC135M Torch Assembly and 25 ft (7.6 m) Lead - 085063 PAC135M Torch Assembly and 35 ft (10.6 m) Lead - 085064 PAC135M Torch Assembly and 50 ft (15.2 m) Lead - 085065 Index No. -
Page 60: Power Supplies - 208/240/480V
POWER SUPPLIES - 230/400V CE, 3φ, 50-60 HZ Part With Pilot Arc With Machine Number Torch Type Control Interface 085003 Hand 085023 Hand 085025 Machine 085024 Machine Note: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations. 5-12 Operator Manual... -
Page 61: Appendix A Standards Index
PPENDIX TANDARDS NDEX STANDARDS INDEX The Standards Index contains a list of publications dealing with plasma arc cutting equipment safety practices. 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. - Page 62 PPENDIX ERATION ANIFOLD 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.
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