Hypertherm powermax 380 Operator's Manual
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Hypertherm powermax 380 Operator's Manual

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Plasma Arc
Cutting System
Operator Manual
803980 Revision 0

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  • Page 1 Plasma Arc Cutting System Operator Manual 803980 Revision 0...

  • Page 2: Operator Manual

    (P/N 803980) Revision 0 – March 2001 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email:info@hypertherm.com © Copyright 2001 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.
  • Page 3 D-63457 Hanau-Wolfgang, Germany 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm Singapore Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 841 2489 Tel...

  • Page 4: Electromagnetic Compatibility (Emc

    The size of the surrounding area to be con- Earthing of Workpiece sidered will depend on the structure of the Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth building and other activities that are taking in compliance with standard EN50199.

  • Page 5: General

    Hypertherm warranty. LIMITATION OF LIABILITY WARNING In no event shall Hypertherm be liable to any person or You are responsible for the safe use of the Product. entity for any incidental, consequential, indirect, or...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Electromagnetic Compatibility (EMC)........................i General ................................ii Patent Indemnity..............................ii Warranty ................................ii Disclaimer of Other Warranties...........................ii National and Local Codes...........................ii Upon Receipt ..............................ii Claims.................................ii Section 1 – Safety ............................1-1 Recognize Safety Information .........................1-2 Follow Safety Instructions ..........................1-2 Cutting Can Cause Fire or Explosion......................1-2 Electric Shock Can Kill ............................1-3 Cutting Can Produce Toxic Fumes........................1-3 A Plasma Arc Can Cause Injury and Burns.....................1-4...
  • Page 7 TABLE OF CONTENTS Section 3 – Installation ..........................3-1 Upon Receipt ..............................3-2 Contents of Box...............................3-2 Locating Power Supply ...........................3-2 115/230 Voltage Configurations ........................3-2 Input Voltage Selector Switch .........................3-3 Power Cord Plugs ............................3-4 Grounding ..............................3-4 Extension Cords..............................3-5 Work Cable and Clamp ...........................3-5 Plasma Air Supply ............................3-6 Additional Air Filtration..........................3-6 Air Hose Connection ............................3-7...

  • Page 8: In This Section

    Grounding Safety ............................1-4 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...

  • Page 9: 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 10: 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 11: 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 4-99...

  • Page 12: 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 13: 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 14: Section 1A – Sécurité

    SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ ........1a-5 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 ÉTIQUETTE DE SÉCURITÉ ................1a-6 HYPERTHERM Systèmes plasma 1a-1 08/99...

  • Page 15: Identifier Les Consignes De 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. 1a-2 HYPERTHERM Systèmes plasma 08/99...

  • Page 16: 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 17: 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 08/99...

  • Page 18: Sécurité Des Bouteilles De Gaz Comprimé

    • 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. HYPERTHERM Systèmes plasma 1a-5 08/99...

  • Page 19: Étiquette De Sécurité

    Porter des vêtements protecteurs couvrant la totalité du corps. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 HYPERTHERM Systèmes plasma 08/99...

  • Page 20: Section 2 - Specifications

    Section 2 SPECIFICATIONS In this section: Specifications – Power Supply ........................2-2 Specifications – PAC110T Torches ........................2-3 Symbols and Markings............................2-4 powermax Operator Manual...

  • Page 21: Specifications - Power Supply

    SPECIFICATIONS Specifications – Power Supply Rated Open Circuit Voltage (U 288 VDC Rated Output Current (I 14 A – 27 A Rated Output Voltage (U 91 VDC Duty Cycle at 40°C 35 % (I =27 A, U =91 V) (See data plate on power supply for 60 % (I =21 A, U =88 V)

  • Page 22: Specifications - Pac110T Torches

    SPECIFICATIONS Specifications – PAC110T Torches Recommended Cutting Capacity 1/4 inch (6 mm) @ 27A (35 % duty cycle) Maximum Cutting Capacity 3/8 inch (10 mm) @ 27A (35 % duty cycle) Severance Cutting Capacity 1/2 inch (12 mm) @ 27A (35 % duty cycle) Gas Flow 270 scfh/4.5 scfm @ 60 psi (127 l/min @ 4.2 bar) Weight...

  • Page 23: Symbols And Markings

    SPECIFICATIONS Symbols and Markings Mark The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. IEC Symbols Used The following symbols may appear on the power supply data plate, control labels and switches. Direct Current (DC) A chopper-based power source Plasma torch in the TEST...
  • Page 24 Section 3 SETUP In this section: Upon Receipt ..............................3-2 Claims ................................3-2 Contents of Box...............................3-2 Locating Power Supply ...........................3-2 115/230 Voltage Configurations ........................3-2 Input Voltage Selector Switch .........................3-3 Power Cord Plugs ............................3-4 Grounding ..............................3-4 Extension Cords..............................3-5 Work Cable and Clamp ...........................3-5 Plasma Gas Supply ............................3-6 Additional Gas Filtration .........................3-6 Gas Supply Connection ..........................3-7...

  • Page 25: 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 the nearest Hypertherm office listed in the front of this manual.

  • Page 26: Input Voltage Selector Switch

    SETUP Input Voltage Selector Switch The input voltage selector switch allows either 115V or 230V to be used as the Powermax380 input voltage. Set the required voltage as shown below: CAUTION Do not reposition Voltage Selector Switch with power ON. Damage to the power supply will result.

  • Page 27: Power Cord Plugs

    SETUP Power Cord Plugs The 115/230V Powermax380 power supplies are shipped with the following power cord configurations: the 60 Hz units are shipped with a 115V plug on the power cord; the 50 Hz units are shipped without a plug on the power cord.

  • Page 28: Extension Cords

    SETUP Extension Cords Use an extension cord of appropriate wire size for the cord length and system voltage. Use a cord that is certified by national or local codes. The cord should be installed by a licensed electrician. Input- Recommended Voltage Phase Cord Gauge Size...

  • Page 29: Plasma Air Supply

    SETUP Plasma Gas Supply The gas supply for the Powermax380 can be shop compressed air or cylinder compressed air. A high-pressure regulator must be used on either type of supply and must be capable of delivering gas to the filter on the power supply at 270 scfh/4.5 scfm (127 l/min) at a pressure of 60 psi (4.2 bar).

  • Page 30: Air Hose Connection

    SETUP Gas Supply Connection Connect the air hose as follows: 1. Air fitting • Install 1/4 NPT quick-disconnect nipple on to air fitting. Use liquid pipe sealant. 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.

  • Page 31: Section 4 – Operation

    Section 4 OPERATION In this section: Controls and Indicators ...........................4-2 Installing Torch Consumables .........................4-3 Turn Power ON ...............................4-4 Adjust Gas Pressure and Current Setting .......................4-4 Check Indicator LEDs .............................4-5 Hand Torch Operation .............................4-6 powermax Operator Manual...

  • Page 32: Controls And Indicators

    OPERATION Controls and Indicators ON (I)/OFF (0) Power Switch Activates the power supply and its control circuits. Green POWER ON LED When illuminated, indicates that the power switch has been set at I (ON) and that the safety interlocks are satisfied. Yellow GAS PRESSURE LED When illuminated, indicates that the gas pressure is below 40 psi (2.8 bar).

  • Page 33: Installing Torch Consumables

    OPERATION Installing Torch Consumables WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated. The plasma arc will quickly cut through gloves and skin. Make sure power is OFF before changing consumables. 220016 120504 020382...

  • Page 34: Turn On Power

    OPERATION Turn Power ON Adjust Gas Pressure and Current Setting Set current knob to gas test. Push regulator knob to lock. Pull regulator knob to unlock. Turn current knob away from gas test to stop gas flow. Set pressure to 60 psi (4.2 bar). powermax Operator Manual...

  • Page 35: Check Indicator Leds

    OPERATION Check Indicator LEDs System is ready when lights are as shown: Power ON / system ready Gas pressure Torch parts Temperature See Basic Troubleshooting, Section 5 for additional information. powermax Operator Manual...

  • Page 36: Hand Torch Operation

    OPERATION Hand Torch Operation WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated. The plasma arc will quickly cut through gloves and skin. • Keep away from the torch tip. •...
  • Page 37 OPERATION Hand Torch Cutting Technique Maintain an approximate 1/16 inch / 1.5 mm torch- to-work distance. When cutting, make sure that sparks are exiting from the bottom of the workpiece. 1/16" (1.5 mm) If sparks are spraying up from the workpiece, you are moving the torch too fast, or without sufficient power.
  • Page 38 OPERATION Starting a cut from the edge of the workpiece Hold the torch vertical at the edge of the workpiece. Start cut at the edge of the workpiece. Pause at the edge until the arc has completely cut through the workpiece. Then, proceed with the cut.
  • Page 39 OPERATION Piercing WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. Hold the torch so that the nozzle is within 1/16 inch / 1.5 mm from the workpiece before firing the torch. Fire the torch at an angle to the workpiece, then slowly rotate it to an upright position.

  • Page 40: Torch Operation

    OPERATION Torch Operation Cut Chart - 27 Amp Standard Consumables • Torch-to-work distance for the following cut chart is 1/16 inch / 1.5 mm for all cuts. Retaining Cap Nozzle Electrode Swirl Ring PAC110T 220016 120504 020382 220013 Torch Material Thickness Recommended Travel Speed Material Current...
  • Page 41 Section 5 MAINTENANCE AND PARTS In this section: Routine Maintenance ............................5-2 Inspect Consumables............................5-3 Controls and Indicators ...........................5-4 Basic Troubleshooting.............................5-5 Technical Questions ............................5-7 Parts ...............................5-8 Torch Consumables.......................See Section 4 PAC110T Hand – Torch Assembly......................5-9 Power Supply – Filter Regulator......................5-10 Power Supply – Work Cable.........................5-10 Powermax380 Labels ...........................5-11 powermax Operator Manual...

  • Page 42: Section 5 - Maintenance

    MAINTENANCE AND PARTS Routine Maintenance WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. Each Use Check consumables for wear Check gas pressure. and proper installation.

  • Page 43: Inspect Consumables

    MAINTENANCE AND PARTS Inspect Consumables Part Check For Action Roundness of through hole Nozzle Center hole Good Worn Replace Electrode Max. 1/16 inch Center surface Maximum pit depth Replace 1/16 inch (1.6 mm) Swirl Ring External surfaces Damage or debris Replace Gas holes Blocked holes...

  • Page 44: Controls And Indicators

    MAINTENANCE AND PARTS Controls and Indicators ON (I)/OFF (0) Power Switch Activates the power supply and its control circuits. Green POWER ON LED When illuminated, indicates that the power switch has been set at I (ON) and that the safety interlocks are satisfied.

  • Page 45: Basic Troubleshooting

    MAINTENANCE AND PARTS Basic Troubleshooting Problem Cause / Solution 1. The ON/OFF power switch is set to I (ON), 1.1 The power cord is not plugged into the power but the fan does not operate and the receptacle. POWER ON LED is not illuminated. Plug the power cord into the receptacle.
  • Page 46 MAINTENANCE AND PARTS Basic Troubleshooting (continued) Problem Cause / Solution 4. The POWER ON LED is illuminated 4.1 The gas supply is not connected to the power supply or is turned. and the GAS PRESSURE LED is Check that the gas is connected to the power supply illuminated.

  • Page 47: Technical Questions

    If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call the nearest Hypertherm office listed in the front of this manual. 3. See the Powermax380 Service Manual for wiring diagrams, higher-level troubleshooting and more parts list information.

  • Page 48: Parts

    MAINTENANCE AND PARTS Parts PAC110T Hand Torch Assembly Item Part Number Description Quantity 070071* PAC110T Hand Torch Assembly with 20 ft (6.1 m) Lead 001288 Handle, 2 Sides 002244 Safety Trigger 128377 Replacement Start Switch (switch and wire splices) 027254 Trigger Spring 004764 Gutcha Retaining Ring...
  • Page 49 MAINTENANCE AND PARTS * Included with replacement assembly. powermax Operator Manual...

  • Page 50: Power Supply - Filter Regulator

    MAINTENANCE AND PARTS Power Supply – Filter Regulator Part Item Number Description Qty. 060197 Air filter element 060203 O-ring Power Supply – Work Cable Part Item Number Description Qty. 060009 Work Cable with clamp, 15 ft (4.6 m) powermax 5-10 Operator Manual...

  • Page 51: Powermax380 Labels

    MAINTENANCE AND PARTS Powermax380 Labels WARNING WARNING AVERTISSEMENT AVERTISSEMENT Protect yourself and others. Read and Protect yourself and others. Read and Pour votre protection et celle des autres, Pour votre protection et celle des autres, understand this marking. understand this marking. lire et comprendre ces consignes.

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