Hypertherm powermax 350 Operator's Manual
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Hypertherm powermax 350 Operator's Manual

Plasma arc cutting system
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See also: Service Manual
Plasma Arc
Cutting System
Operator Manual
802900 Rev. 0
EN50199
EN50192
®

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  • Page 1 ® Plasma Arc Cutting System Operator Manual 802900 Rev. 0 EN50199 EN50192...

  • Page 2: Operator Manual

    P.O. Box 5010 Hanover, New Hampshire 03755-5010 Tel.: 603 643-3441 Fax: 603 643-5352 http://www.hypertherm.com © Copyright 1997 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 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) Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D–63457 Hanau-Wolfgang, Germany...
  • 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 115/230V CE power supply has been hearing aids. short as possible and should be built in compliance with standard f.

  • 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 ....................1-1 Safety Instructions ..........................1-2 Eye Protection ..........................1-2 Skin Protection ..........................1-2 Toxic Fume Protection ........................1-2 Fire Prevention ..........................1-2 Electric Shock Prevention ......................
  • Page 7 ABLE OF ONTENTS Additional Air Filtration ......................... 3-5 Air Hose Connection .......................... 3-5 SECTION 4 OPERATION ......................4-1 Controls and Indicators ........................4-2 Operating Instructions ........................4-3 Operating Tips ............................ 4-4 Changing Consumable Parts ....................... 4-4 Cutting ............................4-5 Piercing ............................4-6 Operating Data - 25A Consumables ....................

  • 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: Noise Protection

    • 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

    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.

  • 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...

  • Page 16: Specifications

    PECIFICATIONS Section 2 SPECIFICATIONS In this section: Introduction ...................... 2-2 Specifications ....................2-2 Power Supply ....................2-2 PAC110 Torch ....................2-3 S Mark ......................2-4 IEC Symbols Used ................... 2-4 Operator Manual...

  • Page 17: Introduction

    PECIFICATIONS INTRODUCTION The Powermax350 plasma cutting system uses a chopper power supply to cut mild steel, stainless steel, aluminum and other metals. Cylinder air or shop air is used as the plasma gas. Air used for plasma cutting must be clean, dry and oil-free. This instruction manual provides information for the user to set up and operate the system and perform limited maintenance on the torch and power supply.

  • Page 18: Pac110 Torch

    PECIFICATIONS Power Powermax350 Cord Work Lead PAC110 Torch Figure 2-1 Powermax350 Plasma Cutting System PAC110 Torch Recommended Cutting Capacity ........1/4 inch (6 mm) @ 25A (35% duty cycle) Maximum Cutting Capacity ........... 3/8 inch (10 mm) @ 25A (35% duty cycle) Severance Cutting Capacity ..........

  • Page 19: Iec Symbols Used

    PECIFICATIONS MARK The Powermax350 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. IEC SYMBOLS USED Direct Current (DC). Alternating current (AC). Plasma cutting torch. AC input power connection.

  • Page 20: Setup

    ETUP Section 3 SETUP In this section: Upon Receipt ....................3-2 Claims ......................3-2 Locating Power Supply ..................3-2 115/230 Voltage Configurations ............... 3-2 Input Voltage Selector Switch ..............3-2 Power Cord Plugs..................3-2 Grounding ......................3-4 Work Cable and Clamp ..................3-4 Plasma Air Supply ....................

  • Page 21: 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 22: Figure 3-1 Repositioning Input Voltage Selector Switch

    ETUP This procedure is necessary if 230V input power is required. Input Voltage Selector switch Retaining screw See the procedure in Fig. 3-2 for installing a power cord plug. • Remove screw and position switch to select required voltage. • Reinstall retaining screw and tighten to secure switch in place.

  • Page 23: Grounding

    ETUP GROUNDING To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the Powermax350 must be properly grounded: The power supply must be properly grounded through the power cord according to national or local electrical codes. Single-phase service must be of the 3-wire type with a green or green/yellow wire for protective earth ground and must comply with national or local electrical requirements.

  • Page 24: Additional Air Filtration

    ETUP Additional Air Filtration Use a three-stage coalescing filtration system as shown when site conditions introduce moisture, oil or other contaminants into the air line. Water/particle filter Oil filter Oil vapor filter From air supply Powermax350 Figure 3-4 Recommended Three-Stage Air Filtration System AIR HOSE CONNECTION Connect the air hose as follows: Air fitting...

  • Page 25: Operation

    PERATION Section 4 OPERATION In this section: Controls and Indicators ................... 4-2 Operating Instructions ..................4-3 Operating Tips ....................4-4 Changing Consumable Parts..............4-4 Cutting ......................4-5 Piercing....................... 4-6 Operating Data - 25A Consumables ............... 4-7 Common Cutting Faults .................. 4-8 Duty Cycle and Overheating ................

  • Page 26: Controls And Indicators

    PERATION CONTROLS AND INDICATORS • Green POWER ON LED When illuminated, indicates that the Power Switch has been set at I (On). • Green READY LED When illuminated, indicates that the safety interlocks are satisfied. • Yellow PRESSURE LED When illuminated, indicates that the air pressure is below 40 psi (2.8 bar). •...

  • Page 27: Operating Instructions

    PERATION OPERATING INSTRUCTIONS 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. Follow the instructions in the Setup section. 2.

  • Page 28: Operating Tips

    PERATION OPERATING TIPS Changing Consumable Parts WARNING SHOCK HAZARD: Always turn off the power and unplug the cord before changing consum- able parts. 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 mainte- nance work is complete.

  • Page 29: 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 start switch and press it again to reset the pilot arc timer.

  • Page 30: Piercing

    PERATION Figure 4-6 Cutting a Circle Piercing • 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. • Hold the torch at an angle to the workpiece away from yourself, then slowly rotate it to an upright position.

  • Page 31: Operating Data - 25A Consumables

    PERATION OPERATING DATA - 25A CONSUMABLES The following recommended settings are for hand-held cutting at 25 amps. Torch-to-work distance for the following cut charts is 1/16 inch (1.6 mm) for all cuts. The settings are optimized to provide the best cut angle, least dross and best cut surface finish.

  • Page 32: Common Cutting Faults

    PERATION 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. •...

  • Page 33: Maintenance/Parts

    AINTENANCE ARTS Section 5 MAINTENANCE/PARTS In this section: Introduction ..................... 5-2 Routine Maintenance ..................5-2 Trouble LED Indicators..................5-3 Pressure ..................... 5-3 Torch Cap ....................5-3 Over-Temp ....................5-3 PAC110 Torch Repair ..................5-4 Parts and Required Tools ................5-4 Remove Torch Main Body ................

  • Page 34: 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 WARNING SHOCK HAZARD: Always turn off the power and unplug the cord before changing consum- able parts.

  • Page 35: Trouble Led Indicators

    AINTENANCE ARTS TROUBLE LED INDICATORS If certain problems occur, the READY LED extinguishes, a trouble LED illuminates and the torch stops firing. • PRESSURE LED - Illuminates if air pressure is below 40 psi (2.8 bar). Turn power Off (O) and check for proper air pressure (see Section 4, Operating Instructions) •...

  • Page 36: Pac110 Torch Repair

    AINTENANCE ARTS PAC110 TORCH REPAIR Parts and Required Tools The PAC110 torch can be repaired in the field by removing the torch main body from the torch assem- bly and installing a new torch main body and a plastic cinch strap (Tyrap). To perform the repair, the following customer-supplied tools are required: •...
  • Page 37 AINTENANCE ARTS 2. Connect the two red wire from the torch lead to the butt splice connecting the red wire to the pilot arc fitting using the crimping tool. 3. Connect the two blue wires from the torch lead to the butt splices connecting the white wires to the microswitch using the crimping tool.

  • Page 38: Basic Troubleshooting

    AINTENANCE ARTS BASIC TROUBLESHOOTING Problem Cause/Solution 1. No pilot arc; difficulty in establishing an arc. 1.1 Clean or replace worn consumables as necessary. 1.2 Check for proper installation of swirl ring. 1.3 Refer to Service Manual IM-292 (802920) for more detailed troubleshooting. 2.
  • Page 39 AINTENANCE ARTS Problem Cause/Solution 7.3 Refer to Service Manual IM-292 (802920) for more detailed troubleshooting. 8. TORCH CAP LED illuminated; READY LED 8.1 Check torch retaining cap to ensure it is tight. extinguished. 8.2 Refer to Service Manual IM-292 (802920) for more detailed troubleshooting.

  • Page 40: Technical Questions

    If you are unable to fix the problem with your Powermax350 by following this basic troubleshooting guide or if you need further assistance: 1. Call your distributor. He/she will be able to help you, or refer you to an authorized Hypertherm repair facility.

  • Page 41: Pac110 Torch Assembly And 15 Ft (4.5 M) Torch Lead, 25A

    AINTENANCE ARTS PAC110 Torch Assembly and 15 ft (4.5 m) Torch Lead, 25A - 070057 PAC110 Torch Assembly and 25 ft (7.6 m) Torch Lead, 25A - 070058 Part Number Description 001192 ......... Handle, PAC110 075339 ......... Screws (3), P/S, # 4 X 1/2, PH, RND, S/B 075341 .........

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