273 Hypertherm Powermax 1100 Manual

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Electromagnetic Compatibility
Warranty
Table of Contents
Section 1 SAFETY
Section 1a SÉCURITÉ
Section 2 SPECIFICATIONS
Section 3 SETUP
Section 4 OPERATION
Section 5 MAINTENANCE/PARTS
Appendix

Plasma Arc

Cutting System

Operator Manual

802730 Revision 2

EN50199

EN50192

powermaxpowermax11001100

Plasma Arc Cutting System

Operator Manual

IM-273

(P/N 802730)

for systems beginning with serial number

1100-010000

Revision 2 November, 2013

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

Hypertherm, Inc.

Hanover, NH

http://www.hypertherm.com

email:info@hypertherm.com

Hypertherm Offices Worldwide

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

Tel.: (603) 643-3441 (Main Office)

Fax: (603) 643-5352 (All Departments)

Tel.: (800) 643-9878 (Technical Service)

Tel.: (800) 737-2978 (Customer Service)

email: info@hypertherm.com (General Information)

email: service@hypertherm.com (Technical/Customer Services)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D–63457 Hanau-Wolfgang, Germany

Tel.: 49 6181 58 2100

Fax: 49 6181 58 2134

European Technical Support Organization (ETSO)

Technologiepark Hanau

Rodenbacher Chaussee 6

D–63457 Hanau-Wolfgang, Germany

Tel.: 49 6181 58 2100

Fax: 49 6181 58 2134

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2

K.B. Warehouse Complex

Singapore 417847, Republic of Singapore

Tel.: 65 841 2489

Fax: 65 841 2490

Hypertherm U.K.

9 Berkeley Court • Manor Park

Runcorn, Cheshire, England WA7 1TQ

Tel.: 44 1928 579 074

Fax: 44 1928 579 604

France

10, Allée de I’lsara

F-95000 Cergy-Pontoise, France

Tel.: 33 1 34 24 03 05

Fax: 33 1 34 25 09 64

Italy

Via Torino 2

20123 Milan, Italy

Tel.: 39 02 725 46 312

Fax: 39 02 725 46 400

EMC INTRODUCTION

The 230/400V CE power supply has been

built in compliance with standard

EN50199. To ensure that the equipment

works in a compatible manner with other

radio and electronic systems, the

equipment should be installed and used in

accordance with the information below to

achieve electromagnetic compatibility.

The limits required by EN50199 may not

be adequate to completely eliminate

interference when the affected equipment

is in close proximity or has a high degree

of sensitivity. In such cases it may be

necessary to use other measures to

further reduce interference.

This plasma equipment should be used

only in an industrial environment. It may

be difficult to ensure electromagnetic

compatibility in a domestic environment.

INSTALLATION AND USE

The user is responsible for installing and

using the plasma equipment according to

the manufacturer's instructions. If

electromagnetic disturbances are

detected then it shall be the responsibility

of the user to resolve the situation with the

technical assistance of the manufacturer.

In some cases this remedial action may be

as simple as earthing the cutting circuit,

see

Earthing of Workpiece

. In other cases

it could involve constructing an

electromagnetic screen enclosing the

power source and the work complete with

associated input filters. In all cases

electromagnetic disturbances must be

reduced to the point where they are no

longer troublesome.

ASSESSMENT OF AREA

Before installing the equipment the user

shall make an assessment of potential

electromagnetic problems in the

surrounding area. The following shall be

taken into account:

a. Other supply cables, control cables,

signalling and telephone cables; above,

below and adjacent to the cutting

equipment.

b. Radio and television transmitters and

receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example

guarding of industrial equipment.

e. Health of the people around, for

example the use of pacemakers and

hearing aids.

f. Equipment used for calibration or

measurement.

g. Immunity of other equipment in the

environment. User shall ensure that

other equipment being used in the

environment is compatible. This may

require additional protection measures.

h. Time of day that cutting or other

activities are to be carried out.

The size of the surrounding area to be

considered will depend on the structure of

the building and other activities that are

taking place. The surrounding area may

extend beyond the boundaries of the

premises.

METHODS OF REDUCING

EMISSIONS

Mains Supply

Cutting equipment should be connected

to the mains supply according to the

manufacturer's recommendations. If

interference occurs, it may be necessary

to take additional precautions such as

filtering of the mains supply.

Consideration should be given to

shielding the supply cable of permanently

installed cutting equipment, in metallic

conduit or equivalent. Shielding should

be electrically continuous throughout its

length. The shielding should be

connected to the cutting mains supply so

that good electrical contact is maintained

between the conduit and the cutting

power source enclosure.

Maintenance of Cutting Equipment

The cutting equipment should be

routinely maintained according to the

manufacturer's recommendations. All

access and service doors and covers

should be closed and properly fastened

when the cutting equipment is in

operation. The cutting equipment should

not be modified in any way except for

those changes and adjustments covered

in the manufacturer's instructions. In

particular, the spark gaps of arc striking

and stabilizing devices should be

adjusted and maintained according to the

manufacturer's recommendations.

Cutting Cables

The cutting cables should be kept as

short as possible and should be

positioned close together, running at or

close to the floor level.

Equipotential Bonding

Bonding of all metallic components in the

cutting installation and adjacent to it

should be considered. However, metallic

components bonded to the workpiece will

increase the risk that the operator could

receive a shock by touching these

metallic components and the electrode at

the same time. The operator should be

insulated from all such bonded metallic

components.

Earthing of Workpiece

Where the workpiece is not bonded to

earth for electrical safety, nor connected

to earth because of its size and position,

for example, ship's hull or building

steelwork, a connection bonding the

workpiece to earth may reduce

emissions in some, but not all instances.

Care should be taken to prevent the

earthing of the workpiece increasing the

risk of injury to users, or damage to other

electrical equipment. Where necessary,

the connection of the workpiece to earth

should be made by a direct connection to

the workpiece, but in some countries

where direct connection is not permitted,

the bonding should be achieved by

suitable capacitances selected

according to national regulations.

Note: The cutting circuit may or may not

be earthed for safety reasons. Changing

the earthing arrangements should only

be authorized by a person who is

competent to assess whether the

changes will increase the risk of injury, for

example, by allowing parallel cutting

current return paths which may damage

the earth circuits of other equipment.

Further guidance is given in IEC TC26

(sec)94 and IEC TC26/108A/CD Arc

Welding Equipment Installation and Use.

Screening and Shielding

Selective screening and shielding of

other cables and equipment in the

surrounding area may alleviate problems

of interference. Screening of the entire

plasma cutting installation may be

considered for special applications.

Operator Manual

LECTROMAGNETIC

OMPATIBILITY

GENERAL

HYPERTHERM, Inc. warrants that Products shall be free from defects in materials and workmanship,

under proper and normal use for which such Equipment is recommended, for a period of two (2) years,

except only with respect to the Torch, for which the warranty period shall be one (1) year, from the date

of its delivery to you.

HYPERTHERM, at its sole option, shall repair, replace, or adjust, free of charge, any Products covered

by this warranty which shall be returned with HYPERTHERM's prior authorization (which shall not be

unreasonably withheld), properly packed, to HYPERTHERM's place of business in Hanover, New

Hampshire, all costs, insurance and freight prepaid, and which examination proves not to be free from

defects in materials and workmanship. HYPERTHERM shall not be liable for any repairs, replace-

ments, or adjustments of Products covered by this warranty, except those made pursuant to this para-

graph or with HYPERTHERM's written consent. This warranty shall not apply to any Product which has

been mishandled, incorrectly installed, modified or assembled by you or any other person. HYPER-

THERM shall be liable for breach of this warranty only if it receives written notice of such breach within

the applicable warranty period specified herein above. THE FOREGOING SHALL CONSTITUTE THE

SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPER-

THERM OF ITS WARRANTY.

PATENT INDEMNITY

Except only in cases of Products not manufactured by HYPERTHERM or manufactured by a person

other than HYPERTHERM not in strict conformity with HYPERTHERM's specifications, and in cases of

designs, processes, formulae or combinations not developed or purported to be developed by HYPER-

THERM, HYPERTHERM agrees to indemnify, protect and hold harmless Distributors and their custom-

ers against any and all liability or claims in any manner imposed upon or accruing against Distributors

and their customers because of the use in or about the construction or operation of Equipment or any

design, system, formula, combination, article or material which infringes or alleges to infringe on any

patent or other right. Distributors shall notify HYPERTHERM promptly upon learning of any action or

threatened action in connection with any such alleged infringement, and each party may appoint its own

counsel for any such action or threatened action.

DISCLAIMER OF OTHER WARRANTIES

HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR

OTHERS (INCLUDING WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANTABILITY

OR FITNESS FOR A PARTICULAR PURPOSE), EITHER EXPRESS OR IMPLIED, EXCEPT AS

PROVIDED HEREIN. This warranty is in lieu of any and all warranties, express or implied, by law or

otherwise; and Distributors are not authorized to give any other warranty purporting to be binding upon

HYPERTHERM upon resale of Products to their customers. IN NO EVENT shall HYPERTHERM be

liable for incidental or consequential damages or injury to the person or property of anyone by reason of

any defect in any Equipment sold hereunder.

WARNING

Genuine Hypertherm parts are the factory-recommended replacement parts for your

Hypertherm system. Any damage caused by the use of other than genuine

Hypertherm parts may not be covered by the Hypertherm warranty.

ii Operator Manual

ARRANTY

TABLE OF CONTENTS

Operator Manual

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 ............................................................................................... 1-2

Explosion Prevention ...................................................................................................... 1-3

Noise Prevention............................................................................................................. 1-4

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

Safety Reminders ........................................................................................................... 1-4

Electronic Health Support Equipment............................................................................. 1-4

SECTION 1A SÉCURITÉ ................................................................................................. 1a-1

Au sujet des Notes, Attention et avertissement.................................................................. 1a-1

Consignes de sécurité........................................................................................................ 1a-2

Protection des yeux ...................................................................................................... 1a-2

Protection de la peau .................................................................................................... 1a-2

Prévention des vapeurs toxiques .................................................................................. 1a-2

Prévention des incendies.............................................................................................. 1a-2

Prévention des chocs électriques ................................................................................. 1a-2

Prévention des explosions ............................................................................................ 1a-3

Protection contre le bruit ............................................................................................... 1a-4

Mise à la masse et à la terre......................................................................................... 1a-4

Rappels de sécurité ...................................................................................................... 1a-4

Prothèses électroniques ............................................................................................... 1a-4

SECTION 2 SPECIFICATIONS ...................................................................................... 2-1

Introduction .......................................................................................................................... 2-2

Specifications ....................................................................................................................... 2-3

PAC135 80A Torches .......................................................................................................... 2-4

IEC Symbols Used ............................................................................................................... 2-6

iii

TABLE OF CONTENTS

Operator Manual

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 ....................................................................................... 3-6

Single-Phase and Three-Phase Power Configurations........................................................ 3-7

Power Cord Plugs ................................................................................................................ 3-8

Power Requirements............................................................................................................ 3-8

Grounding Requirements ..................................................................................................... 3-8

Work Cable and Clamp ........................................................................................................ 3-9

Gas Supply Requirements ................................................................................................... 3-9

Gas Supply Connection ..................................................................................................... 3-10

Torch Lead Connection .......................................................................................................3-11

Machine Interface with PAC135M ...................................................................................... 3-12

SECTION 4 OPERATION ............................................................................................... 4-1

Controls and Indicators ........................................................................................................ 4-2

Operating Instructions .......................................................................................................... 4-3

Operating Tips...................................................................................................................... 4-6

Cut Chart - 80A Standard Consumables............................................................................ 4-12

Cut Chart - 40A Consumables ........................................................................................... 4-13

Common Cutting Faults ..................................................................................................... 4-14

SECTION 5 MAINTENANCE/PARTS............................................................................. 5-1

Introduction .......................................................................................................................... 5-2

Routine Maintenance ........................................................................................................... 5-2

Basic Troubleshooting.......................................................................................................... 5-4

Technical Questions............................................................................................................. 5-7

Parts ..................................................................................................................................... 5-8

Power Supplies - 208/240/480V......................................................................................... 5-12

Power Supplies - 200/230/400V......................................................................................... 5-12

Power Supplies - 200/400V CE.......................................................................................... 5-12

APPENDIX A STANDARDS INDEX .................................................................................. a-1

APPENDIX B AERATION MANIFOLD ............................................................................. b-1

SAFETY

HYPERTHERM Plasma Systems 1-1

5-98

About Notes, Cautions and Warnings

Notes: Throughout this manual, useful information for operating the plasma system is presented in “notes”,

such as shown in this paragraph.

Cautions: Information in bold type and surrounded by a box describes a situation that may cause

damage to the plasma system.

Before using this plasma arc system. . . .

Each person who will operate this equipment, perform

service or maintenance, or supervise its use must read

the safety instructions and warnings in this manual and

the labels on the equipment.

WARNINGS

Warnings describe situations that present a physical danger to the operator, and advice to avoid or

correct the situation. Each type of warning includes applicable danger symbols, such as a hand burn,

electrical shock, fire, explosion, etc.

WARNING — Electric Shock

• Never touch the torch body, workpiece or the water in

a water table when operating the plasma system.

• When using a water table, be sure that it is correctly

connected to earth ground.

• Operating the plasma system completes an electrical

circuit between the torch and the workpiece and

anything touching the workpiece. The workpiece is part

of the electrical circuit.

WARNING — Instant-On

Torches

Instant-on torches produce a plasma

arc immediately after the torch switch

pushed.

Always hold a hand torch away from

your body as a precaution against

accidental torch firing. Be aware of

this hazard, which has potential for

serious bodily injury.

In this section:

About Notes, Cautions and Warnings ..................... 1-1

Safety Instructions................................................... 1-2

Eye Protection .................................................. 1-2

Skin Protection ................................................. 1-2

Toxic Fume Prevention..................................... 1-2

Fire Prevention ................................................. 1-2

Electric Shock Prevention................................. 1-2

Explosion Prevention ........................................ 1-3

Compressed Gas Cylinders .......................... 1-3

Section 1 SAFETY

Pressure Regulators...................................... 1-3

Hoses ............................................................ 1-3

Noise Protection .................................................. 1-4

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

Input Power ................................................... 1-4

Work Cable.................................................... 1-4

Work Table .................................................... 1-4

Safety Reminders ................................................ 1-4

Electronic Health Support Equipment .................. 1-4

HYPERTHERM Plasma Systems

SAFETY

1-2

Eye Protection

• Wear dark safety glasses or goggles with side

shields, or a welding helmet, in accordance with

applicable national or local codes, to protect eyes

against the plasma arc’s ultraviolet and infrared rays.

Lens Shade

Arc Current AWS (USA) ISO-4850

Up to 100 A No. 8 No. 11

100–200 A No. 10 No. 11-12

200–400 A No. 12 No. 13

Over 400 A No. 14 No. 14

• Replace the glasses, goggles or helmet when the lens

becomes pitted or broken.

• Warn other people in the area not to look directly at

the arc unless they are wearing glasses, goggles or a

helmet.

• Prepare the cutting area in a manner that reduces the

reflection and transmission of ultraviolet light:

– Paint walls and other surfaces with dark colors to

reduce reflection.

– Install protective screens or curtains to reduce

ultraviolet transmission.

Skin Protection

• Wear protective clothing to protect against burns

caused by ultraviolet light, sparks and hot metal:

– Gauntlet gloves, safety shoes and hat.

– Flame-retardant clothing which covers all

exposed areas.

– Cuffless trousers to prevent entry of sparks and

slag.

Toxic Fume Prevention

• Keep the cutting area well ventilated.

• Remove all chlorinated solvents from the cutting area

before cutting. Certain chlorinated solvents

decompose when exposed to ultraviolet radiation to

form phosgene gas.

• Wear proper breathing mask and use proper

ventilation when cutting galvanized metal.

• Do not cut containers with toxic materials inside.

Clean containers that have held toxic materials

thoroughly before cutting.

WARNING — Toxic Fumes

Do not cut metal or painted metals

containing zinc, lead, cadmium or beryllium

unless the operator, or anyone else subjected

to the fumes, wears respiratory equipment or

an air-supplied helmet.

5-98

Fire Prevention

• Make fire extinguishers available in the

cutting area.

• Remove all combustible materials from the immediate

cutting area to a distance of at least 35 feet (10 m).

• Quench freshly cut metal or allow metal to cool

before handling it or bringing it into contact with

combustible materials.

• Never use a plasma system to cut containers with

potentially flammable materials inside. Such

containers must be thoroughly cleaned prior to

cutting.

• Ventilate potentially flammable atmospheres before

cutting with a plasma system. When cutting with

oxygen as the plasma gas, an exhaust ventilation

system is required.

• Never operate the plasma system in an atmosphere

which contains heavy concentrations of dust,

flammable gas or combustible liquid vapors unless

properly vented.

Electric Shock Prevention

All Hypertherm plasma systems use high

voltage (up to 300 VDC) to initiate the plasma

arc. Take the following precautions when

operating the plasma system:

• Wear insulated gloves and boots, and keep body and

clothing dry.

• Do not stand, sit or lie on—or touch—any wet surface

when using the plasma system.

• Maintain proper insulation against electrical shock. If

you must work in or near a damp area, use extreme

caution.

• Provide a wall-mounted disconnect switch with

properly sized fuses close to the power supply. This

switch allows the operator to turn the power supply off

quickly in an emergency situation.

• Conform to all local electrical codes for primary wiring

sizes and types.

• Inspect the primary power cord frequently for damage

or cracking of the cover. Bare wiring can kill. Do not

use a system with a damaged power cord. Replace a

damaged power cord immediately.

• Inspect the torch leads. Replace if frayed or

damaged.

• Do not pick up the workpiece, including the waste

cutoff, while you cut. Leave the workpiece in place or

on the workbench with the work cable attached during

the cutting process.

SAFETY

HYPERTHERM Plasma Systems 1-3

• Never use a cylinder that is not upright and secured

in place.

• Never move or transport a cylinder without its

protective valve cover in place.

• Never use a gas cylinder or its contents for any

purpose other than that for which it is intended.

• Never lubricate cylinder valves with oil or grease.

• Never allow electrical contact between the plasma arc

and a cylinder.

• Never expose cylinders to excessive heat, sparks,

slag or open flame.

• Never use hammers, wrenches or other tools to open

stuck cylinder valves.

Pressure Regulators

• Be certain that all pressure regulators are in proper

working condition.

• Never use a regulator for any gas other than that for

which it is intended.

• Never use a regulator that leaks, creeps excessively

or is physically damaged in any way.

• Never attempt to lubricate a regulator with oil or

grease.

WARNING — Hydrogen Detonation

with Aluminum Cutting

When cutting aluminum underwater, or with the

water touching the underside of the aluminum,

free hydrogen gas may collect under the

workpiece and detonate during plasma cutting

operations.

Installing an aeration manifold on the floor of the

water table is an effective way to eliminate the

possibility of hydrogen detonation when cutting

aluminum. Refer to the Appendix section of this

manual for instructions on how to fabricate an

aeration manifold.

Hoses

• Label and color-code all gas hoses in order to clearly

identify the type of gas in each hose. Consult

applicable national or local codes.

• Never use the oxygen hose for any gas other than

oxygen.

• Examine hoses at regular intervals for leaks, wear,

loose connections or other hazard.

• Replace hose that is damaged in any way.

Electric Shock Prevention (continued)

• Before changing the torch parts, disconnect the main

power or unplug the power supply. After changing

torch parts and replacing the retaining cap, plug in the

power supply again.

• Never bypass or shortcut the safety interlocks.

• Before removing a power supply cover for

maintenance, disconnect the main power at the wall

disconnect switch or unplug the power supply. To

avoid exposure to severe electrical hazard, wait five

minutes after disconnecting the main power to allow

capacitors to discharge.

• Never operate the plasma system unless the power

supply unit covers are in place. Exposed power

supply connections present a severe electrical

hazard.

Explosion Prevention

WARNING — Compressed Gas

The plasma system uses compressed gas.

Observe proper precautions when handling and

using compressed gas equipment and cylinders.

• Do not use the plasma system if explosive dust or

vapors may be present.

• Do not cut pressurized cylinders or any closed

container.

WARNING —

Hydrogen Explosion Hazard

If your system uses hydrogen, remember that this

is a flammable gas that presents an explosion

hazard. Keep flames away from cylinders

containing hydrogen mixtures and hoses that

carry hydrogen mixtures. Also, keep flames and

sparks away from the torch when using argon-

hydrogen as the plasma gas.

Compressed Gas Cylinders

Handle and use compressed gas cylinders in accor-

dance with safety standards published by the U.S.

Compressed Gas Association (CGA), American Weld-

ing Society (AWS), Canadian Standards Association

(CSA) or applicable national or local codes.

• Never use a cylinder that leaks or is physically

damaged.

5-98

HYPERTHERM Plasma Systems

SAFETY

1-4

5-98

Safety Reminders

• Never bypass or shortcut the safety interlocks on any

of the plasma system units.

• Except in Hypertherm’s largest mechanized systems,

all Hypertherm torches are designed with a safety

interlock that prevents firing of the plasma arc when

the retaining cap is loosened.

• Each Hypertherm plasma system is designed to be

used only with specific Hypertherm torches. Do not

substitute other torches which could overheat and

present a potentially dangerous situation to the

operator and any personnel in the area. Hypertherm’s

warranty does not cover problems caused by the use

of torches not made by Hypertherm.

• Use only consumable parts and replacement parts

made by Hypertherm. Hypertherm’s warranty does

not cover problems caused by the use of parts not

made by Hypertherm.

• Never operate the plasma system with any of its

covers not in place. This would be hazardous to the

operator and other people in the area, and prevents

the proper cooling of the equipment.

Electronic Health Support Equipment

Plasma arc cutting and gouging systems create electric

and magnetic fields that may interfere with the correct

operation of electronic health support equipment, such

as pacemakers or hearing aids. Any person who wears

a pacemaker or hearing aid should consult a doctor

before operating or being near any plasma system

when it is in use. To minimize exposure to EMF:

• Keep both the work cable and the torch lead on one

side of your body. Keep your body from coming in

between the torch lead and the work cable.

• Route torch leads as close as possible to work cable.

• Do not wrap the torch lead or work cable around your

body.

• Stay as far away from the power supply as possible.

Hoses (continued)

• Keep hose lengths to a minimum to prevent damage,

reduce pressure drop and to prevent possible flow

restrictions.

• Prevent kinking by laying out hoses as straight as

possible between termination points.

• Coil any excess hose and place it out of the way to

prevent damage and to eliminate the danger of

tripping.

Noise Protection

The plasma cutting process can generate high

levels of noise. Depending on the arc current,

material being cut, acoustics and size of the

cutting room, distance from the torch and other factors,

acceptable noise levels as defined by national or local

codes may be exceeded by your plasma system.

• Always wear proper ear protection when cutting or

gouging with the plasma system.

Grounding

Input Power

• Be sure to connect the power cord ground wire to the

ground in the disconnect box.

• If installation of the plasma system involves

connecting the power cord to the power supply, be

sure to properly connect the power cord ground wire.

Conform to Canadian Standards Association (CSA)

standards by placing the power cord ground wire on

the stud first; then place any other ground wires on

top of the power cord ground. Fasten the retaining

nut tightly.

• Tighten all electrical connections to avoid excessive

heating.

Work Cable

• Attach the work cable securely to the workpiece or

the work table by making good metal-to-metal

contact.

Do not connect it to the piece that will fall away when

the cut is complete.

Work Table

• Connect the work table to an earth ground, in

accordance with appropriate national or local

electrical codes.

SÉCURITÉ

HYPERTHERM Systèmes plasma 1a-1

10/6/98

IDENTIFIER LES CONSIGNES

DE SÉCURITÉ

Les symboles indiqués dans cette section sont utilisés pour

identifier les risques éventuels. Si vous trouvez un symbole

de sécurité, que ce soit dans ce manuel ou sur

l’équipement, soyez conscient des risques de blessures et

suivez les instructions correspondantes afin d’éviter ces

risques.

SUIVRE LES INSTRUCTIONS

DE SÉCURITÉ

Lire attentivement toutes les consignes de sécurité dans le

présent manuel et sur les étiquettes de sécurité se trouvant

sur la machine.

• Les étiquettes de sécurité doivent rester lisibles.

Remplacer immédiatement les étiquettes manquantes ou

abîmées.

• Apprendre à faire fonctionner la machine et à utiliser

correctement les commandes. Ne laisser personne utiliser

la machine sans connaître son fonctionnement.

• Garder la machine en bon état. Des modifications non

autorisées sur la machine peuvent engendrer des

problèmes de sécurité et raccourcir la durée d’utilisation

de l’équipement.

DANGER AVERTISSEMENT PRÉCAUTION

Les signaux DANGER ou AVERTISSEMENT sont utilisés

avec un symbole de sécurité, DANGER correspondant aux

risques les plus sérieux.

• Les étiquettes de sécurité DANGER et AVERTISSE-

MENT sont situées sur la machine pour signaler certains

dangers spécifiques.

• Les messages d’AVERTISSEMENT précèdent les

instructions d’utilisation expliquées dans ce manuel et

signalent les risques de blessures ou de mort au cas où

ces instructions ne seraient pas suivies correctement.

• Les messages de PRÉCAUTION précèdent les

instructions d’utilisation contenues dans ce manuel et

signalent que le matériel risque d’être endommagé si les

instructions ne sont pas suivies correctement.

Prévention des incendies

• Avant de commencer, s’assurer que la zone de coupage

ne présente aucun danger. Conserver un extincteur à

proximité.

• Éloigner toute matière inflammable à une distance d’au

moins 10 m du poste de coupage.

• Tremper le métal chaud ou le laisser refroidir avant de

le manipuler ou avant de le mettre en contact avec des

matériaux combustibles.

• Ne jamais couper des récipients pouvant contenir des

matières inflammables avant de les avoir vidés et

nettoyés correctement.

• Aérer toute atmosphère potentiellement inflammable

avant d’utiliser un système plasma.

• Lors de l’utilisation d’oxygène comme gaz plasma, un

système de ventilation par aspiration est nécessaire.

Prévention des explosions

• Ne pas couper en présence de poussière ou de vapeurs.

• Ne pas couper de bouteilles, de tuyaux ou autres

récipients fermés et pressurisés.

• Ne pas couper de récipients contenant des matières

combustibles.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

AVERTISSEMENT

Risque d’explosion

Argon-hydrogène et méthane

L’hydrogène et le méthane sont des gaz inflammables et

potentiellement explosifs. Conserver à l’écart de toute

flamme les bouteilles et tuyaux contenant des mélanges à

base d’hydrogène ou de méthane. Maintenir toute flamme

et étincelle à l’écart de la torche lors de l’utilisation d’un

plasma d’argon-hydrogène ou de méthane.

AVERTISSEMENT

Détonation de l’hydrogène lors du

coupage de l’aluminium

• Lors du coupage de l’aluminium sous l’eau, ou si l’eau

touche la partie inférieure de la pièce d’aluminium, de

l’hydrogène libre peut s’accumuler sous la pièce à couper

et détonner lors du coupage plasma.

• Installer un collecteur d’aération au fond de la table à eau

afin d’éliminer les risques de détonation de l’hydrogène.

Se référer à l’annexe du manuel pour plus de

renseignements sur les collecteurs d’aération.

Section 1a SÉCURITÉ

SÉCURITÉ

1a-2

10/6/98

HYPERTHERM Systèmes plasma

Toucher une pièce électrique sous tension peut provoquer

un choc électrique fatal ou des brûlures graves.

• La mise en fonctionnement du système plasma ferme un

circuit électrique entre la torche et la pièce à couper. La

pièce à couper et tout autre élément en contact avec cette

pièce font partie du circuit électrique.

• Ne jamais toucher le corps de la torche, la pièce à couper

ou l’eau de la table à eau pendant le fonctionnement du

système plasma.

Prévention des chocs électriques

Tous les systèmes plasma Hypertherm utilisent des hautes

tensions pour le coupage (souvent de 200 à 400 V).On doit

prendre les précautions suivantes quand on utilise le

système plasma :

• Porter des bottes et des gants isolants et garder le corps

et les vêtements au sec.

• Ne pas se tenir, s’asseoir ou se coucher sur une surface

mouillée, ni la toucher quand on utilise le système

plasma.

• S’isoler de la surface de travail et du sol en utilisant des

tapis isolants secs ou des couvertures assez grandes

pour éviter tout contact physique avec le travail ou le sol.

S’il s’avère nécessaire de travailler dans ou près d’un

endroit humide, procéder avec une extrême prudence.

• Installer un sectionneur avec fusibles appropriés, à

proximité de la source de courant. Ce dispositif permet à

l’opérateur d’arrêter rapidement la source de courant en

cas d’urgence.

• En cas d’utilisation d’une table à eau, s’assurer que cette

dernière est correctement mise à la terre.

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

• Installer et mettre à la terre l’équipement selon les

instructions du présent manuel et conformément aux

codes électriques locaux et nationaux.

• Inspecter fréquemment le cordon d’alimentation primaire

pour s’assurer qu’il n’est ni endommagé, ni fendu.

Remplacer immédiatement un cordon endommagé. Un

câble dénudé peut tuer.

• Inspecter et remplacer les câbles de la torche qui sont

usés ou endommagés.

• Ne pas saisir la pièce à couper ni les chutes lors du

coupage. Laisser la pièce à couper en place ou sur la

table de travail, le câble de retour connecté lors du

coupage.

• Avant de vérifier, de nettoyer ou de remplacer les pièces

de la torche, couper l’alimentation ou débrancher la prise

de courant.

• Ne jamais contourner ou court-circuiter les verrouillages

de sécurité.

• Avant d’enlever le capot du système ou de la source de

courant, couper l’alimentation électrique. Attendre ensuite

5 minutes pour que les condensateurs se déchargent.

• Ne jamais faire fonctionner le système plasma sans que

les capots de la source de courant ne soient en place.

Les raccords exposés de la source de courant sont

extrêmement dangereux.

• Lors de l’installation des connexions, attacher tout d’abord

la prise de terre appropriée.

• Chaque système plasma Hypertherm est conçu pour être

utilisé uniquement avec des torches Hypertherm

spécifiques. Ne pas utiliser des torches inappropriées qui

pourraient surchauffer et présenter des risques pour la

sécurité.

Le coupage peut produire des vapeurs et des gaz toxiques

qui réduisent le niveau d’oxygène dans l’air et peuvent

provoquer des blessures, voire la mort.

• Conserver le poste de coupage bien aéré ou utiliser un

masque respiratoire homologué.

• Ne pas procéder au coupage près d’endroits où

s’effectuent le dégraissage, le nettoyage ou la

vaporisation. Certains solvants chlorés se décomposent

sous l’effet des rayons ultraviolets et forment du

phosgène.

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

• Ne pas couper des métaux peints ou contenant des

matières toxiques comme le zinc (galvanisé), le plomb, le

cadmium ou le béryllum, à moins que la zone de travail

soit très bien ventilée et que l’opérateur porte un masque

respiratoire. Les revêtements et métaux contenant ces

matières peuvent produire des vapeurs toxiques lors du

coupage.

• Ne jamais couper de récipients pouvant contenir des

matières inflammables avant de les avoir vidés et

nettoyés correctement.

5/27/99

SÉCURITÉ

HYPERTHERM Systèmes plasma 1a-3

10/6/98

Torches à allumage instantané

L’arc plasma s’allume immédiatement après que la torche

soit mise en marche.

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

L’arc plasma coupe facilement les gants et la peau.

• Rester éloigné de l’extrémité de la torche.

• Ne pas tenir de métal près de la trajectoire de coupe.

• Ne jamais pointer la torche vers soi ou d’autres

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

• Gants à crispin, chaussures et casque de sécurité.

• Vêtements ignifuges couvrant toutes les parties exposées

du corps.

• Pantalon sans revers pour éviter que des étincelles ou

des scories puissent s’y loger.

• Avant le coupage, retirer de ses poches tout objet

combustible comme les briquets au butane ou les

allumettes.

Zone de coupage Préparer la zone de coupage afin de

réduire la réverbération et la transmission de la lumière

ultraviolette :

• Peindre les murs et autres surfaces de couleur sombre

pour réduire la réflexion de la lumière.

• Utiliser des écrans et autres dispositifs de protection afin

de protéger les autres personnes de la lumière et de la

réverbération.

• Prévenir les autres personnes de ne pas regarder l’arc.

Utiliser des affiches ou des panneaux.

Câble de retour Bien fixer le câble de retour (ou de

masse) à la pièce à couper ou à la table de travail de façon

à assurer un bon contact métal-métal. Ne pas fixer le câble

de retour à la partie de la pièce qui doit se détacher.

Table de travail Raccorder la table de travail à la terre,

conformément aux codes de sécurité locaux ou nationaux

appropriés.

MISE À LA MASSE ET À LA TERRE Alimentation

• S’assurer que le fil de terre du cordon d’alimentation est

connecté à la terre dans le coffret du sectionneur.

• S’il est nécessaire de brancher le cordon d’alimentation à

la source de courant lors de l’installation du système,

s’assurer que le fil de terre est correctement branché.

• Placer tout d’abord le fil de terre du cordon d’alimentation

sur le plot de mise à la terre puis placer les autres fils de

terre par-dessus. Bien serrer l’écrou de retenue.

• S’assurer que toutes les connexions sont bien serrées

pour éviter la surchauffe.

Protection des yeux Les rayons de l’arc plasma

produisent de puissants rayons visibles ou invisibles

(ultraviolets et infrarouges) qui peuvent brûler les yeux et la

peau.

• Utiliser des lunettes de sécurité conformément aux codes

locaux ou nationaux en vigueur.

• Porter des lunettes de protection (lunettes ou masque

muni d’écrans latéraux ou encore masque de soudure)

avec des verres teintés appropriés pour protéger les yeux

des rayons ultraviolets et infrarouges de l’arc.

Puissance des verres teintés

Courant de l’arc AWS (É.-U.) ISO 4850

Jusqu’à 100 A N

100-200 A N

10 N

11-12

200-400 A N

12 N

Plus de 400 A N

14 N

Protection de la peau Porter des vêtements de sécurité

pour se protéger contre les brûlures que peuvent causer les

rayons ultraviolets, les étincelles et le métal brûlant :

personnes.

4/9/99

SÉCURITÉ

1a-4

10/6/98

HYPERTHERM Systèmes plasma

• Ne jamais lubrifier les robinets des bouteilles ou les

régulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux et

accessoires appropriés et conçus pour chaque application

spécifique.

• Entretenir l’équipement et les pièces d’équipement à gaz

comprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux de

gaz afin d’identifier le type de gaz contenu dans chaque

tuyau. Se référer aux codes locaux ou nationaux en

vigueur.

LES BOUTEILLES DE GAZ

COMPRIMÉ PEUVENT EXPLOSER

EN CAS DE DOMMAGES

SÉCURITÉ DES BOUTEILLES DE GAZ

COMPRIMÉ

Les bouteilles de gaz contiennent du gaz à haute pression.

Si une bouteille est endommagée, elle peut exploser.

• Manipuler et utiliser les bouteilles de gaz comprimé

conformément aux codes locaux ou nationaux.

• Ne jamais utiliser une bouteille qui n’est pas placée à la

verticale et bien assujettie.

• Le capuchon de protection doit être placé sur le robinet

sauf si la bouteille est en cours d’utilisation ou connectée

pour utilisation.

• Éviter à tout prix le contact électrique entre l’arc plasma et

une bouteille.

• Ne jamais exposer des bouteilles à une chaleur

excessive, aux étincelles, aux scories ou aux flammes

nues.

• Ne jamais utiliser des marteaux, des clés ou d’autres

outils pour débloquer le robinet des bouteilles.

Une exposition prolongée au bruit du coupage ou du

gougeage peut provoquer des problèmes auditifs.

• Utiliser un casque de protection homologué lors de

l’utilisation du système plasma.

• Prévenir les personnes aux alentours des risques

encourus en cas d’exposition au bruit.

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

PACEMAKERS ET

PROTHÈSES AUDITIVES

Les champs magnétiques produits par les courants à haute

tension peuvent affecter le fonctionnement des prothèses

auditives et des pacemakers. Les personnes portant ce

type d’appareil doivent consulter un médecin avant de

s’approcher d’un lieu où s’effectue le coupage ou le

gougeage plasma.

Pour réduire les risques associés aux champs

magnétiques :

• Garder loin de soi et du même côté du corps le câble de

retour et le faisceau de la torche.

• 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.

10/16/98

PECIFICATIONS

2-1

Operator Manual

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

Section 2 SPECIFICATIONS

2-2

PECIFICATIONS

Operator Manual

INTRODUCTION

The Powermax1100 plasma cutting system uses an inverter power supply to provide a smooth DC

output voltage, producing excellent cut and gouge quality on mild steel, stainless steel, aluminum and

other metals. The Powermax1100 power supply provides constant-current output variable from 30 to

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.

Air is the primary plasma gas, providing low operating cost combined with high-speed performance.

Cylinder air or shop air can be used as long as it is clean, dry and oil-free. When properly set and

maintained, the pressure regulator and gas filter on the power supply ensure that the correct pressure

and flow rate is supplied to the system at the proper quantity and quality. The Powermax1100 can also

cut with nitrogen when extended electrode life is a priority.

This instruction manual provides information for the user to set up and operate the system and perform

limited maintenance on the power supply. This manual also provides a detailed list of safety practices

so that the system can be safely operated and maintained. READ THE SAFETY SECTION

(Section 1) FIRST!

The Powermax1100 service manual provides higher-level troubleshooting and a more complete parts

list.

Figure 2-1 Powermax1100 Hand Plasma Cutting System

PECIFICATIONS

2-3

Operator Manual

SPECIFICATIONS

Power Supply

Rated Open Circuit Voltage (OCV) (U0) ............... 280-320 VDC

Rated Output Current (I2) ..................................... 30–80 amps

Rated Output Voltage (U2).................................... 140 VDC

Duty Cycle (X) @ 104° F (40° C) ......................... 50% (I2=80A, U2=140V)

100% (I2=57A, U2=140V) See data tag on power

supply for more information on duty cycle

Ambient temperature ............................................ Power supplies will operate between +14° and

104° F (-10° and +40° C).

Apparent Input Power (S1).................................... 19.2 kVA (U1I1) non CE power supplies

13.1 kVA (U1I1) CE power supplies

Input Voltage (U1)/Input Current (I1)

@11.2 kw Output.................................................. 208V/92A; 240V/80A; 480V/40A - 1φ, 50/60 Hz

208V/53A; 240V/46A; 480V/23A - 3φ, 50/60 Hz

200V/96A; 230V/84A; 400V/48A - 1φ, 50/60 Hz

200V/56A; 230V/49A; 400V/28A - 3φ, 50/60 Hz

230V/33A; 400V/19A (CE) - 3φ, 50/60 Hz

600V/20A - 3φ, 60 Hz

Gas Type .............................................................. Air or Nitrogen

Gas Quality, Air .................................................... Clean, dry, oil-free

Gas Quality, Nitrogen ........................................... 99.995% pure

Gas Inlet Pressure................................................ 90 psi (6.2 bar)

Gas Flow .............................................................. 400 scfh/6.7 scfm at 90 psi (189 l/min at 6.2 bar)

supplied to power supply pressure regulator

Power Supply pressure regulator setting ............. 65 psi (4.5 bar) flowing

Dimensions and Weight:

Depth .................................................................... 25.1" (638 mm)

Width .................................................................... 10.4" (264 mm) without wheels

15.8" (401 mm) with wheels

Height ................................................................... 19.6" (498 mm) without wheels

23.7" (602 mm) with wheels

Weight, 208/240/480V and 200/230/400V

without power cord ............................................... 77 pounds (35 kg) without wheels

89 pounds (40 kg) with wheels

Weight, 230/400V CE with power cord................. 87 pounds (39 kg) without wheels

99 pounds (45 kg) with wheels

Weight, 600V with power cord.............................. 160 pounds (73 kg) with wheels

2-4

PECIFICATIONS

Operator Manual

Figure 2-2 Powermax1100 Power Supply Dimensions

10.4"

(264 mm)

19.6"

(498 mm)

25.1"

(638 mm)

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) ............. 1/2" (12 mm) @ 50% duty cycle

Recommended 80A Cutting Capacity (PAC135M) .... 3/8" (9.5 mm) @ 100% duty cycle

Maximum current at 50% duty cycle .......................... 80 amps

Gas Flow .................................................................... 400 scfh/6.7 scfm at 65 psi (189 l/min at

4.5 bar)

Gouging Capability (metal removal rate).................... 6.6 pounds (3.0 kg)/hr

Weight PAC135T ....................................................... 9.3 pounds (4.2 kg) with 25 ft (7.6 m) lead

17.8 pounds (8.1 kg) with 50 ft (15 m) lead

Weight PAC135M....................................................... 9.6 pounds (4.4 kg) with 25 ft (7.6 m) lead

18 pounds (8.2 kg) with 50 ft (15 m) lead

19.6"

(498 mm)

PECIFICATIONS

2-5

Operator Manual

Figure 2-4 PAC135M Torch with Dimensions

PAC135M Machine Torch Assembly

S 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.

Figure 2-3 PAC135T Torch with Dimensions

PAC135T Hand Torch Assembly

4.8"

(122 mm)

3.5"

(89 mm)

1.2"

(30 mm)

1.9"

(48 mm)

9.1"

(231 mm)

1.2"

(30 mm)

1.8"

(45 mm)

55°

3.3"

(83 mm)

14"

(356 mm)

10.8"

(274 mm)

1.4"

(35 mm)

2-6

PECIFICATIONS

Operator Manual

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" characteristic

IEC SYMBOLS USED

3-1

ETUP

Operator Manual

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 .................................................................... 3-6

Single-Phase and Three-Phase Power Configurations..................................... 3-7

Single-Phase................................................................................................ 3-7

Three-Phase ................................................................................................ 3-7

Power Cord Plugs ............................................................................................. 3-8

Power Requirements ........................................................................................ 3-8

Line Voltage Disconnect Box........................................................................ 3-8

Grounding Requirements.................................................................................. 3-8

Work Cable and Clamp..................................................................................... 3-9

Gas Supply Requirements................................................................................ 3-9

Air Supply Quality......................................................................................... 3-9

Additional Air Filtration ............................................................................... 3-10

Nitrogen Supply Quality ............................................................................. 3-10

Gas Supply Connection .................................................................................. 3-10

Torch Lead Connection................................................................................... 3-11

PAC135M ON/OFF Pendant Connection ................................................... 3-11

PAC135M Torch ON/OFF Switch Connection Data ................................... 3-11

PAC135M Torch Alignment ........................................................................ 3-11

Machine Interface with PAC135M................................................................... 3-12

Arc Voltage................................................................................................. 3-13

3-2

ETUP

Operator Manual

UPON RECEIPT

1 . Verify that all parts and items on your order have been received. Alert your distributor if any

parts or items are damaged or missing.

2. Inspect the power supply for any physical damage that may have occurred during shipping. If

there is evidence of damage, refer to the

Claims

section below.

All communications regarding this equipment must include the model number and serial number

located on the back of the Powermax1100.

3. Before setting up and operating the Powermax1100, read the Safety section of this manual.

CLAIMS

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.

Claims for defective or missing merchandise — All units shipped from Hypertherm undergo rigorous

quality control inspections for defects. If any of the merchandise is defective or missing, call your

authorized Hypertherm distributor. If you need additional assistance, call Customer Service at 1 800

643 0030 in the U.S. and Canada, or your authorized Hypertherm distributor.

3-3

ETUP

Operator Manual

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). Use a hoisting machine with a hoisting strap through both handles to

hoist the power supply. Always hoist the power supply with its cover secured in place. Do

not hoist the power supply by one handle; it is not designed to support the weight of the

power supply. Failure to heed this warning could result in personal injury and damage to

the power supply.

1. Use a hoisting strap rated for a minimum hoisting weight of 400 pounds (182 kg). Approved

hoisting straps have attached labels with ratings.

2. Ensure the power supply cover is in place prior to hoisting.

3. Route the strap between the two handles as shown in Fig. 3-1.

4. Bring the strap ends together over the center of the power supply and connect them to the

hoisting machine.

5 . Hoist and lower the power supply slowly and smoothly.

Figure 3-1 Powermax1100 Power Supply Hoisting Setup

Hoisting

Machine

Approved hoisting

strap

Cover in place

HOISTING REQUIREMENTS

In the event that the power supply has to be hoisted, follow the steps below.

3-4

ETUP

Operator Manual

400V or 480V200V or 208V 230V or 240V

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.

Notes: • When switching from the 480V or 400V configuration, use the spare jumper in the clip located

on the floor of the power supply.

• If using the 600V transformer option kit, configure the Powermax1100 for 480V.

WARNING

SHOCK HAZARD: Always turn off the power, unplug the cord and wait 5 minutes before

removing any power supply cover. If the power supply is directly connected to a line

disconnect switch, place switch in the OFF position. In the U.S., use a "lock-out / tag-out"

procedure until the service or maintenance work is complete. In other countries, follow

appropriate local or national safety procedures.

Figure 3-3 200V or 208V

Configuration Figure 3-4 230V or 240V

Configuration Figure 3-5 400V or 480V

Configuration

Figure 3-2 Rear Panel

Remove 8 screws to

remove panel

Black

White

Black

White

TB2

TB3

Black

White

Approximate location

of TB2 and TB3

TB2

TB3

TB2

TB3

Jumper

3-5

ETUP

Operator Manual

Input Phase Input Recommended Power Cord Wire Size (mm2)

Voltage Current < 3 m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45 m

200 VAC 1 96A 25 25 25 35 35

230 VAC 1 84A 25 25 25 25 35

400 VAC 1 48A 10 10 10 10 16

200 VAC 3 56A 10 10 16 16 16

230 VAC 3 49A 10 10 10 10 16

400 VAC 3 28A 4 4 4 6 6

5" (140 mm)

7.5" (178 mm)

Ground

Input Phase Input Recommended Power Cord Wire Size (AWG)

Voltage Current < 10 ft 10 – 25 ft 25 – 50 ft 50 – 100 ft 100 – 150 ft

208 VAC 1 92A 4 4 4 2 2

240 VAC 1 80A 6 6 4 4 4

480 VAC 1 40A 8 8 8 8 6

208 VAC 3 53A 6 6 6 6 4

240 VAC 3 46A 8 8 8 6 6

480 VAC 3 23A 10 10 10 10 8

Figure 3-6 Power Cord Stripping for 208/240/480V and 200/230/400V Power Supplies

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. In other

countries, use cords that are certified by local or national codes. Strip the power cord wires as shown in

Fig. 3-6. Cap or tin the conductor leads and use a #10 terminal on the ground wire. The cord should be

installed only by a licensed electrician.

The 600V conversion kit comes with a 10 AWG 7 ft (2 m) power cord. If changing the cord length, use a

10 AWG power cord.

208/240/480V Power supplies

200/230/400V Power supplies

#10

3-6

ETUP

Operator Manual

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" type cord. Strip the power cord wires as shown in Fig. 3-7. Cap or tin

conductor leads and use a #10 terminal on the ground wire. The cord should be installed only by a

licensed electrician.

Input Phase Input Recommended Power Cord Wire Size (mm2)

Voltage Current < 3 m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45m

230 VAC 3 33A 4 4 6 6 6

400 VAC 3 19A 4 4 4 4 4

Figure 3-7 Power Cord Stripping 230/400V CE Power Supplies

5" (140 mm)

7.5" (178 mm)

Ground

Wind the ground wire 8 turns around the toroid

#10

CHANGING THE STRAIN RELIEF SLEEVE

Depending on the diameter of the power cord you choose, the rear panel strain relief sleeve may need

to be changed. Alternate sleeves are located on the floor of the power supply behind the rear panel.

1. Remove strain

relief cap 2. Remove strain

relief sleeve

3. Install new strain

relief sleeve and press

it into place

4. Replace strain relief

cap - After installing

power cord, tighten

cap.

Figure 3-8 Changing a Power Cord Strain Relief Insert

Power Cord Diameter Use

Over 7/8" (22mm) Largest sleeve

3/4" to 7/8" (19mm to 22mm) Second largest sleeve

Under 3/4" (19mm) Smallest sleeve

To choose the correct sleeve, either push

the power cord through the smallest

sleeve that it will go through, or measure

the power cord diameter and use the

adjacent table.

To change a sleeve:

3-7

ETUP

Operator Manual

Conductor Color

L1 (U) Brown or Black

L2 (V) Blue or White

L3 (W) Black or Red

Ground Green/Yellow or Green

Three-Phase

Remove the rear panel (Fig. 3-2) and connect the power cable to the contactor as shown in Fig. 3-10.

Connect the ground wire to the stud marked .

Figure 3-10

Three-Phase Power

Blue

Black

Green/

Yellow

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.

Power cords must meet the specifications described earlier in this section. Follow applicable local or

national wire color conventions. See also EMC Compatibility and

Mains Supply

on page i for further

CE compliance recommendations.

Single-Phase

Remove the rear panel (Fig. 3-2) and connect the power cable to contactor as shown in Fig. 3-9.

Connect the ground wire to the stud marked .

Black

White

Green

Figure 3-9

Single-Phase Power

Brown

Conductor Color

Line (U) Black or Brown

Neutral/Line (V) White or Blue

Ground Green or Green/Yellow

WARNING

SHOCK HAZARD: Always turn off the power, unplug the cord and wait 5 minutes before

removing any power supply cover. If the power supply is directly connected to a line

disconnect switch, place switch in the OFF position. In the U.S., use a "lock-out / tag-out"

procedure until the service or maintenance work is complete. In other countries, follow

appropriate local or national safety procedures.

3-8

ETUP

Operator Manual

POWER CORD PLUGS

The user must obtain a power cord plug that is certified by national or local electrical codes. The plug

should be connected to the power cord by a licensed electrician.

POWER REQUIREMENTS

Line Voltage Disconnect Box

Use a separate line disconnect box for each power supply. This disconnect box allows the operator to

turn the power supply off quickly in an emergency situation. The switch should be located near the

power supply, and should be easily accessible to the operator. The interrupt level of the switch must be

equal to or exceed the continuous rating of the fuses. Use slow-blow fuses according to the power

requirements listed below.

Input Input Current Recommended

Voltage Phase @ 11.2 kw Output Slow-Blow Fuse Size

200 VAC 1 96 amps 125 amp

208 VAC 1 92 amps 125 amp

230 VAC 1 84 amps 110 amp

240 VAC 1 80 amps 110 amp

400 VAC 1 48 amps 70 amp

480 VAC 1 40 amps 60 amp

200 VAC 3 56 amps 80 amp

208 VAC 3 53 amps 70 amp

230 VAC 3 49 amps 70 amp

230 VAC CE 3 33 amps 40 amp

240 VAC 3 46 amps 60 amp

400 VAC 3 28 amps 35 amp

400 VAC CE 3 19 amps 30 amp

480 VAC 3 23 amps 30 amp

600 VAC 3 20 amps 30 amp

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. Single-phase service must be of the 3-wire type with

a green or green/yellow wire for protective earth ground. It must comply with local electrical

requirements. Do not use a 2-wire service! Refer to

Grounding

, in the Safety section. Three-phase

service must be of the 4-wire type with a green/yellow wire for protective earth ground.

3-9

ETUP

Operator Manual

WORK CABLE AND CLAMP

The work clamp must be attached to the workpiece when plasma cutting. Ensure that the work clamp

and the workpiece make good metal-to-metal contact. Attach the work clamp as close as possible to

the area being cut to reduce exposure to electric and magnetic fields (EMF). Do not attach the work

clamp to the portion of the workpiece to be cut away.

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. A high-pressure regulator on either type of supply must be used and must be

capable of delivering the following:

400 scfh/6.7 scfm (189 l/min) at a pressure of 90 psi (6.2 bar) to the filter on

the power supply.

The filter location is shown in Fig. 3-13.

WARNING

Do not allow the gas inlet pressure to the filter on the power supply to exceed 120 psi (8.2

bar). The plastic filter bowl is rated for 150 psi (10.3 bar) and may explode if this pressure

is exceeded. See the label on the filter bowl for other safety warnings.

Air Supply Quality

The cylinder or shop compressed air supply must be clean, dry and oil-free. If air supply quality is poor,

cut speeds decrease, cut quality deteriorates, cutting thickness capability decreases, and parts life

shortens.

Figure 3-11 Proper Work Clamp Connection

3-10

ETUP

Operator Manual

Additional Air Filtration

Use a three-stage coalescing filtration system as shown in Fig. 3-12 when site conditions introduce

moisture, oil or other contaminants into the air line.

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. (Note: These conditions also occur if there are leaks in the gas supply hoses or

connections.) The nitrogen supply can be compressed gas cylinders or liquid containers.

GAS SUPPLY CONNECTION

Use a 3/8 inch (9.5 mm) ID inert gas hose to connect the gas supply (air or nitrogen) to the power

supply filter. To connect the hose, install a 1/4 NPT nipple to the filter block as shown in Fig. 3-13.

Apply liquid pipe sealant to the threads to ensure a leak-free installation. A nipple and adapters are

included in the consumable parts kit.

CAUTION: Never use 37)( 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.

Figure 3-13 Rear Panel, Gas Supply Connection to Filter

Filter

From air

supply To

Powermax1100

Water/particle filter Oil filter Oil vapor filter

Figure 3-12 Recommended Three-Stage Air Filtration System

1/4 NPT Nipple

Gas Supply

Hose Connection

3-11

ETUP

Operator Manual

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. Before tightening, turn the connector securing ring 1/4 turn to the left to ensure that the securing

ring threads and the connector receptacle threads are aligned.

3. Turn the securing ring to the right to tighten.

PAC135M ON/OFF Pendant Connection

To connect the on/off pendant lead to the PAC135M machine torch pigtail:

1. Align the pendant lead connector key plug with the connector receptacle key slot on the pigtail

and push in until the pins seat.

2. Turn the connector securing ring to the right to tighten.

PAC135M Torch ON/OFF Switch Connection Data

The PAC135M torch lead is supplied with a pigtail so that the on/off pendant may be used. If you want

to use a different on/off switch configuration, note that the wiring configuration to the 3-socket female

receptacle on the pigtail is as follows:

WARNING

Do not connect the cutting machine interface START signal if using the

ON/OFF pendant! (See page 3-12)

Socket A White Wire

Socket B Not Used

Socket C Black Wire

PAC135M Torch Alignment

Make sure that the machine torch is mounted at right angles to the workpiece in order to get a vertical

cut. Use a square to align the torch at 0° and 90° as shown in Fig. 3-14.

3-12

ETUP

Operator Manual

Torch - (typical)

Figure 3-14 Aligning the Machine Torch with Square

0°90°

Figure 3-15 Machine Interface Cable 023206 and Signals

MACHINE INTERFACE WITH PAC135M

Signals for arc transfer, start, and arc voltage are available on power supplies that have the machine

interface option.

• Plug the machine interface cable into the connector on the rear panel and connect the machine

interface cable to the cutting machine.

WARNING

Do not connect the cutting machine interface START signal if using an ON/OFF pendant!

Signal:

Type:

Notes:

Rear panel

sockets

Cable wires

START (start plasma)

Input

Normally open. 24 VAC open circuit voltage

at START terminals.

Requires dry contact closure to activate.

3, 4

Green, Black

XFER (start machine motion)

Output

Normally open. Dry contact closure when arc

transfers. 120 VAC maximum at machine

interface relay or switching device.

12, 14

Red, Black

Green

Black

Red

Black

3-13

ETUP

Operator Manual

ARC VOLTAGE (torch height control)

Output

Full arc voltage. No voltage divider.

300 VDC maximum.

(Signal not available on rear panel

connector.)

+VDC

-VDC

Arc Voltage

If arc voltage is necessary for activating a torch height control, the customer must supply an 18 AWG,

single pair, unshielded cable rated for 300V or greater. The arc voltage signal should be connected

only by qualified service personnel.

1. Disconnect power from Powermax1100.

2. Remove the screws that attach Powermax1100 cover to the chassis. Remove the cover.

3. Push the cable through the strain relief at the rear of Powermax1100.

Figure 3-17 Machine Interface Board Connections for Arc Voltage

Figure 3-16 Location of Arc Voltage Cable Strain Relief

Strain Relief - arc voltage cable

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.

START

XFER

ARC

VOLTAGE

Signal:

Type:

Notes:

J1-6

J1-8

WARNING

SHOCK HAZARD: Always turn off the power, unplug the cord and wait 5 minutes before

removing any power supply cover. If the power supply is directly connected to a line

disconnect switch, place switch in the OFF position. In the U.S., use a "lock-out / tag-out"

procedure until the service or maintenance work is complete. In other countries, follow

appropriate local or national safety procedures.

PERATION

4-1

Operator Manual

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..................................................................................................... 4-10

Gouging .....................................................................................................4-11

Cut Chart - 80A Standard Consumables ....................................................... 4-12

Cut Chart - 40A Consumables ...................................................................... 4-13

Common Cutting Faults ................................................................................ 4-14

4-2

PERATION

Operator Manual

CONTROLS AND INDICATORS

• Green POWER ON LED

When illuminated, indicates that all control circuits are activated, the torch safety interlock is

satisfied and the system is ready for operation.

• Yellow LINE VOLTAGE LED

When illuminated, indicates that the AC line voltage is below proper operating limits.

• Yellow TEMP LED

When illuminated, indicates that the power supply temperature has exceeded operating limits.

• Green GAS PRESSURE LED

When illuminated, indicates that the gas pressure is within operating limits.

• GAS TEST Switch

When pushed in, allows the operator to adjust the pressure setting.

• AMPS Output Adjustment Knob

Adjusts output current between 30 and 80 amps.

• Pressure Regulator

Regulates input gas pressure to the power supply.

• Pressure Gauge

Indicates gas pressure at the power supply.

• ON (I)/OFF (0) Power Switch

Activates the power supply and its control circuits.

GAS

PRESSURE

AMPS

ON (I)/OFF (0) Power Switch

POWER

LINE

VOLTAGE TEMP GAS

TEST

Figure 4-1 Powermax1100 Controls and Indicators

Pressure Gauge Pressure Regulator

4-2 Operator Manual

PERATION

4-3

Operator Manual

OPERATING INSTRUCTIONS

1. Ensure that the work environment and your clothing meet the safety requirements outlined in

the Safety section.

2. Follow the instructions in the Setup section. Verify that the input gas supply pressure is set to

90 psi (6.2 bar).

3. At the rear of the power supply, set the power switch to the ON (I) position. The POWER ON

and GAS PRESSURE LEDs should illuminate. The LINE VOLTAGE LED will blink and then

extinguish. The TEMP LED will remain extinguished.

4. Adjust the gas pressure REGULATOR to 65 psi (4.5 bar):

• Pull the REGULATOR CAP out

• Push the GAS TEST switch in

• Turn the REGULATOR CAP while still pushing in the GAS TEST switch

• After adjusting to 65 psi (4.5 bar), release the GAS TEST switch

• Push the REGULATOR CAP back in

Note: If using 50 ft (15.2 m) torch leads, adjust the pressure to 70 psi (4.8 bar).

5. Adjust the AMPS knob to the desired setting. See

Cut Chart

later in this section if necessary.

WARNING

Before operating this system, read the Safety section of this manual thoroughly!

PRESSURE GAUGE

Figure 4-2

Powermax1100 Operating Indicators and Adjustments

REGULATOR

AMPS

GAS TEST

REGULATOR

CAP

POWER ON

GAS PRESSURE

4-4

PERATION

Operator Manual

6. Attach the work clamp securely to the workpiece. Do not attach it to the portion that will fall

away.

Figure 4-3 Proper Work Clamp Connection

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.

To begin cutting from within the workpiece see

Piercing

later in this section.

8. As the torch moves across the workpiece, the arc will transfer from the torch to the workpiece.

Move the torch in the desired direction, at a speed which will ensure good cut quality. When

using shielded consumables, drag the torch tip directly on the workpiece. See

Operating Tips

and

Cut Charts

later in this section.

9. When the cut is finished, release the torch switch to extinguish the arc. The arc will also extin-

guish when transfer to the workpiece is no longer sensed.

Pilot Arc Controller (Optional)

In power supplies with the pilot arc controller option, the torch will return to a pilot arc after finishing a

cut if the torch switch remains pressed. After 5 seconds, the pilot arc will then extinguish if no arc

transfer is sensed. The pilot arc controller option is especially useful if you are cutting expanded metal.

See

Powermax1100 Field Upgrade Kits and Optional Parts

in Section 5 for part number information.

WARNING

The PAC135 torches are contact-start torches that produce a plasma arc immedi-

ately after the torch start switch closes. Always hold the hand torch away from

your body as a precaution against accidental torch firing. Be aware of this haz-

ardous potential. Failure to do so can result in serious bodily injury.

PERATION

4-5

Operator Manual

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.

Safety Off position. In this position,

the trigger can be pulled back so that

the torch can be fired.

Release the safety to return to the

Safety On position as shown in step 1.

Figure 4-4 PAC135T Torch Safety Trigger Operation

4-6

PERATION

Operator Manual

OPERATING TIPS

Changing Consumable Parts

1. Unscrew the retaining cap. The nozzle will be released when the retaining cap is removed.

2. 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.

3. Unscrew the shield from the retaining cap. Inspect the gas holes from the inside. The holes

should be clear of metal debris. If the gas holes are blocked by debris, try to open them by

pushing a pin through each one from the outside of the shield to the inside. If the shield is still

good, screw it back on to the retaining cap. If it is damaged, replace it with a new one.

4. Inspect the nozzle for damage or wear. If the hole in the nozzle is worn or oval-shaped, replace

the nozzle.

5. Using the electrode wrench supplied in the consumable parts kit, unscrew the electrode from

the torch body. The swirl ring will be released when the electrode is removed.

6. Inspect the electrode. If the center of the electrode has a pit more than 1/16 inch (1.6 mm)

deep, replace it.

7. Inspect the swirl ring. It should be clean, and the holes along the side should not be plugged. If

the swirl ring is damaged, replace it.

8. Inspect the O-ring on the torch. It should be lubricated and undamaged. If it is dry, lubricate it

with a thin film of the lubricant provided in the consumable parts kit. If it is damaged, replace it.

9. Replace the consumable parts as shown in Fig. 4-5.

10. When the retaining cap is tightened, the circuit between the pin contacts located on the torch

head will close, indicating that the torch is again ready for operation. Plug the power cord back

in, or place the line disconnect switch to the ON position.

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.

In the U.S., use a "lock-out / tag-out" procedure until the service or maintenance work is

complete. In other countries, follow appropriate local or national safety procedures.

PERATION

4-7

Operator Manual

Retaining Cap

120520 - 40A

Retaining Cap

120483 - 80A

Electrode

120473 Swirl Ring

120474 PAC135T

Torch

Hand Shield

120475

Figure 4-5 Consumables

Nozzle

120515 - 40A

Shield

120510 Nozzle

120509

O-Ring

026020

Nozzle

120476 - 80A

Gouging

Shielded - 80A, 40A

Extended

Deflector

120519 Nozzle

120518 Electrode

120517

Retaining Cap

120483

Retaining Cap

120483

Machine Shield

120516

Electrode

120473

Description of Consumables

•Shielded 80A For cutting above 40A. Shielded nozzle allows the torch tip to be dragged directly on the

workpiece.

•Shielded 40A For optimal cutting on thinner materials at or below 40A.

•Extended For increased visibility and access for special applications. The nozzle is not shielded.

Maintain a standoff distance from the workpiece of approximately 1/8" (3 mm) when

cutting above 40A to avoid accelerated consumable parts wear. Use only with the

machine torch in CE countries.

•Gouging For metal removal without cutting. Use for weld removal or setup. Nozzle shield may be

placed directly on the workpiece.

1-98

4-8

PERATION

Operator Manual

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.

• Start cutting from the edge of the workpiece (Fig. 4-6). To penetrate fully and cut cleanly

through the workpiece, pause momentarily at the beginning and at the end of each cut.

• When cutting, make sure that the sparks are coming out of the bottom of the workpiece. If they

are spraying on top of the workpiece, you are moving the torch too fast, or you do not have

sufficient power to fully penetrate the workpiece.

• Hold the torch lightly on the metal (if using shielded consumables) or just above the metal.

Holding the torch firmly to the workpiece causes the shield to stick and makes smooth cutting

difficult. The arc transfers to the workpiece once the torch is within 1/8 inch (3 mm) of the

workpiece.

• Pulling the torch through the cut is easier than pushing it.

• Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line (Fig. 4-8).

By lightly dragging the shield on the workpiece, you can maintain a steady cut. For straight-line

cuts, use any straight edge as a guide.

• When cutting thin material, reduce the amps until you get the best quality cut.

• To cut circles, use a template or a radius cutter attachment (Fig. 4-7).

Figure 4-6 Starting a Cut

PERATION

4-9

Operator Manual

Figure 4-8 Dragging the Torch

Figure 4-7 Cutting a Circle

4-10

PERATION

Operator Manual

1. Tilt the torch and press the start button.

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. This is particularly important when cutting thicker

material. Make sure that the torch is pointed away from you and the people near you to avoid

any danger from sparks and hot metal.

• When the pierce is complete, bring the torch head to a perpendicular position and proceed with

the cut.

Figure 4-9 Piercing

2. Rotate the torch to an upright position.

PERATION

4-11

Operator Manual

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.

• Install the gouging nozzle and shield the same as a standard cutting nozzle and shield. See

Changing Consumable Parts

earlier in this section.

• Adjust the air pressure to 60–65 psi (4.1–4.5 bar) with air flowing from the torch. Note that this

is lower than the cutting pressure.

• Tilt the torch approximately 45° from the surface to be gouged and push the torch in the desired

direction. Multiple passes or "wearing" may be necessary to gouge wider and deeper sections.

Figure 4-10 Gouging

Direction of travel

45°

3-98

4-12

PERATION

Operator Manual

Recommended

Material Arc Arc Travel Pierce

Thickness Material Current Voltage Speed* Delay

(in.) (mm) (A) (V) (ipm) (mm/min ) (S)

3/16" 4.8 Mild steel 80 115 160 4060 0

1/4" 6.4 Mild steel 80 117 110 2800 0.25

3/8" 9.5 Mild steel 80 116 57 1450 0.50

1/2" 12.7 Mild steel 80 120 38 965 0.75

5/8" 15.9 Mild steel 80 124 25 635 1.75

3/4" 19.0 Mild steel 80 124 20 510 n/a

7/8" 22.2 Mild steel 80 132 14 355 n/a

1" 25.4 Mild steel 80 133 11 280 n/a

3/16" 4.8 Stainless Steel 80 120 160 4060 0.25

1/4" 6.4 Stainless Steel 80 121 100 2540 0.50

3/8" 9.5 Stainless Steel 80 122 53 1345 1.00

1/2" 12.7 Stainless Steel 80 123 32 810 1.25

5/8" 15.9 Stainless Steel 80 123 25 635 1.75

3/4" 19.0 Stainless Steel 80 126 18 460 n/a

1" 25.4 Stainless Steel 80 133 10 255 n/a

1/8" 3.2 Aluminum 80 119 340 8640 0

1/4" 6.4 Aluminum 80 120 140 3560 0.25

3/8" 9.5 Aluminum 80 122 90 2285 0.50

1/2" 12.7 Aluminum 80 129 60 1525 1.00

3/4" 19.0 Aluminum 80 131 31 790 n/a

* Recommended travel speeds are 10–20% slower than maximum. These slower speeds will produce optimum

cut quality.

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

120516 Retaining Cap

120483 - 80A Electrode

120473 Swirl Ring

120474

Nozzle

120476 - 80A

PERATION

4-13

Operator Manual

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

120516 Retaining Cap

120520 - 40A Electrode

120473 Swirl Ring

120474

Recommended

Material Arc Arc Travel Pierce

Thickness Material Current Voltage Speed* Delay

(ga. or in.) (mm) (A) (V) (ipm) (mm/min ) (S)

26 ga. 0.5 Mild steel 30 116 510 12950 0

22 ga. 0.8 Mild steel 30 116 360 9140 0

20 ga. 0.9 Mild steel 30 116 240 6100 0

18 ga. 1.2 Mild steel 30 118 210 5330 0

16 ga. 1.5 Mild steel 30 118 120 2050 0

14 ga. 1.9 Mild steel 40 117 200 5080 0.25

10 ga. 3.4 Mild steel 40 121 100 2540 0.50

3/16" 4.8 Mild steel 40 116 70 1780 1.00

1/4" 6.4 Mild steel 40 119 42 1070 1.25

3/8" 9.5 Mild steel 40 126 19 480 n/a

1/2" 12.7 Mild steel 40 131 14 355 n/a

26 ga. 0.5 Stainless steel 30 116 520 13200 0

22 ga. 0.8 Stainless steel 30 116 260 6600 0

20 ga. 0.9 Stainless steel 30 117 170 4320 0

18 ga. 1.2 Stainless steel 40 116 310 7870 0

16 ga. 1.5 Stainless steel 40 117 200 5080 0

14 ga. 1.9 Stainless steel 40 115 170 4320 0.25

10 ga. 3.4 Stainless steel 40 118 70 1780 0.50

3/16" 4.8 Stainless steel 40 119 48 1220 1.00

1/4" 6.4 Stainless steel 40 120 35 890 1.50

3/8" 9.5 Stainless steel 40 125 16 410 n/a

1/2" 12.7 Stainless steel 40 126 11 280 n/a

1/32" 0.8 Aluminum 30 117 600 15240 0

1/16" 1.6 Aluminum 30 117 240 6100 0

3/32" 2.4 Aluminum 40 117 250 6350 0.25

1/8" 3.2 Aluminum 40 117 170 4320 0.50

1/4" 6.4 Aluminum 40 122 53 1350 1.50

3/8" 9.5 Aluminum 40 132 28 710 n/a

Nozzle

120515 - 40A

* Recommended travel speeds are 10–20% slower than maximum. These slower speeds will produce optimum

cut quality.

4-14

PERATION

Operator Manual

Cut Chart Notes:

The cut charts are optimized to provide the best cut angle, least dross and best cut surface finish. Remember

that cut charts are intended to provide a good starting point for each cutting assignment. Every cutting

system requires "fine-tuning" each cutting set up to the materials on site, in order to obtain optimum cut

quality.

• Maximum recommended mechanized cutting capacity with 80A consumables: 1/2 inch

(12 mm) on mild steel, and 3/8 inch (9.5 mm) on stainless steel and aluminum.

• A manual machine motion signal must be given in mechanized applications when cutting material thinner

than 18 gauge (1.2 mm).

• See page 4-7 or Section 5 for additional consumable parts.

• Compressed air or nitrogen must be available to the power supply filter/pressure regulator at a flow rate of

400 scfh/6.7 scfm (189 l/min) at a pressure of 90 psi (6.2 bar). The dynamic (flowing) pressure when

operating is 65 psi (4.5 bar). If torch leads are 50 ft (15.2 m), the dynamic pressure when operating is 70

psi (4.8 bar). If the pressure to the power supply falls below 40 psi (2.8 bar), the torch will extinguish.

• After several minutes of running, the torch retaining cap may become hot. To cool it, push in and hold the

GAS TEST switch until the cap cools down.

• 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° F (40° C). At these conditions, the plasma arc can remain on 5

minutes out of every 10 minutes without causing the temperature sensors to disable the unit. The duty

cycle increases to 100% at a temperature of 104° F (40° C) when the current is set below 57 amps.

• To avoid performance deterioration of the Powermax1100, input voltage should be within 10% of the

specified system line voltage setting.

• When using extended consumables, maintain a torch-to-work distance of approximately 1/8" (3 mm)

when cutting above 40A to avoid accelerated consumable parts wear. The torch will extinguish if the

nozzle is pressed back against the electrode.

COMMON CUTTING FAULTS

• If the workpiece is not totally penetrated,

- The current may be too low.

- The cut speed may be too high.

- The torch parts may be worn.

- The metal being cut may be too thick.

- The work clamp may not be properly attached to the workpiece.

• If dross forms on the bottom of the cut,

- The cutting speed may be too slow.

- The torch parts may be worn.

- The metal being cut may be too thick.

- The current may be too low.

AINTENANCE

ARTS

5-1

Operator Manual

Section 5 MAINTENANCE/PARTS

Introduction ..................................................................................................... 5-2

Routine Maintenance ...................................................................................... 5-2

Bowl Draining and Filter Element Cleaning ................................................ 5-2

Removal, Cleaning and Replacement of the Cooling Air Filter................... 5-3

Basic Troubleshooting ..................................................................................... 5-4

Technical Questions ........................................................................................ 5-7

Parts ................................................................................................................ 5-8

PAC135 Consumable Parts ........................................................................ 5-8

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

In this section:

Operator Manual

5-2

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. If moisture builds up in the bowl of the filter, drain the bowl and clean the filter element:

1. Shut off the gas supply and disconnect the gas supply hose from the filter assembly before

proceeding.

2. Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to

release water from the bowl.

3. Unscrew the filter bowl.

4. Unscrew the filter element.

5. Clean the filter element with alcohol, then blow it out with air.

Clean the bowl with household soap only.

6. Replace the filter element and filter bowl.

7. Reconnect the gas supply hose.

Figure 5-1 Filter Assembly

Gas supply hose

connection

Filter element

Filter Bowl

Cap

AINTENANCE

ARTS

5-3

Operator Manual

Removal, Cleaning and Replacement of the Cooling Air Filter

Powermax1100 systems are normally shipped without an air filter. If your Powermax1100 has the air

filter option, the filter will need cleaning periodically. Excessively dirty or dusty environments can block

the filter (if installed) and cause the power supply to overheat and shut down.

Figure 5-2 Air Filter Removal

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.

2. Remove the screws that secure the power supply cover to the chassis.

3. Remove the cover, and remove the cooling air filter from the clips by sliding the filter to the left

and then up.

4. Clean the air filter with either soap and water or with low-pressure compressed air.

5. Replace the dry filter in the power unit with the wire mesh facing the fan.

6. Replace and refasten the power supply cover's screws.

WARNING

SHOCK HAZARD: Always turn off the power, unplug the cord and wait 5 minutes before

removing any power supply cover. If the power supply is directly connected to a line

disconnect switch, place switch in the OFF position. In the U.S., use a "lock-out / tag-out"

procedure until the service or maintenance work is complete. In other countries, follow

appropriate local or national safety procedures.

Operator Manual

5-4

AINTENANCE

ARTS

1.1 The power cord is not plugged into the

power receptacle.

Plug in the power supply.

1.2 The disconnect power switch is not set to

ON or there is no power available to the

disconnect power switch box.

Turn the power ON at the main power panel

or at the disconnect power switch box.

2.1 The gas supply is turned OFF or not

connected to the power supply.

Verify that the gas is turned on and

connected to the power supply.

2.2 Gas pressure is too low.

Set gas supply pressure to 90 psi (6.2 bar).

Verify that there are no leaks in the gas

supply line.

3.1 Power supply voltage links are incorrect.

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.

BASIC TROUBLESHOOTING

ON/OFF

Power Switch

POWER

LINE

VOLTAGE TEMP GAS

PRESSURE

Problem

1. The ON/OFF power switch is set to I (ON),

but the fan does not operate and the

POWER ON LED is not illuminated.

2. The POWER ON LED is illuminated but the

GAS PRESSURE LED is not illuminated.

3. The POWER ON LED is illuminated and the

LINE VOLTAGE LED is illuminated.

Cause

/ Solution

AINTENANCE

ARTS

5-5

Operator Manual

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. To avoid

performance deterioration, the input voltage

should be within +/-10% of the System Line

Voltage. System

Lower Limit Line Voltage Upper Limit

170VAC 200VAC 235VAC

178VAC 208VAC 239VAC

195VAC 230VAC 270VAC

204VAC 240VAC 276VAC

340VAC 400VAC 470VAC

408VAC 480VAC 552VAC

510VAC 600VAC 690VAC

4.1 The retaining cap is loose.

Tighten the retaining cap.

4.2 The torch is defective.

See

Technical Questions

on page 5-7.

5.1 Power supply voltage links are incorrect.

See voltage configuration settings in

Section 3.

5.2 Line voltage is too high.

See the table above.

6.1 The power supply has exceeded the

capacity of the fuse.

Check the fuse for proper amperage rating.

See

Power Requirements

in Section 3.

Check power cable for a short circuit or loose

connection.

7.1 One of the internal thermostat switches

has opened due to overheating.

Leave power supply on to allow the fan to

cool the power supply down, then shut the

power supply down and restart. Clean the

internal air filter (if installed). See

Removal,

Cleaning and Replacement of the Cooling Air

Filter

earlier in this section.

4. The power supply shuts off immediately

after it is switched on.

5. The power supply shuts off approximately

5 seconds after it is switched on.

6. The fuse on the incoming power line fails

during cutting.

7. The POWER ON LED is illuminated, the

TEMP LED stays illuminated and the torch

will not fire.

Problem

Cause

/ Solution

Operator Manual

5-6

AINTENANCE

ARTS

Problem

Cause

/ Solution

8. The arc does not transfer after 5 seconds.

9. The arc blows out, but reignites when the

torch switch is depressed.

10. The torch sputters and hisses.

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.

Connect or repair the work clamp.

8.3 The work clamp is not making good metal-to-

metal contact.

Verify that the work clamp is properly attached to

the workpiece. Remove paint or any coating on

the workpiece before attempting to cut.

8.4 The workpiece is too far away from the torch.

Move the torch head closer (1/8 inch (3 mm)

maximum distance) to the workpiece and start

the torch again.

9.1 There are faulty consumable parts.

Inspect and change the consumable parts, if

necessary. See

Operating Tips

in Section 4.

9.2 The gas pressure is incorrect.

See

Operating Instructions

in Section 4 to adjust

the gas pressure, if necessary.

9.3 The gas filter at the rear of the supply

contains excessive moisture.

Drain the filter bowl and clean the filter. See

Routine Maintenance

earlier in this section.

9.4 When using extended consumables, the

torch nozzle is being pressed against the

electrode.

Maintain a torch-to-work distance of

approximately 1/8" (3 mm) when using

extended consumables..

9.4 The torch is defective.

See

Technical Questions

on page 5-7.

10.1 The gas filter at the rear of the supply

contains excessive moisture.

Drain the filter bowl and clean the filter. See

Routine Maintenance

earlier in this section.

AINTENANCE

ARTS

5-7

Operator Manual

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.

2. Call the nearest Hypertherm office, listed in the front of this manual.

3. See the Powermax1100 service manual for wiring diagrams, higher level troubleshooting and

more parts list information.

11. The torch cuts poorly.

Problem

Cause

/ Solution

11.1 Power supply voltage links are incorrect.

See voltage configuration settings in

Section 3.

11.2 Torch consumables are worn.

See

Operating Tips

in Section 4.

11.3

Line voltage is too low.

See Cause/Solution 3.2.

Operator Manual

5-8

AINTENANCE

ARTS

PARTS

PAC135 Consumable Parts

Figure 5-3 PAC135 Consumable Parts

See page 4-7 for a description

of the consumable parts

Retaining Cap

120520 - 40A

Retaining Cap

120483 - 80A

Electrode

120473 Swirl Ring

120474

Hand Shield

120475

Nozzle

120515 - 40A

Shield

120510 Nozzle

120509

Nozzle

120476 - 80A

Gouging

Shielded - 80A, 40A

Extended

Deflector

120519 Nozzle

120518 Electrode

120517

Retaining Cap

120483

Retaining Cap

120483

Machine Shield

120516

Electrode

120473

AINTENANCE

ARTS

5-9

Operator Manual

Machine Consumable Parts Kit (128149)

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 ................Shield, PAC135 Gouging

120519 ................Deflector, PAC135

026020 ................O-Ring, .864 X .070

027055 ................Lubricant, Silicone 1/4 Oz Tube

027526 ................Electrode Wrench, PAC135

015152 ................Nipple, 1/8 NPT,QDisc, Steel

015570 ................Bushing, Reducer, 1/4 X 1/8, Brass

001285 ................Box, Consumable Parts

Part Number Description

120473 ................Electrode, PAC135

120476 ................Nozzle, PAC135, 80A

120509 ................Nozzle, PAC135 Gouging

120475 ................Shield, PAC135 Hand

120510 ................Shield, PAC135 Gouging

026020 ................O-Ring, .864 X .070

027055 ................Lubricant, Silicone 1/4 Oz Tube

027526 ................Electrode Wrench, PAC135

015145 ................Adapter, 1/4NPT X G 1/4 Hose

001285 ................Box, Consumable Parts

Part Number Description

120473 ................Electrode, PAC135

120516 ................Shield, PAC135 Machine

120476 ................Nozzle, PAC135, 80A

120515 ................Nozzle, PAC135, 40A

120520 ................Cap, PAC135, 40A

026020 ................O-Ring, .864 X .070

027055 ................Lubricant, Silicone 1/4 Oz Tube

027526 ................Electrode Wrench, PAC135

015152 ................Nipple, 1/8 NPT, QDisc, Steel

015570 ................Bushing, Reducer, 1/4 X 1/8, Brass

001285 ................Box, Consumable Parts

Consumable Parts Kits

Consumable Parts Kit - CE (128170)

Operator Manual

5-10

MAINTENANCE/PARTS

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

1 001615 Handle, PAC135T 1

2 075497 #6 X 5/8 Pillips Head, Pan Head 5

3002299 Safety Trigger Assembly, PAC135T 1

4005212 Switch Assembly, Cap on Sensor 1

120473 Electrode, Air: PAC135 1

120474 Swirl Ring: PAC135 1

120475 Shield: PAC135 80A 1

120476 Nozzle: PAC135 80A Shield 1

120483 Retaining Cap: PAC135 1

5120477 Torch Main Body, PAC135T 1

6 026020 O-Ring: Silicon .864 X .070 1

7129559* Torch Lead, 25 ft (7.6 m) 1

7129560** Torch Lead, 50 ft (15.2 m) 1

8 005247 Push Button Switch: Lo-Profile 1

9 128122 Plug Assembly: PAC135T Torch Quick Disconnect 1

10 074069 Splice:22-18 Butt 2

11 046056 Tubing:5/8" ID 4"

12 046072 Heatshrink:1/2" ID 2.5"

* Used only in 085001 ** Used only in 085061

Note: See page 5-8 for detail of consumable parts

Figure 5-4 PAC135T Torch Assembly and Leads

7-99

MAINTENANCE/PARTS

5-11

Operator Manual

Figure 5-5 PAC135M Torch Assembly and Leads

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. Part No. Description Qty.

1 020243................ Sleeve, Torch Position 1

2 129240* .............. Torch Lead, 14 ft (4.3 m) 1

2 129241** ............. Torch Lead, 25 ft (7.6 m) 1

2 129242*** ........... Torch Lead, 35 ft (10.6 m) 1

2 129243**** .......... Torch Lead, 50 ft (15.2 m) 1

3 128122...................... Plug Assembly:PAC135 Torch Quick Disconnect 1

4 008268...................... Plug:3-Socket Female 1

5 108034...................... Receptacle Housing:2-Position 26-22AWG 1

120473................ Electrode 1

120474................ Ring, Swirl 1

120516................ Shield: PAC135M Machine Torch 1

120476................ Nozzle: PAC135 80A Shield 1

120483................ Cap, Retaining 1

6120508................ Torch Main Body, PAC135M 1

7 026020...................... O-Ring: Silicon .864 X .070 1

8 108035...................... Pin Housing:2-Position 26-22AWG 1

9 108040...................... Contact:PAC135M Cap-On Sensor Switch 1

10 046056...................... Tubing:5/8" ID 4"

11 046072...................... Heatshrink:1/2" ID 2.5"

* Used only in 085062 assembly *** Used only in 085064 assembly

** Used only in 085063 assembly **** Used only in 085065 assembly

Note: See page 5-8 for detail of consumable parts

234

910

Operator Manual

5-12

AINTENANCE

ARTS

Powermax1100 Field Upgrade Kits and Optional Parts

Part Number Description

028714 ................................... On/Off Pendant with Lead, 25 ft (7.6 m) (Also comes standard with most

machine torch system configurations.)

128061 ................................... On/Off Pendant with Lead, 50 ft (15.2 m)

128062 ................................... On/Off Pendant with Lead, 75 ft (23 m)

128142 ................................... Kit: Wheels, Powermax1100

128143 ................................... Kit: Pilot Arc Controller, Powermax1100

128144 ................................... Kit: Machine Interface, Powermax1100, 208/240/480V

128168 ................................... Kit: Machine Interface, Powermax1100, 200/230/400V

128169 ................................... Kit: Machine Interface, Powermax1100, 230/400V CE

128145 ................................... Kit: Work Cable, 50 ft (15.2 m), Powermax1100

128146 ................................... Kit: Cooling Air Filter, Powermax1100

128147 ................................... Kit: 600V Conversion, Powermax1100

011079 ................................... Filter Element: Gas Supply Filter

129146 ................................... Jumper: Powermax1100 Link Box

023206 ................................... Cable: Machine Interface, 25 ft (7.6 m) (Comes standard with machine torch

system configurations and with machine interface kits.)

109068 ................................... Toroid for power cord ground, Powermax1100 (CE power supplies only)

002282 ................................... Strain Relief Sleeve: 0.875

002283 ................................... Strain Relief Sleeve: 0.750

002286 ................................... Strain Relief Sleeve: 0,625 - Shipped in CE power supply rear panels

Note: Field upgrade kits must be installed by qualified service personnel.

POWER SUPPLIES - 208/240/480V, 1φ/3φ, 50/60 HZ

Part For With Pilot Arc With Machine

Number Torch Type Control Interface

085000 Hand No No

085012 Hand Yes No

085013 Machine No Yes

085014 Machine Yes Yes

POWER SUPPLIES - 200/230/400V, 1φ/3φ, 50/60 HZ

Part For With Pilot Arc With Machine

Number Torch Type Control Interface

085002 Hand No No

085034 Hand Yes No

085035 Machine No Yes

085036 Machine Yes Yes

POWER SUPPLIES - 230/400V CE, 3φ, 50-60 HZ

Part For With Pilot Arc With Machine

Number Torch Type Control Interface

085003 Hand No No

085023 Hand Yes No

085025 Machine No Yes

085024 Machine Yes Yes

Note: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations.

STANDARDS INDEX

The

Standards Index

contains a list of publications dealing with plasma arc cutting equipment safety

practices.

1. 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.

2. NIOSH,

Safety and Health in Arc Welding and Gas Welding and Cutting

, obtainable from the

Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

3. OSHA,

Safety and Health Standards

, 29FR 1910, obtainable from the U.S. Government Printing Office,

Washington, D.C. 20402.

4. ANSI Standard Z87.1,

Safe Practices for Occupation and Educational Eye and Face Protection

, obtainable

from the American National Standards Institute, 1430 Broadway, New York, NY 10018.

5. ANSI Standard Z41.1,

Standard for Men's Safety-Toe Footwear

, obtainable from the American National

Standards Institute, 1430 Broadway, New York, NY 10018.

6. ANSI Standard Z49.2,

Fire Prevention in the Use of Cutting and Welding Processes

, obtainable from the

American National Standards Institute, 1430 Broadway, New York, NY 10018.

7. AWS Standard A6.0,

Welding and Cutting Containers Which Have Held Combustibles

, obtainable from the

American Welding Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135.

8. NFPA Standard 51,

Oxygen — Fuel Gas Systems for Welding and Cutting

, obtainable from the National

Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.

9. NFPA Standard 70-1978,

National Electrical Code

, obtainable from the National Fire Protection Association,

470 Atlantic Avenue, Boston, MA 02210.

10. NFPA Standard 51B,

Cutting and Welding Processes

, obtainable from the National Fire Protection

Association, 470 Atlantic Avenue, Boston, MA 02210.

11. CGA Pamphlet P-1,

Safe Handling of Compressed Gases in Cylinders

, obtainable from the Compressed

Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

12. CSA Standard W117.2,

Code for Safety in Welding and Cutting

, obtainable from the Canadian Standards

Association Standard Sales, 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada.

13. NWSA booklet,

Welding Safety Bibliography

, obtainable from the National Welding Supply Association,

1900 Arch Street, Philadelphia, PA 19103.

14. American Welding Society Standard AWS F4.1,

Recommended Safe Practices for the Preparation for

Welding and Cutting of Containers and Piping That Have Held Hazardous Substances

, obtainable from the

American Welding Society, 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135.

15. ANSI Standard Z88.2,

Practices for Respiratory Protection

, obtainable from the American National

Standards Institute, 1430 Broadway, New York, NY 10018.

16. Canadian Electrical Code Part 1,

Safety Standards for Electrical Installations

, obtainable from the Canadian

Standards Association, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W1R3.

a-1

STANDARDS INDEX

PPENDIX

Operator Manual

b-1

AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM

Introduction

When plasma arc cutting aluminum at the water table surface or below water, free hydrogen gas may

be generated by the cutting process. The high temperature of the plasma process causes

disassociation of oxygen and hydrogen from the water in the water table. The hot aluminum, which has

a high affinity for oxygen, then combines with the oxygen leaving free hydrogen.

An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the floor of

the water table to replenish the oxygen content of the water.

Making an Aeration Manifold - Figure b-1

Make an Aeration Manifold with two-inch (50 mm) PVC tubing with one-inch (25 mm) Distribution

Lines connected to it. Drill 1/8 inch (3 mm) holes every six inches (150 mm) in the distribution lines.

Cap the ends of the distribution lines and install the lines so that oxygen is delivered to all parts of the

cutting area.

Connect the manifold to a shop air line. Set a pressure regulator to obtain a steady stream of bubbles.

Figure b-1 Aeration Manifold

Regulated air in

Distribution Lines

Aeration Manifold

PPENDIX

Operator Manual

AERATION MANIFOLD

273 Hypertherm Powermax 1100 Manual

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