Hypertherm MAX200 Instruction Manual Download

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6-16

MAX200

Instruction Manual

PARTS LIST

Recommended Spare Parts

Power Supply

Part
Number

Description

Designator

005044

Switch, toggle SPDT

005121

Pushbutton, green, illmn.

PB1

005122

Pushbutton, red, extended

PB2

005088

Holder, lamp

005168

Bulb, 28VDC

005089

Lens, white

009604

Resistor, variable, 100 K, 1 turn

027080

Fan, 225 CFM, 120 VAC, 50/60 Hz

027079

Fan, 450-550 CFM, 120 VAC, 50/60 Hz

027080

Fan, 225 CFM, 120 VAC, 50/60 Hz

041151*

PCB, THC motherboard

PCB10

041186*

PCB, SA-THC

PCB9

041143

PCB, Control

PCB7

005102

Thermostat, 160°C, 6 Amp

TS1

006014

Valve, solenoid

005093

Switch, pressure, 0-90 psi

PS1

129118

Chopper SA, CH130 CE/LVD

CH1/CH2

009384

Diode, 85 Amp, 1000V, fwd polarity

D1, D2, D3

009385

Diode, 85 Amp, 1000V, rev polarity

D4, D5, D6

041534

PCB, power distribution

PCB6

008322

Fuse, Amp., 250 VAC

008317

Fuse, semiconductor, 125 Amp, 250 V

F3, F4

003021

Relay, 120 VAC

CR1

005130

Switch, pressure, SPDT, 0-15 psi

PS3

029317

Transformer, High Voltage SA

029202

Sensor, current

CS1

006045

Valve, solenoid, coolant return

027005

Filter, coolant, deionizing

011025

Filter/regulator

FR1

011031

Filter Element (used with 011025)

011027

Gauge, high pressure

029325

Coolant Pump SA

029323

Switch, water temperature, 162°F

TS2

029326

Switch, level

LS1

029361

Switch, flow, 0.5 gpm

FS1

028872

Coolant, propylene glycol 30%/
deionized water 70% (standard mixture)

028873

Coolant, propylene glycol 100%

* Power Supplies with THC

Summary of Contents for MAX200

Page 1: ...Machine Torch Plasma Arc Cutting System Instruction Manual 800980 Revision 15 MAX200 EN50199 EN60974 1 ...

Page 2: ... 027005 6 17 Part corrected Torch main body was 020470 changed to 120584 Removed revision reference it said revision 1 next to P N in parentheses 6 18 Retaining cap part number changed from 120837 to 020423 Ohmic contact does not work with 40Amp under water beveling or gouging processes 6 19 Retaining cap part number 020423 and art added to cutting section 6 20 6 22 Retaining cap part number chang...

Page 3: ...Revised coolant mixture 3 22 Added P N 128404 DC relay 4 13 Part number correction 4 19 Part number correction 4 20 General correction 4 21 General correction 4 26 Part number correction 4 11 4 46 Added production cutting recommendation to applicable cut charts 5 1 General correction 5 14 5 15 New Coolant tank 5 21 New 120894 sleeve 5 22 Added diameter to torch sleeve 5 23 Spelling correction 6 7 ...

Page 4: ...achine torch and optional torches 5 24 5 28 Page number shift 6 6 Removed P N reference b 1 Spelling correction diagrams Spelling correction Changed Page Description 800980 Rev 10 to 11 Cover New Revision Title Page New Revision 2 3 General Correction PS P N 5 14 Revise Figure 5 73 New Solenoid valve subassembly 5 15 New Solenoid valve subassembly Ap B New Coolant MSDS Diagrams 013179 Added sheet ...

Page 5: ...to show new designations 3 14 Changed figure to show new designations 3 15 Changed figure to show new designations 3 33 Changed figure to show new designations 4 01 Added STATUS indicators Before Startup to Sect 4 TOC 4 02 Added new STATUS logic Added STATUS indicators Before Startup 4 04 Added See Status Indicators Before Startup to step 5 5 03 Changed part nos of items 1 10 5 07 Changed referenc...

Page 6: ... Serial Numbers beginning with 200 003654 Copyright 2002 Hypertherm Inc All Rights Reserved Hypertherm and Command THC are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Hanover NH USA www hypertherm com ...

Page 7: ...2490 Fax 65 6 841 2489 Technical Service Japan 1952 14 Yata Natsumegi Mishima City Shizuoka Pref 411 0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax Hypertherm UK Ltd 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax France 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S r l Via Torino 2 20123...

Page 8: ...nnection 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 au thorized by a person who is competent to assess whether the changes will increase the ris...

Page 9: ...herm 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 Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against...

Page 10: ... sécurité 1a 2 Suivre les instructions de sécurité 1a 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Les chocs électriques peuvent être fatals 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Mise à la masse et à la terre 1a 4 Les rayons de l arc peuvent brûler les yeux et la peau 1a 4 Sécurité des bouteilles de g...

Page 11: ...ir and Gas Hoses 3 13 Connect the Torch Lead 3 16 Connect the Work Cable 3 16 Grounding 3 16 Work Table 3 16 Work Clamp 3 16 Machine Torch System Installations 3 19 Install the MAX200 without THC Option 3 19 Install the MAX200 with THC Option 3 23 Install the MAX200 with IHS Option 3 31 Adjust the Torch Position 3 40 Install the Water Muffler Option 3 41 Section 4 OPERATION 4 1 Front Panel Control...

Page 12: ... Leads 6 18 MAX200 Machine Torch Consumables 6 18 Consumable Configurations 6 19 Consumable Parts Kits 6 20 MAX200 Machine Torch Assembly 6 21 Machine Torch Lead Assemblies 6 24 Section 7 WIRING DIAGRAMS 7 1 MAX200 Electrical Schematic Block Diagram 013 2 179 9 Sheets Coolant System Schematic Diagram 029 2 313 1 Sheet Appendix A FILTERS a 1 Appendix B PROPYLENE GLYCOL SAFETY DATA b 2 BENZOTRIAZOLE...

Page 13: ...n Kill 1 3 Cutting Can Produce Toxic Fumes 1 3 A Plasma Arc Can Cause Injury and Burns 1 4 Arc Rays Can Burn Eyes and Skin 1 4 Grounding Safety 1 4 Compressed Gas Equipment Safety 1 5 Gas Cylinders Can Explode If Damaged 1 5 Noise Can Damage Hearing 1 5 Pacemaker and Hearing Aid Operation 1 5 A Plasma Arc Can Damage Frozen Pipes 1 5 Additional Safety Information 1 5 Warning Label 1 6 ...

Page 14: ... sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres...

Page 15: ... on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge N...

Page 16: ...rdant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect...

Page 17: ...s possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible PACEMAKER AND HEARING AID OPERATION ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and...

Page 18: ...cutting path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use fo...

Page 19: ...vention des chocs électriques 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Torches à allumage instantané 1a 4 Les rayons de l arc peuvent brûler les yeux et la peau 1a 4 Protection des yeux Protection de la peau Zone de coupage 1a 4 Mise à la masse et à la terre 1a 4 Câble de retour Table de travail Alimentation 1a 4 Sécurit...

Page 20: ...e 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 ...

Page 21: ...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 alimentati...

Page 22: ...sées 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 ...

Page 23: ...e 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 pe...

Page 24: ... peut être fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4...

Page 25: ...MAX200 Instruction Manual 2 1 14 Section 2 SPECIFICATIONS In this section General 2 2 Product Specifications 2 2 MAX200 Power Supplies 2 2 MAX200 CE Power Supplies 2 3 MAX200 Machine Torch 2 4 ...

Page 26: ...re nitrogen and carbon dioxide An EMI filter standard with all 400V CE power supplies 073200 and 073213 meets the CE requirement for filtering incoming power Refer to Appendix D to connect incoming power to the filter and for part numbers specific to the CE power supplies Product Specifications MAX200 Power Supplies The MAX200 is a constant current secondary converter chopper power supply providin...

Page 27: ...sma Gas Inlet Pressure 90 120 psi dynamic flowing Shield Gas Inlet Pressure 90 psi dynamic flowing Plasma Gas Pressure Test Run 13 48 22 48 psi Air 13 44 15 48 psi O2 15 35 17 37 psi N2 23 56 psi H35 Shield Gas Pressure 70 psi Torch Coolant Tank Capacity 2 9 gallons 11 liters refer to Section 3 Torch Coolant System for coolant specifications warning and cautions CE Power Supplies The specification...

Page 28: ...h conforms to the following specifications Maximum cutting thickness 2 inches Maximum current at 100 duty cycle 200 amps Plasma Gas Flow 66 scfh Air 60 scfh N2 70 scfh H35 72 scfh O2 Shield Gas Flow 220 scfh CO2 280 scfh Air 290 scfh N2 Water Coolant Flow Rate 0 8 gpm Weight 2 1 2 lbs 1 13 kg ...

Page 29: ...quirements 3 8 Line Disconnect Switch 3 8 Power Cables 3 8 240 480V Linkboard Configurations 3 9 220 380 400 415V Transformer T1 and T2 Configurations 3 10 Power Gas and Torch Lead Connections 3 12 Connect the Power Cable 3 12 Connect the Air and Gas Hoses 3 13 Connect the Torch Lead 3 16 Connect the Work Cable 3 16 Grounding 3 16 Work Table 3 16 Work Clamp 3 16 Machine Torch System Installations ...

Page 30: ...ded Alert your distributor if any of the items or parts are missing All communications regarding this equipment must include the model number and serial number located on the back of the MAX200 See the Claims and Technical Questions in this section for details MAX200 System Machine Torch Configuration MAX200 Power Supply MAX200 machine torch and torch lead assembly 25 foot work cable ground with c...

Page 31: ...tly 1 Read the Troubleshooting section of this manual You may find the problem is quite easy to fix such a loose connection 2 If you are unable to solve the problem call your distributor He will be able to help you or refer you to an authorized Hypertherm repair facility 3 If you need additional assistance call Technical Service listed in the front of this manual or your authorized Hypertherm dist...

Page 32: ...ering air at a pressure of between 110 and 130 psi to the filter pressure regulator on the power supply The filter pressure regulator must be set for a 90 psi input to the power supply refer to the procedure below Refer to Section 4 Cut Charts for detailed information Shop Compressed Air The shop air supply must be clean dry and oil free Shop air must capable of delivering air at a pressure of bet...

Page 33: ...gon hydrogen as the plasma gas it must be supplied to the MAX200 at these purities nitrogen 99 995 and oxygen 99 5 The gas supply source can be compressed gas cylinders or liquid containers It must be capable of delivering the required gas at a delivery pressure of 120 psi to the power supply Refer to Section 4 Cut Charts for detailed information Note If the purity level of the gas is too low or i...

Page 34: ...Refer to the Material Safety Data Sheets in Appendix B for data on safety handling and storage of propylene glycol and benzotriazole WARNING Propylene glycol and benzotriazole are irritating to skin and eyes and harmful or fatal if swallowed Upon contact flush skin or eyes with water If swallowed drink water and call a physician immediately Do not induce vomiting Caution Always use propylene glyco...

Page 35: ...onnect switch box to be placed close to the power supply for safety purposes Placement of the power supply should also include the following criteria Place the power supply in an area that is free of excessive moisture has proper ventilation and is relatively clean Place the power supply so that air flow is not blocked in any way Cooling air is drawn in through the front panel grating and is exhau...

Page 36: ...s you to turn the power supply off quickly in an emergency situation The switch should be located on a wall 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 Refer to Power Requirements listed above Power Cables Use AWG wire sizes as outlined by applicable local electrical codes Wire...

Page 37: ...ion The links must be moved for 240 volt operation Ensure that the linkboard is configured properly to the appropriate voltage line see Figure 3 1 WARNING Danger High Voltage Line voltage may be present on this linkboard Disconnect input power before servicing Figure 3 1 Dual Voltage 240 480 Volt Linkboard Configurations 240 Volt Configuration 480 Volt Configuration ...

Page 38: ... To change the power supply to a different voltage control transformer T1 and 30 kw transformer T2 must be reconfigured see Figure 3 2 WARNING Danger High Voltage Line voltage is present in the power supply unless disconnected Always disconnect input power at the line disconnect switch before servicing T2 T1 220 380 T1 T2 A long 6 wire is shipped with every unit Figure 3 2 220 380 400 415V Transfo...

Page 39: ...MAX200 Instruction Manual 3 11 14 SETUP 400 T1 T2 415 T2 T1 Figure 3 2 220 380 400 415V Transformer T1 and T2 Configurations 2 of 2 ...

Page 40: ...elow To connect the power cable to the MAX200 proceed as follows see Figure 3 3 1 Insert the power cable through the strain relief at the rear of the MAX200 Connect the power cable leads to TB1 located at the rear center panel of the right side 2 Connect the power leads to the L1 L2 and L3 terminals of TB1 3 Connect the ground lead to the yellow green terminal of TB1 Figure 3 3 Power Cable Connect...

Page 41: ...filter pressure regulator The filter is used to maintain a high air purity level All moisture oil and other contaminants must be removed If the air hoses must be re connected proceed as follows see Figure 3 4 1 Connect the plasma air hose from the regulator to the PLASMA gas inlet 2 Connect the shield air hose from the regulator to the SHIELD gas inlet 3 Connect the shop supplied or cylinder suppl...

Page 42: ...e Figure 3 5 1 Connect the plasma gas supply hose to the PLASMA gas inlet 2 Connect the shield air hose from the regulator to the SHIELD gas inlet Note In this configuration the plasma air hose must be disconnected from the regulator and replaced by a supplied 6 JIC cap The cap is required to stop the discharge of air from the regulator plasma output in order to keep the shield air pressure within...

Page 43: ...ly Hose Shield Gas Supply Hose Plasma Gas and Shield Gas Hoses When gases other than air are used connect the liquid or compressed bottled gases to the MAX200 as follows see Figure 3 6 1 Connect the plasma gas supply hose to the PLASMA gas inlet 2 Connect the shield gas supply hose to the SHIELD gas inlet ...

Page 44: ...ack to the bulkhead adapter See Figure 3 7 Grounding To ensure proper operation personal safety and to reduce emission of radio frequency interference the properly ground the MAX200 as follows Work Table Connect the work table to a high quality earth ground within 20 feet of the table A suitable ground consists of a solid copper rod of at least 1 2 inch diameter driven to a depth of at least 8 fee...

Page 45: ...MAX200 Instruction Manual 3 17 14 SETUP Figure 3 7 Machine Torch Lead Connections to MAX200 ...

Page 46: ...3 18 MAX200 Instruction Manual 14 SETUP Figure 3 8 Proper Work Clamp Connection ...

Page 47: ...e 3 9 to make interconnections Connect the Cutting Machine to the MAX200 Connect the interface cable from the MACHINE 1X6 receptacle on the MAX200 to the cutting machine interface See Figure 3 10 for cable layout cable part numbers and lengths socket pin configurations and wire colors and signal names Connect the Remote Switch to the MAX200 1 Remove the right side cover of the power supply 2 Feed ...

Page 48: ...3 20 MAX200 Instruction Manual 14 SETUP Figure 3 9 Machine Torch System Interconnection Diagram without THC Option Remote Switch Assembly Machine Interface Cable Fig 3 10 ...

Page 49: ...r to Machine Interface Cable Signal List on next page Figure 3 10 MAX200 to Machine Interface Cable Diagram 1 of 2 Part No Length 023334 25 ft 7 6 m 023335 50 ft 15 2 m 023336 75 ft 23 m 023337 100 ft 30 5 m 023338 150 ft 46 m 023339 200 ft 61 m ...

Page 50: ...RRENT 50 COM BLK 8 136 SHIELD N A 13 PLASMA START SIG BLU 9 82 PLASMA START SIG BLK 15 83 SHIELD N A 14 KEY 008190 19 24VAC NEUTRAL WHT 21 76 24VAC HOT RED 22 77 SHIELD N A 20 DOWN RELAY LINE BLK 29 170 DOWN RELAY LOAD RED 34 169 SHIELD N A 23 UP RELAY LINE BLK 30 168 UP RELAY LOAD GRN 35 167 SHIELD N A 24 MACHINE MOTION DELAYED SIG BLU 31 85 MACHINE MOTION DELAYED SIG RED 36 84 SHIELD N A 25 MACH...

Page 51: ...o be connected Connect the Remote Control Station to the MAX200 Connect the interface cable from either the Switch Remote SR Digital Remote DR or Programmable Remote PR receptacle at the rear to the REMOTE V C 1X4 receptacle at the rear of MAX200 See Figures 3 12 through 3 14 for cable layouts cable part numbers and lengths socket pin configurations and wire colors and signal names Connect the Pro...

Page 52: ...DR Interface Cable Fig 3 13 PR to Computer Interface Cable used with PR only Fig 3 14 Remote V C Option Serial Remote SR Digital Remote DR Programmable Remote PR shown Machine Interface Cable Fig 3 10 Figure 3 11 Machine Torch System Interconnection Diagram with THC Option ...

Page 53: ...ATA COM BLK 8 10 SHIELD N A 13 SERIAL OUTPUT DATA SIG RED 9 7 SERIAL OUTPUT DATA COM BLK 15 8 SHIELD N A 14 RED UNUSED WHT 19 N A RED UNUSED GRN 20 N A 24 VAC AUX HOT ORN 29 11 24 VAC AUX NEUT BLK 23 12 SHIELD N A 24 120 VAC NEUT WHT 35 16 120 VAC HOT BLK 36 15 SHIELD N A 31 KEY BLANK 22 Power Supply SR Remote Figure 3 12 MAX200 to Switch Remote Interface Cable Diagram Part No Length 023319 25 ft ...

Page 54: ... KEY 6 19 32 6 BLK SOD COMMON 7 20 33 7 WHT AC POWER 8 BLK SID COMMON 21 34 8 BLK AC POWER 9 RED SOD DATA 22 008176 KEY BLANK 35 WHT AC POWER 9 10 23 36 BLK AC POWER 11 24 37 12 25 13 SHIELD GRN BLK 26 INPUT DATA TO THC OUTPUT FROM THC OUTPUT FROM PS THC INDICATES PAIRS Part No Length 023346 25 ft 7 6 m 023347 50 ft 15 m 023348 75 ft 23 m 023349 100 ft 30 5 m 023742 125 ft 38 1 m 023350 150 ft 46 ...

Page 55: ...k Common Remote Chassis 8 Wht on Blk Voltage Program V5 9 Blk on Blu V10 10 Blk on Grn V20 11 Blk on Orn V40 12 Blk on Red V80 13 Wht on Grn V100 14 Wht on Red V200 15 Blk on Wht Spare Remote Chassis 16 Shield Wire Shield Remot Chassis Part No Length 023098 10 ft 3 m 023099 25 ft 7 6 m 023100 50 ft 15 2 m Figure 3 14 Programmable Remote to Computer Interface Cable Diagram 5X2 ...

Page 56: ...X200 see Figure 3 15 Also see Figure 3 16 for the cable layout cable part numbers and lengths socket pin configurations and wire colors and signal names Connect to the Shop Air Supply 1 The customer must supply the 20 psig regulated shop air and the air hose A 4 swivel fitting 015006 is provided 2 Attach the swivel fitting to the air hose Connect this fitting to the air inlet fitting on the IHS Co...

Page 57: ...14 SETUP 2 Position the torch until the torch body extends all the way through the bracket so that the bracket is now around the plastic torch sleeve Tighten the bracket 3 The final torch position adjustment is described on page 3 40 ...

Page 58: ... 20 Psi Regulated Shop Air IHS Sensor Cables Fig 3 17 IHS Interface Cable Fig 3 16 Machine Hold Cable Fig 3 18 Machine Interface Cable Fig 3 10 PR to Computer Interface Cable Fig 3 14 PR DR Interface Cable Fig 3 13 SR Interface Cable Fig 3 12 Remote V C Option SR 073001 DR 073007 PR 055004 Cable used depends on Remote V C option selected PR is shown Used only with PR TB3 Figure 3 15 Machine Torch ...

Page 59: ...C Power 9 Drain Shield Grn Blk 9 Blk AC Power 10 11 Blk AC Power 12 13 14 Wht AC Power Part No Length 023111 25 ft 7 6 m 023112 50 ft 15 m 023155 75 ft 23 m 023113 100 ft 30 5 m 023114 150 ft 46 m 023284 200 ft 61 m Figure 3 16 MAX200 to IHS Interface Cable Indicates Pairs NOTE On IHS End Cut Red Black Shield White Black Shield Wires 008176 Pin 9 008190 Key 047002 Cable 22 3 Pr Shielded Belden 877...

Page 60: ... Cable 22 3 TW OA Shielded Belden 8771 40 008144 Plug 3 Pin F Amphenol 008195 Strain Relief 009211 Plug Shell 11 4 Rev Sex Inductive Sensor End IHS End LEGEND INDUCTIVE SENSOR END SOCKET COLOR FUNCTION A Brn Power 15 VDC B Blu Common C Blk Signal Part No 005074 Inductive Probe Assembly Figure 3 17 IHS Control Module to Inductive Probe Assembly Interface Cables Rearview 004085 Nut Insulating 027109...

Page 61: ...ly closed It opens when the torch is fully retracted The required operating specifications are 12 VDC 1 2 mA Gold type contacts are preferred Connect the Upper Limit Switch to the IHS Control Module Caution To avoid electromagnetic interference problems caused by the close proximity of the upper limit switch cable to the torch lead set follow the cable installation procedure 1 Use a shielded twist...

Page 62: ...s recommended to avoid ground loop problems Connect the MAX200 Machines Together with Machine Hold Cables To connect MAX200 machines with the IHS option together with hold interconnecting cables 1 Pass the hold interconnection cable through the feed through at the rear of the MAX200 See Figure 3 18 for the cable layout cable part numbers and lengths socket pin configurations and wire colors and si...

Page 63: ...AX200 End Blk Shield Red Blk Shield LEGEND MAX200 END WIRE COLOR FUNCTION 86 Blk Hold Signal 87 Red Hold Common Shield Shld Hold Shield LEGEND OTHER MAX200 END WIRE COLOR FUNCTION 86 Blk Hold Signal 87 Red Hold Common Shield Shld Hold Shield Figure 3 18 Machine Hold Interconnection Cable Part No Length 023340 15 ft 4 6 m 023341 25 ft 7 6 m 023342 50 ft 15 m 023343 100 ft 30 5 m 023344 150 ft 46 m ...

Page 64: ...e Note Two people may be required to perform the torch position adjustment 1 Retract the torch from the work at least 3 4 inches 2 Manually extend probes fully by pulling down on the plastic mounting yoke 3 Adjust the position of the torch in the mounting bracket by loosening the securing bolt and positioning the torch so that the torch shield is within 1 16 to 1 8 inch of the extended probe plast...

Page 65: ...The Water Muffler option can be used with the 1 75 inch 44 5 mm diameter torch bodies only The 2 inch 51 mm diameter torch body can not support the Water Muffler option To install the Water Muffler option refer to the MAX200 Water Muffler Instruction Manual IM 205 P N 802050 ...

Page 66: ... 4 2 Status 4 2 Status Indicators Before Startup 4 2 Gas 4 3 Pre operation 4 4 Operation 4 4 Operating Tips 4 5 Changing Consumable Parts 4 5 Cutting Techniques 4 7 Torch Alignment 4 7 Cutting 4 8 Piercing 4 8 Common Cutting Faults 4 9 Duty Cycle 4 9 Claims and Technical Questions 4 9 Cut Charts 4 10 ...

Page 67: ...mer or one of the choppers has overheated COOLANT LEVEL LED When illuminated indicates the coolant level is too low SHIELD GAS CAP LED When illuminated indicates the shield gas pressure is too low or the cap is not installed properly on the torch PLASMA GAS LED When illuminated indicates that the plasma gas pressure is too low COOLANT TEMP LED When illuminated indicates that the torch coolant temp...

Page 68: ... Panel Controls Machine System with THC Machine System without THC MACHINE DELAY 6 SEC AMPS 0 3 20 E Z R O 100 80 60 40 O E Z R 20 100 80 40 60 ON POWER OFF 0 2 DC ON 0 COOLANT FLOW COOLANT TEMP PLASMA GAS COOLANT LEVEL TRANSFORMER SHIELD GAS CAP STATUS INTERLOCK RUN TEST PLASMA SHIELD GAS MACHINE DELAY 6 SEC 0 3 20 E Z R O 100 80 60 40 O E Z R 20 100 80 40 60 ON POWER OFF DC ON COOLANT FLOW COOLA...

Page 69: ...ction of the workpiece that will drop off Make sure that there is good metal to metal contact between the work clamp and the workpiece 5 Apply power to the MAX200 power supply via the wall disconnect switch See Status Indicators Before Startup earlier in this section Operation Note When using the MAX200 machine torch with extended torch leads 100 125 or 150 feet be aware that the 40A consumable pa...

Page 70: ...piece if you are straight cutting or angle the torch as required to accomplish your cut Operating Tips Changing Consumable Parts The consumable parts in the torch need to be monitored periodically for signs of wear A good rule of thumb is to check the parts after every 150 starts To remove the consumables 1 Unscrew the retaining cap First bring the torch to the edge of the machine with the lifter ...

Page 71: ...damaged If it is dry lubricate it lightly with a very thin film of lubricant provided in the spare parts kit If it is damaged replace it 8 Remove the swirl ring from the electrode and inspect it It should be clean and the holes on the top and sides should not be plugged If the swirl ring is still good inspect its O ring It should be lubricated and undamaged If it is dry lubricate it lightly with a...

Page 72: ...Alignment Prior to cutting with a machine torch ensure that the torch is at right angles to the workpiece to get a clean vertical cut Use a square to align the torch The torch should be aligned at 90 increments 0 90 180 and 270 See Figure 4 2 Figure 4 2 Torch Alignment ...

Page 73: ...f the workpiece If there is not sufficient power to fully penetrate the workpiece reduce the travel speed If this does not work stop cutting and re check the cutting chart specifications Piercing Note The MAX200 can pierce metals up to a thickness of one 1 inch Set the torch to work distance standoff so that the shield cap is 1 8 inch or more away from the workpiece Refer to the Adjust the Torch P...

Page 74: ...aint rust etc Arc voltage is greater than 150 volts at 200 amps Claims and Technical Questions Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request Claims for defective merchandise All units shipped from Hypertherm undergo rigorous quality control testing However ...

Page 75: ...irl Ring Electrode Air Air 200 020424 120837 020608 020607 220021 100 020448 120837 020611 020607 120547 40 020688 020423 020689 020613 220021 200 gouging 020485 020423 020615 020607 220021 O2 Air 200 020424 120837 020605 020604 220021 100 020448 120837 020616 020617 120547 H35 N2 200 020602 120837 020608 020607 020415 100 020448 120837 020611 020607 020415 200 gouging 020485 020423 020615 020607 ...

Page 76: ...150 1140 45 2 5 25 6 1 4 160 635 25 2 5 32 6 1 4 165 380 15 50 8 5 16 185 130 5 60 Plasma Gas Pressure English Plasma Gas Flowrate SCFH Shield Gas Flowrate SCFH 66 44 48 58 62 270 Plasma Gas Pressure Shield Gas Flowrate l min Metric Plasma Gas Flowrate l min Torch to Work Distance Torch to Work Distance Travel Speed Travel Speed 4 0 31 3 0 3 3 4 0 4 3 127 MAX200 Instruction Manual 4 11 14 OPERATIO...

Page 77: ...1 5 1 8 3 3 3 6 127 4 0 2 2 5 3 32 120 6050 0 0 Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 17 1 5 1 8 127 4 0 3 7 4 0 270 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH 37 22 26 54 58 Torch to Work Distance 60 Torch to Work Distance Torch to Work Distance Trave...

Page 78: ...15 1250 50 6 2 5 3 32 120 850 35 10 2 5 3 32 125 500 20 Travel Speed Travel Speed Torch to Work Distance Torch to Work Distance Shield Gas Flowrate SCFH Plasma Gas Pressure Plasma Gas Flowrate SCFH English Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 4 0 25 16 20 56 60 275 60 12 1 1 1 4 3 9 4 1 129 Mild Steel Above Water 40 amps Air Plasma Air Shield This gas comb...

Page 79: ...Shield Gas Flowrate l min 72 48 52 64 68 270 34 3 3 3 6 4 4 4 7 127 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Torch to Work Distance Travel Speed Travel Speed Mild Steel Above Water 200 amps O2 Plasma Air Shield This gas combination gives superior cut speed minimum dross minimum amount of surface nitriting and excellent weldability Set pla...

Page 80: ...ork Distance Travel Speed 19 0 8 1 1 3 6 3 9 127 4 0 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 40 12 16 52 56 270 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Mild Steel Above Water 100 amps O2 Plasma Air Shield This gas combination gives good cut speed low dross level and is very economica...

Page 81: ...5 2 0 20 5 3 16 145 635 25 2 5 25 6 1 4 160 380 15 3 0 32 6 1 4 165 250 10 4 0 Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 210 28 2 5 2 8 3 6 3 9 99 60 Metric 36 40 52 56 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed Travel Speed 60 Torch to Work Distance Mild Steel Above Water 200 amps N2 Plasma CO2 Sh...

Page 82: ...20 5 3 16 140 1400 55 2 5 25 6 1 4 150 760 30 32 6 1 4 160 380 15 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 66 44 48 58 62 270 60 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 31 3 0 3 3 4 0 4 3 127 4 0 Stainless Steel Above Water 200 amps Air Plasma Air Shie...

Page 83: ... 150 510 20 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 37 22 26 54 58 270 60 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 17 1 5 1 8 3 7 4 0 127 4 0 Stainless Steel Above Water 100 amps Air Plasma Air Shield This gas combination gives good cut speed low dross...

Page 84: ...s Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 4 0 25 16 20 56 60 275 60 12 1 1 1 4 3 9 4 1 129 Stainless Steel Above Water 40 amps Air Plasma Air Shield This gas combination gives good cut speed low dross levels and is very economical Some surface nitriting and surface ...

Page 85: ...40 45 2 5 25 6 1 4 150 510 20 32 6 1 4 160 380 15 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 60 34 38 50 54 270 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 3 2 6 3 4 3 7 127 4 0 Stainless Steel Above Water 200 amps N2 Plasma Air Shield This gas combi...

Page 86: ...16 140 1250 50 2 5 25 6 1 4 150 760 30 32 6 1 4 160 380 15 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 60 36 40 52 56 210 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 5 2 8 3 6 3 9 99 4 0 Stainless Steel Above Water 200 amps N2 Plasma CO2 Shield This g...

Page 87: ...275 60 Torch to Work Distance Travel Speed Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 4 0 33 2 5 2 8 4 3 4 5 129 Stainless Steel Above Water 200 amps H35 Plasma N2 Shield This gas combination Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas gives maximum thickness cutting capability minimum dross levels minimum amount of surface con...

Page 88: ...erial Thickness Arc Voltage Setting Approx Motion Delay Time Test bar Run bar bar mm mm Inches Volts mm min ipm sec 3 2 5 3 32 130 1260 50 0 0 5 3 1 8 135 1060 40 0 5 6 3 1 8 140 890 35 0 5 10 3 1 8 140 750 30 0 5 12 3 1 8 145 630 25 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 20 32 36 56 60 270 60 Torch to Work Distance Travel ...

Page 89: ... 145 2800 110 2 5 15 4 16 150 2200 85 2 5 20 5 3 16 155 1650 65 2 5 25 6 1 4 165 900 35 32 6 1 4 170 500 20 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 66 44 48 58 62 270 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 31 3 0 3 3 4 0 4 3 127 4 0 Aluminum Above...

Page 90: ...8 150 1010 40 15 4 16 155 760 30 20 5 3 16 160 635 25 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 37 22 26 54 58 270 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 17 1 5 1 8 3 7 4 0 127 4 0 Aluminum Above Water 100 amps Air Plasma Air Shield This gas combina...

Page 91: ...l Speed English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 12 1 1 1 4 3 9 4 1 129 4 0 60 25 16 20 56 60 275 Aluminum Above Water 40 amps Air Plasma Air Shield This gas combination gives good cut speed low dross levels and is very economical Set plasma gas in...

Page 92: ...6 140 1780 70 2 0 20 5 3 16 150 1270 50 2 5 25 6 1 4 165 635 25 32 6 1 4 175 510 20 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 60 34 38 54 54 270 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 3 2 6 3 7 3 7 127 4 0 Aluminum Above Water 200 amps N2 Plasm...

Page 93: ... 16 140 1800 70 2 5 20 5 3 16 150 1400 55 3 0 25 6 1 4 165 840 33 32 6 1 4 175 510 20 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 60 36 40 52 56 210 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 5 2 8 3 6 3 9 99 4 0 Aluminum Above Water 200 amps N2 Plas...

Page 94: ... 8 5 16 185 180 7 4 0 33 2 5 2 8 4 3 4 5 129 Torch to Work Distance Travel Speed Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 70 36 40 62 66 275 60 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Set plasma gas inlet pressure to 120 psi 8 3 bar Set shield gas inlet pressure to 90 psi 6 2 bar If lead...

Page 95: ...e Travel Speed 9 2 2 2 5 3 9 4 1 127 4 0 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 20 32 36 56 60 270 60 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Set plasma gas inlet pressure to 120 psi 8 3 bar Set shield gas inlet pressure to 90 psi 6 2 bar If leads are greater than 50 feet increase TEST...

Page 96: ...re psi Shield Gas Inlet Pressure bar RUN bar Metric Plasma Gas Pressure Shield Gas Pressure bar Plasma Gas Inlet Pressure bar TEST bar Plasma Gas Pressure Mild Steel Gouging 200 amps Air Plasma Air Shield If leads are greater than 50 feet increase TEST pressure 5 psi for every extra 50 feet of torch lead length 020485 Shield 020615 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring ...

Page 97: ...ar Plasma Gas Inlet Pressure bar English Plasma Gas Pressure Shield Gas Pressure psi Plasma Gas Inlet Pressure psi Stainless Steel Gouging 200 amps H35 Plasma N2 Shield Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas 020485 Shield 020615 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring If leads are greater than 50 feet increase TEST pressure 5 psi for e...

Page 98: ...e bar Plasma Gas Inlet Pressure bar English Plasma Gas Pressure Shield Gas Pressure psi Plasma Gas Inlet Pressure psi Aluminum Gouging 200 amps H35 Plasma N2 Shield Hypertherm recommends a mixture of 35 hydrogen and 65 argon for the plasma gas 020485 Shield 020615 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring If leads are greater than 50 feet increase TEST pressure 5 psi for every...

Page 99: ... 4 16 145 1200 50 2 0 20 5 3 16 150 850 35 2 5 25 6 1 4 165 400 15 3 0 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 66 44 48 58 62 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 31 3 0 3 3 4 0 4 3 132 4 8 Mild Steel 3 Under Water 200 amps Air Plasma Air Sh...

Page 100: ... 0 Travel Speed 37 22 26 54 58 280 70 17 1 5 1 8 3 7 4 0 132 Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Torch to Work Distance Travel Speed 4 8 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Mild Steel ...

Page 101: ...6 135 1500 60 2 0 20 5 3 16 140 1200 48 2 5 25 6 1 4 145 680 25 3 0 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 72 48 52 64 68 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 34 3 33 3 6 4 4 4 7 132 4 8 Mild Steel 3 Under Water 200 amps O2 Plasma Air Shiel...

Page 102: ...eld Gas Flowrate SCFH Torch to Work Distance Travel Speed 40 20 24 60 64 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 19 1 4 1 6 4 1 4 4 132 4 8 Mild Steel 3 Under Water 100 amps O2 Plasma Air Shield This gas combination gives good cut speed low dross level and is very economical Some surface nitriting can occur While thi...

Page 103: ...150 45 2 5 25 6 1 4 155 570 22 English Metric Torch to Work Distance Travel Speed Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 31 3 0 3 3 4 0 4 3 132 4 8 Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 70 66 44 48 58 62 280 Stainless Steel 3 Under Water 200 amps Air Plasma Air Shield This gas combination gives goo...

Page 104: ... Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 37 22 26 54 58 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 17 1 5 1 8 3 7 4 0 132 4 8 Stainless Steel 3 Under Water 100 amps Air Plasma Air Shield This gas combination gives good cut speed low dross levels and is very economical Some surfac...

Page 105: ...00 30 2 5 Torch to Work Distance Travel Speed English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min 70 28 2 3 2 6 3 5 3 7 132 4 8 60 34 38 50 54 280 Stainless Steel 3 Under Water 200 amps N2 Plasma Air Shield This gas combination is used when cut edge quality s...

Page 106: ...50 2 0 20 5 3 16 145 950 38 2 5 Torch to Work Distance Travel Speed English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 5 2 8 3 6 3 9 99 4 8 70 60 36 40 52 56 210 Stainless Steel 3 Under Water 200 amps N2 Plasma CO2 Shield This gas combination is used wh...

Page 107: ... 8 150 2240 90 2 5 15 4 16 155 1650 65 3 0 20 5 3 16 160 1150 45 3 0 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 66 44 48 58 62 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 31 3 0 3 3 4 0 4 3 132 4 8 Aluminum 3 Under Water 200 amps Air Plasma Air Shield...

Page 108: ...5 750 30 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 37 22 26 54 58 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 17 1 5 1 8 3 7 4 0 132 4 8 Aluminum 3 Under Water 100 amps Air Plasma Air Shield This gas combination gives good cut speed low dross levels ...

Page 109: ...0 65 2 0 15 4 16 145 1350 55 2 5 20 5 3 16 155 890 35 3 0 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 60 34 38 50 54 280 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 3 2 6 3 4 3 7 132 4 8 Aluminum 3 Under Water 200 amps N2 Plasma Air Shield This gas co...

Page 110: ...0 75 2 5 15 4 16 145 1350 55 2 5 20 5 3 16 155 980 40 3 0 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 60 36 40 52 56 220 70 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel Speed 28 2 5 2 8 3 6 3 9 103 4 8 Aluminum 3 Under Water 200 amps N2 Plasma CO2 Shield This gas co...

Page 111: ...125 2540 100 1 0 12 4 16 125 2030 80 2 0 15 4 16 130 1780 70 2 0 20 5 3 16 135 1400 55 2 5 25 6 1 4 140 890 35 2 5 32 6 1 4 150 560 22 50 8 5 16 170 180 7 English Plasma Gas Flowrate SCFH Plasma Gas Pressure Shield Gas Flowrate SCFH Torch to Work Distance Travel Speed 72 48 52 64 68 270 60 Metric Plasma Gas Flowrate l min Plasma Gas Pressure Shield Gas Flowrate l min Torch to Work Distance Travel ...

Page 112: ...al 5 1 15 Section 5 MAINTENANCE In this section Routine Maintenance 5 2 Troubleshooting 5 2 Removal and Replacement of Torch 5 6 Removal and Replacement of Torch Lead 5 7 Removal and Replacement of Individual Torch Leads 5 7 ...

Page 113: ...ire very little regular maintenance under normal use Refer to MAX200 Service Manual IM 162 801620 for torch torch leads torch coolant and power supply routine maintenance checks to keep your system in top running condition Troubleshooting Becoming familiar with the contents of this manual will aid in safely troubleshooting the MAX200 power supply and torch should the need arise The following proce...

Page 114: ... switch PB1 the red POWER OFF 0 pushbutton switch PB2 or the associated switch wiring is not making good contact or is defective Solution Replace the defective switch or correct or replace the switch wiring as required Problem The green POWER ON pushbutton switch PB1 is pressed the fans are operating but the green POWER ON indicator does not illuminate Cause Pushbutton switch PB1 was not held down...

Page 115: ... is no high frequency and no pilot arc Cause There is no spark between the spark gap electrodes Solution Clean with emery cloth align and or regap 020 per gap the electrodes if necessary Ensure the electrode surfaces between the gaps are flat If they are rounded replace and regap The two outside electrode assemblies are part no 004061 the inside electrode assembly is part no 004089 Solution Visual...

Page 116: ...board PCB7 is defective Solution Replace board PCB7 Problem The unit shuts itself off after it is turned on Cause The unit has overheated Solution Wait for the unit to cool down Cause There is insufficient air or gas pressure Solution Check the gauge on the back panel Increase the air or gas pressure to the unit Cause Auxilliary switches on the safety contactor are loose Solution Tighten the switc...

Page 117: ...a 7 16 open end wrench to turn the torch lead fittings Turn the torch lead fittings counterclockwise ccw to loosen the connections Note that the red lead fitting is reverse threaded and must be turned in the opposite direction 3 Remove the torch main body Replacement 1 Connect the torch leads to the replacement torch main body Thread the torch main body fittings and the torch lead fittings togethe...

Page 118: ...move and replace individual torch leads perform the following procedure and see Figure 5 2 Refer to the Machine Torch Lead Assembly Parts list Removal 1 Disconnect the torch lead from the power supply by reversing the Connect the Torch Lead procedure on page 3 16 2 Disconnect the torch from the torch lead as described in the Torch Removal procedure on page 5 6 3 Lay the torch lead on the floor and...

Page 119: ... in Figure 5 2 5 Tape both ends of the shield braid to the torch lead 6 Slide the shrink tubing 7 over the torch end of the shield braid Heat the shrink tubing until it tightly bonds around the shield braid and torch lead 7 Replace the compression ring 9 shield collar 10 and hose clamp 11 over the power supply end of the shield braid Tighten the hose clamp 8 Connect the torch lead to the power sup...

Page 120: ...ply 6 2 Illustrations Parts Lists 6 2 Recommended Spare Parts 6 16 MAX200 Consumables Torch Assembly and Torch Leads 6 18 MAX200 Machine Torch Consumables 6 18 Consumable Configurations 6 19 Consumable Parts Kits 6 20 MAX200 Machine Torch Assembly 6 21 Machine Torch Lead Assemblies 6 24 ...

Page 121: ...6 2 MAX200 Instruction Manual 15 PARTS LIST Figure 6 1 Power Supply Control Panel SA Front 2 0 0 6 SEC 3 0 MACHINE DELAY AMPS 1 2 3 4 5 6 7 10 11 9 8 12 13 14 15 ...

Page 122: ...e needle 125 orifice V5 1 7 001222 Panel control 1 8 005121 Pushbutton green illmn PB1 1 9 005122 Pushbutton red extended PB2 1 10 005088 Holder lamp 1 005168 Bulb 28VDC 1 005089 Lens white for 005088 1 11 001250 Panel machine delay 1 12 009604 Resistor variable 100 K 1 turn R9 1 13 029360 Panel thumbwheel machine delay SA 1 14 005123 Thumbwheel S3 1 15 009604 Resistor variable 100 K 1 turn R9 1 P...

Page 123: ...6 4 MAX200 Instruction Manual 15 PARTS LIST Figure 6 2 Power Supply Front View 1 2 3 4 5 6 7 8 ...

Page 124: ... O THC SA 1 6 041151 PCB THC motherboard PCB9 1 7 041186 PCB SA THC PCB10 1 P O Power Supply Assy 8 041143 PCB control PCB7 1 001566 Panel MAX200 front filter 1 001567 Cover MAX200 front filter panel 1 027441 Filter 24 X 24 X 2 fiberglass air 1 Power Supplies with THC 073020 073021 073022 073023 073024 and 073213 CE Power Supplies without THC 073002 073003 073004 073005 073026 and 073200 CE Items ...

Page 125: ...6 6 MAX200 Instruction Manual 15 PARTS LIST Figure 6 3 Power Supply Right Side Front View 12 1 11 10 2 3 9 7 6 8 5 4 ...

Page 126: ... 60 Hz T2 1 014097 Trans 30 kw 208V 3Ø 60 Hz T2 1 014100 Trans 30 kw 200V 3Ø 60 Hz T2 1 5 005102 Thermostat 160 C 6 Amp TS1 1 029314 P O Plasma Gas Supply SA 6 006014 Valve solenoid V3 1 7 006014 Valve solenoid V1 1 8 005235 Switch pressure 0 90 psi PS1 1 9 006014 Valve solenoid V9 1 10 005239 Switch pressure 0 90 psi PS4 1 11 129118 Chopper SA CH130 CE LVD CH1 1 005199 Switch temperature 82 C TSW...

Page 127: ...6 8 MAX200 Instruction Manual 15 PARTS LIST Figure 6 4 Power Supply Right Side Rear View 1 2 3 9 4 5 6 8 7 11 12 17 14 13 15 16 19 18 20 10 ...

Page 128: ...1 1 12 014078 Trans 30 kw 240 480V 3Ø 60 Hz T2 1 014088 Trans 30 kw 220 380 400 415V 3Ø 50 Hz T2 1 014082 Trans 30 kw 600V 3Ø 60 Hz T2 1 014097 Trans 30 kw 208V 3Ø 60 Hz T2 1 014100 Trans 30 kw 200V 3Ø 60 Hz T2 1 029314 P O Plasma Gas Supply SA 13 14 15 See Figure 6 3 16 17 18 129118 Chopper SA CH130 CE LVD CH1 1 005199 Switch temperature 82 C TSW1 1 P O Power Supply Assy 19 014079 Trans control 2...

Page 129: ...6 10 MAX200 Instruction Manual 15 PARTS LIST Figure 6 5 Power Supply Left Side Front View 1 2 3 4 5 6 7 8 ...

Page 130: ... 30 kw 600V 3Ø 60 Hz T2 1 014097 Trans 30 kw 208V 3Ø 60 Hz T2 1 014100 Trans 30 kw 200V 3Ø 60 Hz T2 1 3 014080 Inductor 4 mh 100 Amps DC L2 1 4 007022 Shunt 100 Amp 100 mv R2 1 5 007022 Shunt 100 Amp 100 mv R1 1 6 007024 Shunt 200 Amp 100 mv R3 1 7 008317 Fuse semiconductor 125 Amp 250 V F4 1 8 008317 Fuse semiconductor 125 Amp 250 V F3 1 128236 Phase loss detection upgrade kit 1 Power Supplies wi...

Page 131: ...6 12 MAX200 Instruction Manual 15 PARTS LIST Figure 6 6 Power Supply Left Side Rear View 1 2 4 5 6 7 8 11 12 10 9 13 14 15 16 18 17 3 ...

Page 132: ...or 4 mh 100 Amps DC L2 1 6 009684 Resistor 4 Ohm 420 W R6 2 7 009015 Resistor 10 K Ohm 10 W R5 1 8 009438 Resistor 5 Ohm 50 W R4 1 9 009506 Capacitor elec 250 uf 350 VDC C9 1 10 003021 Relay 120 VAC CR1 1 029314 P O Plasma Gas Supply SA 11 005228 Switch pressure SPDT 0 15 psi PS3 1 P O Power Supply Assy 12 029317 Transformer High Voltage SA T5 1 13 008479 Terminal strip quick connect TB2 1 14 0293...

Page 133: ...6 14 MAX200 Instruction Manual 15 PARTS LIST Figure 6 7 Power Supply Rear View 3 2 4 5 1 13 12 14 15 16 11 10 9 8 6 7 ...

Page 134: ...0V 3 8 NPT NC V7 1 029361 Flowswitch Subassembly w elec connector 1 5 005119 Flowswitch 0 5 GPM FS1 1 6 006053 Valve Check 1 3 PSI 1 4 NPTM 1 7 027136 Heat Exchanger Water Air MX1 1 8 027139 Filter Housing 10 X 3 8 NPT 1 9 027005 Filter Element 1 10 011025 Filter Regulator 1 11 011027 Gauge High Press for 011025 1 12 002304 Reservoir coolant 1 13 022036 Gauge liquid level 1 14 129618 Level Switch ...

Page 135: ...90 psi PS1 129118 Chopper SA CH130 CE LVD CH1 CH2 009384 Diode 85 Amp 1000V fwd polarity D1 D2 D3 009385 Diode 85 Amp 1000V rev polarity D4 D5 D6 041534 PCB power distribution PCB6 008322 Fuse Amp 250 VAC 008317 Fuse semiconductor 125 Amp 250 V F3 F4 003021 Relay 120 VAC CR1 005130 Switch pressure SPDT 0 15 psi PS3 029317 Transformer High Voltage SA T5 029202 Sensor current CS1 006045 Valve soleno...

Page 136: ...orch lead 15 ft 028456 Shielded torch lead 20 ft 028383 Shielded torch lead 25 ft 028457 Shielded torch lead 30 ft 028458 Shielded torch lead 35 ft 028459 Shielded torch lead 40 ft 028460 Shielded torch lead 45 ft 028384 Shielded torch lead 50 ft 028773 Shielded torch lead 60 ft 028599 Shielded torch lead 75 ft 028781 Shielded torch lead 100 ft 028782 Shielded torch lead 125 ft 028783 Shielded tor...

Page 137: ...0837 020611 020607 020415 200 gouging 020485 020423 020615 020607 020415 N2 CO2 200 020424 120837 020608 020607 020415 N2 Air 200 020424 120837 020608 020607 020415 Beveling Consumables O2 Air 200 beveling 120260 020423 120259 120833 120258 Water Tube 120257 Consumables Used with MAX200 Water Muffler Air Air 200 020566 020423 020608 020607 220021 100 020618 020423 020611 020607 120547 O2 Air 200 0...

Page 138: ...0607 020613 020608 020611 020612 020424 020448 020514 Retaining Cap Electrode Swirl Ring Nozzle Shield Cutting Consumable Configurations 020423 120258 120833 120259 120260 Beveling Water Tube 120257 020423 220021 020415 120547 020607 020613 020615 020485 Gouging Figure 6 8 MAX200 Machine Torch Consumable Parts 020423 ...

Page 139: ...licon 1 4 Oz Tube 1 027194 Wrench Nozzle 3 4 1 044027 O Ring 2 027347 Tool Water Tube Removal 1 120547 Electrode Air Oxygen 3 020963 Tube Water 1 Consumable Parts Kit International 028429 Part Description Quantity 001067 Enclosure Consumable Parts Kit 1 015015 Adapter 90 1 4 NPT x 6 1 220021 Electrode Air Oxygen 5 020415 Electrode Nitrogen H35 5 020423 Cap Shield 1 020424 Shield Machine 200A 1 020...

Page 140: ...00 Mach 2 0 diameter 1 2 120584 MAX200 Machine Torch Main Body 1 3 020536 Lead insulator 9 16 X 2 5 Tef 1 4 044027 O ring Buna N 1 The following consumables are part of the MAX200 Machine Torch Assembly See Figure 6 8 for details 020424 Shield MAX200 Mch 200A 1 120837 Cap Nozzle Retaining MAX200 1 020608 Nozzle MAX200 200A 086 Air N2 H35 1 020607 Swirl ring MAX200 Air N2 H35 1 220021 Electrode MAX...

Page 141: ...sembly 1 1 020041 Sleeve Insul MAX200 Mach 2 0 diameter 1 2 120356 MAX200 Machine Torch Main Body 1 3 020536 Lead insulator 9 16 X 2 5 Tef 1 4 044027 O ring Buna N 1 The following consumables are part of the MAX200 Machine Torch Assembly See Figure 6 8 for details 020424 Shield MAX200 Mch 200A 1 020423 Cap Nozzle Retaining MAX200 1 020608 Nozzle MAX200 200A 086 Air N2 H35 1 020607 Swirl ring MAX20...

Page 142: ...embly 1 1 020431 Sleeve Insul MAX200 Mach 1 75 diameter 1 2 120584 MAX200 Machine Torch Main Body 1 3 020536 Lead insulator 9 16 X 2 5 Tef 1 4 044027 O ring Buna N 1 The following consumables are part of the MAX200 Machine Torch Assembly See Figure 6 8 for details 020424 Shield MAX200 Mch 200A 1 120837 Cap Nozzle Retaining MAX200 1 020608 Nozzle MAX200 200A 086 Air N2 H35 1 020607 Swirl ring MAX20...

Page 143: ... 024217 Lead Plasma Gas 15 Ft red 1 3 024222 Lead Cap Sensor 15 Ft gray 1 4 023034 Cable Water Cooled 15 Ft blue red band 1 5 023034 Cable Water Cooled 15 Ft blue green band 1 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046061 2 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 ...

Page 144: ...e 1 2 024229 Lead Plasma Gas 30 Ft red 1 3 024224 Lead Cap Sensor 30 Ft gray 1 4 023014 Cable Water Cooled 30 Ft blue red band 1 5 023014 Cable Water Cooled 30 Ft blue green band 1 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046061 2 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16...

Page 145: ...e 1 2 024231 Lead Plasma Gas 45 Ft red 1 3 024227 Lead Cap Sensor 45 Ft gray 1 4 023387 Cable Water Cooled 45 Ft blue red band 1 5 023387 Cable Water Cooled 45 Ft blue green band 1 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046061 2 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16...

Page 146: ...gray 1 4 023262 Cable Water Cooled 75 Ft blue red band 1 5 023262 Cable Water Cooled 75 Ft blue green band 1 6 020536 Lead Insulator 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046061 2 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 4 1 Note Hypertherm does not recommend using torch leads longer tha...

Page 147: ...tor 9 16 ID x 2 1 2 1 7 046026 Tubing 1 1 2 ID Shrink Black 1 8 046061 2 ID Tinned Braid 1 9 027015 Ring Compress Shield Torch Lead 1 10 004080 Collar Shield Torch Leads 1 11 015090 Clamp Hose 1 5 16 2 1 4 1 028783 Shield Torch Lead 150 Ft 1 1 023810 Lead Pilot Shield Gas 150 Ft blue 1 2 024418 Lead Plasma Gas 150 Ft red 1 3 024415 Lead Cap Sensor 150 Ft gray 1 4 023807 Cable Water Cooled 150 Ft b...

Page 148: ...ge to page referencing is done in the following manner C SHEET 4 D3 C SHEET 4 D3 Destination and Source Coordinates refer to letters A D on the Y axis of each sheet and numbers 1 4 on the X axis of each sheet Lining up the coordinates will bring you to the source or destination blocks similar to a road map Wiring Diagram Symbols Wiring diagram symbols and their identification precede the system wi...

Page 149: ...ck Fan Feedthru LC Filter AC DC supply Fuse Ground Clamp Ground Chassis Ground Earth IGBT Inductor LED Light Pin Plug PNP Transistor Potentiometer Push Button Normally Closed MOV Push Button Normally Open Receptacle Relay Coil Relay Normally Closed Relay Normally Open Relay Solid State AC Relay Solid State DC Relay Solid State Dry SCR Shield Shunt Spark Gap Switch Flow Resistor ...

Page 150: ...ansformer Coil Valve Solenoid Voltage Source Zener Diode VAC Source Triac Switch Pressure Normally Closed Switch Pressure Normally Open Switch 1 Pole 1 Throw Switch 1 Pole 2 Throw Switch 1 Pole 1 Throw Center Off Switch Temperature Normally Closed Switch Temperature Normally Open Time Delay Closed NC Off Time Delay Open NO Off Time Delay Open NC On Terminal Block Torch HyDefinition ...

Page 151: ... SHEET 023870 023869 Air Hose 024144 IHS Sensor Cable IHS Sensor Cable IHS 028390 Unit 8 8X2 8X3 PS IHS Cable 023859 3 Phase Power w Ground Shielded Torch Leads 028546 8X1 1X9 Unit 1 MAX200 200 Amp Power Supply IHS Probe 029334 OFF Valve Workpiece Torch Positive Lead 023403 5X2 Programmable Remote only 023100 1X6 Machine Interface Cable 023334 I O Interface Computer Customer Supplied Unit 5 Remote...

Page 152: ...75 176 PL13 3 2 R3 R4 R5 P1 120 VAC RED AOut WHT 83 BIn 61 60 178 REC26 AIn C6 R1 POS WHT C2 PA Pilot Arc TB2 177 RED RED BLK PL26 2 T6 1 Remote Start Plasma WORKPIECE Torch 5000 VAC C7 C1 NEG C8 SG1 T5 283 VDC 3 D3 A 3 A2 B 4 C3 C 6 D3 F 5 C4 E 4 C3 D TSW1 TSW2 3 D3 U 15 RED 14 RED 13 RED 14 RED 013179 013 2 179 013179B2 ELEC GAS SCHEM MAX200 N A MAX200 2 OF 9 BC 5 9 96 NECESSARY WITH CHAMFER OR ...

Page 153: ...1 6 5 4 3 2 REC1 REC2 D4 RN1A 11 6 LED2 8 7 5 RN1H LED1 RN1G RN1F RN1E U1D 10 9 12 4 3 1 RN1C RN1D LED3 RN1B U1C 14 U1B 13 16 4 D1 1 2 D2 3 D3 5 6 7 2 2 1 LED4 RN2B LED5 RN2A RN2F 16 U1A 15 U2A 15 6 5 8 7 RN2H LED6 RN2E RN2G LED7 U2C 12 11 U2D 10 9 11 9 10 8 D7 12 14 D6 D5 13 6 C2 K ASSY 041536 PCB 041535 2 D2 U 15 RED SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET 013179 013 2 179 013179B3...

Page 154: ...O BRN GRY WHT BLK 142 141 144 143 147 146 145 148 GRN 142 ORN RED 141 139 140 YEL 145 144 143 BLU 200 Amp M2 4 Switch M1 2 M1 1 M2 8 Optional M2 2 M2 1 M2 COM M1 COM 2 B1 D 6 D4 N 2 B2 C 3 D2 G 3 A2 M 3 D2 H 6 D2 P 5 D3 R Arc on IHS Start IHS Complete COM 10A 20A 200A 100A 80A 40A THC Option Thumbwheel Option PL9 1 2 4 3 5 6 7 RCC Option 023462 145 BLU VIO RED ORN 140 139 142 141 143 YEL GRN 144 W...

Page 155: ... 140 141 142 143 144 145 146 147 148 175 176 100 101 133 134 82 83 167 168 169 170 171 172 173 174 RED RED BLK RED WHT RED RED BLK RED RED BLK BLU WHT BLU WHT 6 C2 T 4 A2 R 2 B2 E 3 A2 L 6 C1 S 5X1 8X1 023319 023859 120 VAC SID SOD GND SIG SIG GND L N SIG L N GND SIG GND 073001 041065 PCB 041186 Assy 041186 SCH 041150 PCB 041294 Assy 041294 SCH 15 9 14 8 4 13 36 35 31 1X4 BLK RED BLK GRN BLK WHT 0...

Page 156: ...RED 81 80 168 24 25 5 15 9 27 14 1 10 36 31 32 37 4 26 1X6 35 13 8 30 WHT RED WHT YEL BLK YEL BLU 83 82 86 85 87 84 YEL BLK YEL 167 78 79 BLU 174 7 29 34 3 23 2 12 11 6 173 172 WHT WHT RED BLK RED RED BLK 171 169 170 RED BLU WHT RED VDC Motor Motor VDC BLU WHT 136 135 84 87 86 85 RED RED BLK RED BLK RED S2 60 61 60 61 88 89 34 76 77 35 COM NO 5 B4 S 3 D2 J 5 D2 T 3 B1 K 4 A3 P 2 B1 F 4 B3 N 78 82 ...

Page 157: ...le PE L3 L2 208 60 L1 E Stop Fuse Handle PE L3 L2 BRN WHT T1 C4 B4 A4 LT3 F1 F2 14 13 L1 200 VAC 4 1 L2 5 2 CON1 6 3 200 VAC 0 VAC T2 WIRED FOR 200 VAC 073026 073024 200 50 60 50 OR 60 Hertz 3 Phase 200 VAC 0 VAC 380 VAC GRY 415 VAC 013179 013 2 179 013179B7 ELEC GAS SCHEM MAX200 N A MAX200 7 OF 9 BC 5 9 96 NECESSARY WITH CHAMFER OR RADIUS 015 MATERIAL THIS DRAWING AND ALL INFORMATION FROM HYPERTH...

Page 158: ...15 VAC 3 Phase C C B B FL1 L3 380 415 50 CE B4 380 VAC 415 VAC T1 380 VAC 415 VAC L1 1 4 2 C4 0 VAC T2 5 3 6 CON1 A4 BLUE 14 F2 L2 400 VAC 240 VAC 220 VAC BRN VIO 013179 013 2 179 013179B8 ELEC GAS SCHEM MAX200 N A MAX200 8 OF 9 BC 5 9 96 NECESSARY WITH CHAMFER OR RADIUS 015 MATERIAL THIS DRAWING AND ALL INFORMATION FROM HYPERTHERM INC FOR MANUFACTURING OR FABRICATION CONTAINED THEREON IS CONSIDER...

Page 159: ...REACHES 26 psi NOTES 1 IN TEST MODE V1 V2 AND V3 ARE THE ONLY VALVES THAT ARE ACTIVE 2 WHEN V1 BECOMES ACTIVE AFTER START 10 TO 15 psi WILL BE REGISTERED AT PG1 3 THE HV TRANSFORMER IS ACTIVATED 2 SECONDS AFTER THE PLASMA START SIGNAL IT WILL STAY ACTIVE FOR 5 SECONDS OR UNTIL THE ARC TRANSFERS TO THE WORK PIECE WHICH EVER HAPPENS FIRST 013179 013 2 179 013179B9 ELEC GAS SCHEM MAX200 N A MAX200 9 ...

Page 160: ... PART MUST BE FREE OF BURRS AND DIMENSIONS ARE IN INCHES TOLERANCES ARE ANGULAR 5 FRACTIONS 1 64 2 PL DECIMAL 01 SCALE MODEL UNLESS OTHERWISE SPECIFIED DATE DATE DATE CHECKED BY APP BY DRAWN BY DESCRIPTION FILE NAME SHEET 029313 029 2 313 029313B4 RSVR SA MAX200 HT2000 PWR SPLY N A BMD 8 13 90 MER 10 10 91 WVB OVERFLOW RESERVOIR ON OFF PUMP RELIEF VALVE FLOAT SWITCH TEMP SWITCH CATHODE BLOCK HEAT ...

Page 161: ...MAX200 Instruction Manual a 1 14 Appendix A FILTERS In this section Hankison Centriflex Filters a 2 Hankison Aerolescer Filters a 4 Hankison Hypersorb Filters a 6 Wilkerson Type PC6 Filter regulator a 8 ...

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Page 170: ...1 Toxicological Information b 4 Section 12 Ecological Information b 5 Section 13 Disposal Considerations b 5 Section 14 Transport Information b 5 Section 15 Regulatory Information b 5 Section 16 Other Information b 5 Benzotriazole COBRATEC Safety Data Section I b 7 Section II Ingredients b 7 Section III Physical Data b 7 Section IV Fire and Explosion Hazard Data b 8 Section V Health Hazard Data b ...

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Page 175: ...b 6 Figure b 1 Freezing Point of Propylene Glycol Solution of Propylene Glycol Temperature F 70 60 50 40 30 20 10 0 10 20 30 40 0 10 20 30 40 50 60 ...

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Page 180: ...MAX200 Instruction Manual c 1 14 Appendix C AERATION MANIFOLD In this section Aeration Manifold for Plasma Cutting Aluminum c 2 Introduction c 2 Making an Aeration Manifold Figure c 1 c 2 ...

Page 181: ...en 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 c 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 eve...

Page 182: ...on Manual d 1 14 Appendix D ELECTROMAGNETIC COMPABILITY EMC In this section EMC Introduction d 2 General d 3 Power Cable d 3 Connect Power Cable d 3 Power Supply d 3 Line Disconnect Switch d 5 EMI Filter Parts List d 6 ...

Page 183: ...necessary to take additional precautions such as filter ing of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equiva lent Shielding should be electrically con tinuous throughout its length The shield ing should be connected to the cutting mains supply so that good electrical con tact is maintained betwe...

Page 184: ...ed cable sizes Final specification and installation of the power cord should be made by a licensed electrician and according to applicable national or local codes See also Mains Supply on page d 2 for further power supply cable shielding recommendations Connect power cable Connect one end of the power cable to the EMI filter first and then connect the other end to the line disconnect switch Power ...

Page 185: ... 60 40 20 O Z E R 80 GAS SHIELD 40 20 Z E R O 80 60 100 CAUTION d 4 MAX200 Instruction Manual 15 APPENDIX D ELECTROMAGNETIC COMPABILITY EMC 2 Unscrew the four filter cover screws and remove cover to access input voltage connections at TB1 see Figure d 2 3 Insert the power cable through the strain relief see Figure d 1 4 Connect leads L1 to U L2 to V and L3 to W terminals of TB1 see Figure d 3 Ensu...

Page 186: ...ents and Line Disconnect Switch on page 3 8 Figure d 3 Power Cable Connections to TB1 WARNING The neon light attached to the line filter will turn ON as soon as the line disconnect switch is ON This indicator is a warning that there is line voltage at the filter even if the ON 1 pushbutton on the MAX200 power supply has not been pressed As a common safety practice ALWAYS verify that the line disco...

Page 187: ...0 O Z E R 80 GAS SHIELD 40 20 Z E R O 80 60 100 CAUTION d 6 MAX200 Instruction Manual 15 APPENDIX D ELECTROMAGNETIC COMPABILITY EMC EMI Filter Parts List Part Item Number Description Qty 001557 Cover 200 2000 CE Electronic Filter Enclosure 1 1 001558 Enclosure 200 2000 CE Electronic Filter 1 2 001559 Cover 200 2000 CE Top 1 3 008489 Bushing 1 97 ID X 2 5 Hole Black Snap 1 4 008610 Strain Relief 1 ...

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Hypertherm MAX200, Instruction Manual

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