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MAXPRO200

Instruction Manual 807700 Revision 1

41

Installation

Upon receipt

•

Verify that all system components on your order have been received. Contact your supplier if any items
are missing.

•

Inspect the system components for any physical damage that may have occurred during shipping. If
there is evidence of damage, refer to

Claims

. All communications regarding claims must include the

model number and serial number located on the rear of the power supply.

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 listed in the front of this manual, or your authorized Hypertherm distributor.

Claims for defective or missing merchandise

– If any of the merchandise is defective or missing, contact your

supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized
Hypertherm distributor.

Installation requirements

All installation and service of the electrical and plumbing systems must conform to national and local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.

Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual,
or your authorized Hypertherm distributor.

Noise levels

Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always wear
proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific
environment in which the system is used. See also

Noise can damage hearing

in the Safety section of this manual.

Specific information by product can be found in the Hypertherm downloads library at:

https://www.hypertherm.com/Xnet/library/DocumentLibrary.jsp

Select the product you are looking for from the Product Type drop down menu, choose “Regulatory” from the Category
drop down menu, and choose “Acoustical Noise Data Sheets” from the Sub Category drop down menu. Press Submit.

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Summary of Contents for MAXPRO200

Page 1: ...MAXPRO200 Instruction Manual 807700 Revision 1 ...

Page 2: ...___________________________ ____________________________________________________________________________ Maintenance notes ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ______________________________________________...

Page 3: ...MAXPRO200 Instruction Manual 807700 Revision 1 English March 2013 Hypertherm Inc Hanover NH 03755 USA ...

Page 4: ...89 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service H...

Page 5: ...ircuit boards 13 Compressed gas equipment safety 14 Gas cylinders can explode if damaged 14 A plasma arc can cause injury and burns 14 Arc rays can burn eyes and skin 15 Pacemaker and hearing aid operation 16 Noise can damage hearing 16 A plasma arc can damage frozen pipes 16 Dry dust collection information 17 Laser radiation 18 Symbols and marks 19 Additional safety information 20 Warning labels ...

Page 6: ...ation test marks 27 Differences in national standards 27 Safe installation and use of shape cutting equipment 28 Procedures for periodic inspection and testing 28 Qualification of test personnel 28 Residual current devices RCDs 28 Higher level systems 29 Environmental Stewardship 31 Introduction 31 National and local environmental regulations 31 The RoHS directive 31 Proper disposal of Hypertherm ...

Page 7: ...actices 44 Placement of the power supply 48 Torch lead connections 49 Work lead connections 52 Torch connections 53 Connect the torch to the quick disconnect receptacle 54 Torch mounting and alignment 55 Mounting the torch 55 Torch alignment 55 CNC interface cable 56 Notes to CNC interface cable run list 56 Remote ON OFF switch provided by customer 58 Power requirements 60 General 60 Line disconne...

Page 8: ...ls and indicators 76 Power supply operation 77 General 77 3 digit display functions 78 Choosing a cutting process 79 Handheld cutting 80 Specifications 80 Consumable selection and gas settings 80 Starting a cut 80 Piercing 81 Gouging 82 Specifications 82 Gouging safety 82 Gouge a workpiece 82 Gouging techniques 83 Straight gouging 83 Side gouging 84 Gouge profiles and metal removal rates 85 Varyin...

Page 9: ... torch 95 Optimizing cut quality 96 Tips for table and torch 96 Plasma setup tips 96 Maximize the life of consumable parts 96 Additional factors of cut quality 97 Cut angle 97 Dross 98 Straightness of the cut surface 98 How to increase cutting speed 98 Estimated kerf width compensation 99 Metric 99 English 100 Cut charts 101 Maintenance 119 Introduction 119 Preventive maintenance 119 Power supply ...

Page 10: ...rrent 151 Chopper tests 152 Automatic chopper and current sensor tests during power up 152 Using a meter to measure open circuit voltage OCV 153 Phase loss detection 154 Torch lead test 155 Preventive maintenance 156 Introduction 156 Preventive maintenance protocol 156 The power supply 156 Cooling system 157 Torch main body 157 Gas flows 157 Cable connections 158 Ignition enclosure 158 System grou...

Page 11: ...23273 173 Power supply gas hose kit 228862 173 Machine torches 174 Straight torch 174 Quick disconnect torch 174 Leads and cables 175 Machine torch leads 175 CNC cables 175 Work leads 175 Work clamp 175 Hand torch leads 175 Inline valve kit 175 Hand torch heat shield 127389 175 90 degree hand torch 176 65 degree hand torch 177 Consumable parts kits 178 Mechanized torch consumable kit 428013 178 Ha...

Page 12: ...on information on ingredients 198 4 First aid measures 198 5 Fire fighting measures 198 6 Accidental release measures 199 7 Handling and storage 199 8 Exposure controls personal protection 199 9 Physical and chemical properties 200 10 Stability and reactivity 200 11 Toxicological information 201 12 Ecological information 201 13 Disposal considerations 201 14 Transport information 202 15 Ecological...

Page 13: ...hine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the controls properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life ELECTRICAL HAZARDS Only trained and author...

Page 14: ... quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn ...

Page 15: ... any closed container Do not cut containers that have held combustible materials WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma WARNING Explosion Haza...

Page 16: ...ite owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations The air quality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Durat...

Page 17: ...ower 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 connect the power cord ground wire properly Place the power cord s 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...

Page 18: ...de Handle and use compressed gas cylinders in accordance with applicable national and local codes Never use a cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Neve...

Page 19: ...onal and local codes Wear eye protection safety glasses or goggles with side shields and a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays 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 to cover all exposed ...

Page 20: ...hearing protection is not necessary per relevant international regional and local codes Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation and or locating the workstation away from the plasma arc Implement administrative controls in the workplace to restrict access li...

Page 21: ...NFPA68 for definitions and explanations of regulatory terms such as deflagration AHJ adopted by reference the Kst value deflagration index and other terms Note 1 Hypertherm s interpretation of these new requirements is that unless a site specific evaluation has been completed to determine that all dust generated is not combustible the 2007 edition of NFPA 68 requires the use of explosion vents des...

Page 22: ...s in the hands of untrained users Do not look into the laser aperture or beam at any time Position the laser as instructed to avoid unintentional eye contact Do not use the laser on reflective workpieces Do not use optical tools to view or reflect the laser beam Do not disassemble or remove the laser or aperture cover Modifying the laser or product in any way can increase the risk of laser radiati...

Page 23: ... manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated with...

Page 24: ...ng yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 6 Become trained Only qualiﬁed personnel should operate this equipment Use torches speciﬁed in the manual Keep non qual...

Page 25: ...mplete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not oper...

Page 26: ...22 MAXPRO200 Instruction Manual 807700 Revision 1 Safety ...

Page 27: ...n 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 signaling and telephone cables above below and adjacent to the cutt...

Page 28: ...d receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components Earthing of the 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 steel work a connection bondi...

Page 29: ...of delivery to you This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any product which has been incorrectly installed modified or otherwise damaged H...

Page 30: ...ty of such damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices Liability cap In no event shall Hypertherm s liability if any whether such liabi...

Page 31: ...t is designed into the product as part of the certification or otherwise CE marking constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters nee...

Page 32: ...ion be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment is installed Residual current devices RCDs In Australia and some other countries local codes may require the use of a Residual Current Devices RCD when portable electrical equipment is used in the workplace or at construction sites to protect operators from...

Page 33: ...ertified when the OEM incorporates Hypertherm products into it the installation also may be subject to approval by local authorities Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use instal...

Page 34: ...30 MAXPRO200 Instruction Manual 807700 Revision 1 Product Stewardship ...

Page 35: ...oHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm There is also a RoHS mark on the Powermax CE versions below the CE Marking on the data plate of CE versions of Powermax series units shipped since 2006 Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt ...

Page 36: ...herm com On the Search screen insert MSDS in the document title and click on Search In the USA OSHA does not require Material Safety Data Sheets for articles such as electrodes swirl rings retaining caps nozzles shields deflectors and other solid parts of the torch Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials t...

Page 37: ... coupled to the pilot arc lead Torch The maximum production cutting capacity is the maximum thickness that can be cut with a 100 duty cycle The maximum production cutting capacity of the MAXPRO200 torch is 32 mm 1 1 4 inches for mild steel using the 200 amp O2 Air process 22 mm 7 8 inch for stainless steel and 19 mm 5 8 inch for aluminum using the 200 amp Air Air process Maximum pierce capacity is...

Page 38: ...34 MAXPRO200 Instruction Manual 807700 Revision 1 Specifications ...

Page 39: ...ssure 10 Flow rate O2 oxygen 99 5 pure liquid gas recommended Clean dry and oil free 621 kPa 6 2 bar 90 psi 3400 l h 120 scfh N2 nitrogen 99 9 pure liquid gas recommended Clean dry and oil free 621 kPa 6 2 bar 90 psi 11330 l h 400 scfh Air Clean dry and oil free ISO 8573 1 class 1 4 2 621 kPa 6 2 bar 90 psi 11330 l h 400 scfh Gases by process Mild steel Stainless steel Aluminum Amperage Plasma gas...

Page 40: ...ing Forced air Class F Insulation Class H Power supply part numbers AC Voltage U1 Phase Frequency Hz Amperage l1 Regulatory approval Power kVA 10 U1 x l1 x 1 73 078610 200 208 3 50 108 104 CSA 37 4 078611 220 3 50 60 98 CSA 37 4 078612 240 3 60 90 CSA 37 4 078613 380 3 50 57 CCC 37 4 078614 400 3 50 60 54 CE GOST R 37 4 078615 415 3 50 52 CE GOST R 37 4 078616 440 3 50 60 49 CSA 37 4 078609 480 3 ...

Page 41: ...ide diameter of the torch mounting sleeve is 50 8 mm 2 0 inches The minimum bend radius for the torch lead is 152 4 mm 6 0 inches 1 397 15 mm 15 64 inches 2 279 40 mm 11 00 inches 3 117 75 mm 4 64 inches 4 12 70 mm 0 50 inches 5 44 20 mm 1 74 inches 6 46 degrees 7 44 20 mm 1 74 inches 7 6 5 4 3 2 1 1 02 kg 2 25 lb ...

Page 42: ...le with an outside diameter of 50 8 mm 2 0 inches or 44 45 mm 1 75 inches The minimum bend radius for the torch lead is 152 4 mm 6 0 inches 1 435 33 mm 17 14 inches 2 279 40 mm 11 00 inches 3 76 98 mm 3 03 inches 4 78 95 mm 3 11 inches 5 12 70 mm 0 50 inches 6 44 20 mm 1 74 inches 7 46 degrees 8 57 15 mm 2 25 inches 9 44 20 mm 1 74 inches 7 6 5 4 3 2 1 8 9 1 45 kg 3 20 lb ...

Page 43: ...ecifications Hand torches 90 degree hand torch 420108 The minimum bend radius for the torch lead is 152 4 mm 6 0 inches 1 310 40 mm 12 22 inches 2 90 degrees 3 44 20 mm 1 74 inches 4 305 05 mm 12 01 inches 5 149 10 mm 5 87 inches 4 3 2 1 5 0 91 kg 2 0 lb ...

Page 44: ...n 1 Specifications 65 degree hand torch 420107 The minimum bend radius for the torch lead is 152 4 mm 6 0 inches 1 290 58 mm 11 44 inches 2 65 degrees 3 44 20 mm 1 74 inches 4 285 24 mm 11 23 inches 5 238 51 mm 9 39 inches 4 3 2 1 5 0 91 kg 2 0 lb ...

Page 45: ...d in the front of this manual or your authorized Hypertherm distributor Installation requirements All installation and service of the electrical and plumbing systems must conform to national and local electrical and plumbing codes This work should be performed only by qualified licensed personnel Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the fr...

Page 46: ...Use the diagram in this section for component placement guidelines Ground all system components to earth See Recommended grounding and shielding practices on page 44 for details To prevent leaks in the system tighten all gas connections as shown below Torque specifications Gas or water hose size kgf cm lbf in lbf ft Up to 10 mm 3 8 in 8 9 9 8 75 85 6 25 7 12 mm 1 2 in 41 5 55 360 480 30 40 ...

Page 47: ...00 Revision 1 43 Installation System components Power supply Torch Cable and lead Torch lead Work lead CNC interface cable Supply gas hoses Air N2 O2 Customer supplied power cable Main power cable A 2 B 1 2 3 4 5 6 7 A B 1 2 3 4 5 6 7 ...

Page 48: ...ground also called cutting current ground is the grounding system that completes the path of the cutting current from the torch back to the plasma system It requires that the positive lead from the plasma system be firmly connected to the cutting table ground bus with a properly sized cables It also requires that the slats on which the workpiece rests make firm contact with the table and the workp...

Page 49: ...e whether if it is bolted to the plasma system or to the cutting table 10 The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch It must be electrically insulated from any metal and from any contact with the floor or building The torch lead can be run in a plastic cable tray or track or covered with a plastic or leather sheath 11 The torch hold...

Page 50: ... individual ground cables from the components mounted on the gantry go to the bus A single heavy cable then goes from the gantry ground bus to the table ground bus The following diagram shows an example of grounding the components in a plasma cutting system 5 4 3 2 6 7 1 Gantry ground bus 2 Ground rod 3 Plasma system lead 4 Remote high frequency RHF console 5 CNC enclosure 6 Torch holder 7 Plasma ...

Page 51: ...Connect to table ground bus bar 2 Gantry 8 9 System specific component such as metering console gas console or selection console 3 Plasma system 10 CNC chassis 4 Table ground bus bar 11 Torch height control module ArcGlide CommandTHC 5 Gantry ground bus bar 12 System specific component such as a cooler or chiller 6 Torch height control lifter ArcGlide Sensor THC Sensor PHC or other ...

Page 52: ...is free of excessive moisture has proper ventilation and is relatively clean Allow 1 m 3 ft of space on all sides of the power supply for ventilation and service Cooling air is drawn in through the side panel and is exhausted through the rear of the unit by a cooling fan Do not place any filter device over the air intake locations which reduces cooling efficiency and VOIDS THE WARRANTY Do not plac...

Page 53: ...ng of the ignition enclosure as shown below Secure the collar on the torch lead to the ignition enclosure by aligning the tabs on the collar with the corresponding openings in the ignition enclosure rotate the collar until it stops and verify that the collar will not detach when released 2 Connect the CPC connector to the CPC receptacle 1 ...

Page 54: ...nect fittings To make a connection push the hose fitting into the appropriate connector until it stops 12 mm 0 472 in To disconnect a fitting push the connector collar and hose toward the fitting hold the collar in place and pull the hose away from the fitting 3 Connect the coolant return hose red 4 Connect the plasma gas hose black Connector collar ...

Page 55: ... below are slightly different push to connect fittings Slide the hose fitting over the connector and press until it clicks into place To disconnect a fitting pull the connector collar toward the hose and pull the hose away from the fitting 5 Connect the pilot arc shield gas hose blue 6 Connect the negative lead coolant supply hose blue with green tape ...

Page 56: ...Work lead connections Remove the first nut and washer from the work lead terminal and use it to secure the work lead to the terminal Part number Length 223335 7 5 m 25 ft 223336 15 m 50 ft 223337 23 m 75 feet 223338 30 m 100 feet 2 Lower frame of work table typical ...

Page 57: ...tween the straight torch main body and the torch leads are identical to the connections between the quick disconnect receptacle and the torch leads Align the quick disconnect receptacle or the straight torch main body to the torch leads and secure using the push to connect fittings B Connect to torch lead ...

Page 58: ...rch body to the quick disconnect receptacle and connect them by screwing completely together Apply a thin film of silicone lubricant to each o ring The o rings should look shiny but there should not be any excess or built up lubricant Be certain that there is no space between the torch body and the o ring on the quick disconnect ...

Page 59: ... bracket so that the bracket is around the lower portion of the torch sleeve but not touching the torch quick disconnect 3 Tighten the securing screws Note The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch Torch alignment To align the torch at right angles to the workpiece use a square as shown above 1 2 3 1 Torch sleeve 2 Mounting bracket 3...

Page 60: ...e next page Part Number Length Part Number Length 223327 1 3 m 5 feet 223330 15 m 50 feet 223328 3 0 m 10 feet 223331 23 m 75 feet 223329 7 5 m 25 feet 223332 30 m 100 feet Power supply end CNC end Wire color Pin number Input Output Signal name Function Input Output Notes Orange 1 Input Start The CNC initiates preflow and if the hold input is not active continues with the plasma arc The system wil...

Page 61: ...MAXPRO200 Instruction Manual 807700 Revision 1 57 Installation CNC cable routing and connection to control board To J6 on the control board from the CNC ...

Page 62: ...2 Remove the jumper wire between terminal 1 and terminal 2 Use a sturdy tool to depress the corresponding orange release buttons on the spring clamp connector WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring the removal of the plasma system cover must be performed by a qualified technician See Safety on page 9 of your instruction manu...

Page 63: ...se buttons on the spring clamp connector Note The power switch on the power supply must be in the ON position for the remote switch to function and the remote switch must be in the ON position closed for the power switch on the power supply to function 1 2 3 4 5 6 7 Note Use a switch relay or solid state relay that is compatible with 24 VDC 100 mA Wires should be a twisted pair ...

Page 64: ...ads for both inrush and steady state current The power supply must be wired into one of the branch feed circuits The power supply has a steady state current listed in the table below Use a motor start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national codes Time delay fuses and circuit breakers must be capable of withstanding inrush current that i...

Page 65: ...pply voltage when in the OFF position Have one OFF and one ON position clearly marked with O OFF and l ON Have an external operating handle capable of being locked in the OFF position Contain a power operated mechanism that serves as an emergency stop Have slow blow fuses installed for the proper breaking capacity see table on previous page Main power cable Wire sizes vary based on the temperature...

Page 66: ...isconnect switch is in the OFF position and remains in the OFF position for the remainder of the installation of the system 5 Connect the power cord leads to the line disconnect switch following national and local electrical codes WARNING ELECTRIC SHOCK CAN KILL The line disconnect switch must be in the OFF position before making the power cable connections In the U S use a lock out tag out proced...

Page 67: ...F to 104 F Refer to the custom coolant mix recommendations if temperatures during operation are ever outside of this range Hypertherm premixed coolant consists of 69 8 water 30 propylene glycol and 0 2 benzotriazole WARNING COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF SWALLOWED Propylene glycol and benzotriazole are irritating to skin and eyes and harmful or fatal if swallowe...

Page 68: ...e chart below for water purity requirements to achieve the required protection from freezing Note The maximum percentage of propylene glycol should never exceed 50 Freezing Point of Propylene Glycol Solution CAUTION For operating temperatures colder than the temperature stated above the percentage of propylene glycol must be increased Failure to do so could result in a cracked torch head hoses or ...

Page 69: ...imum specifications in the table below when using a custom coolant mix Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will alter the water flow and produce an unstable arc Water that does not meet the maximum purity specifications below can also cause problems Deionized water that is too pure will cause leaching problems with the co...

Page 70: ... times as needed until the flow symbol is selected The flow rate will be shown in the three digit display There is a 45 second delay before the system will report a low coolant flow error If the flow rate has not reached 1 9 liters per minute lpm 0 5 gallons per minute gpm the system will turn off the pump 3 If the system displays an error turn OFF the power to the system and add coolant to the ta...

Page 71: ...n 1 Disconnect the air supply hose from the filter regulator 2 Remove the Air fitting 015012 1 4 inch NPT X 6 MALE from the filter regulator a Install an 015103 adaptor to use the nitrogen supply gas hose offered by Hypertherm b Use the 1 4 inch NPT Female port from which the air fitting was removed to connect a user supplied N2 supply gas hose 3 Set the gas pressure regulators See Setting the sup...

Page 72: ... See Gas regulators on page 72 for a suitable oxygen regulator Note An oxygen fitting kit 428054 with the parts described below is available from Hypertherm There are several options for connecting the oxygen supply gas line a Remove the 015811 fitting and put on an 015009 fitting user must order the part See the note above Use the correct Hypertherm supply gas tubing 046231 to connect to the fitt...

Page 73: ...1 69 Installation b Use a suitable O2 fitting to connect to the 8 mm 5 16 inch tubing that you removed from the plasma gas Inlet c Remove the plasma gas tubing and 8 mm 5 16 inch fitting 015811 and connect to the 1 4 inch NPT female threads 015811 ...

Page 74: ...07700 Revision 1 Installation d Remove the bushing and fitting to connect to 1 4 inch G female threads 5 Reconnect the air supply 6 Set the gas pressure regulators See Setting the supply gas regulators on page 71 015810 and 051811 and ...

Page 75: ... to the system 3 After the purge cycle is complete press the current selection knob to get to the test mode When the test mode icon is illuminated turn the knob to get to test 005 Flow gas at full pressure Set all supply regulators to a system inlet pressure of 6 2 bar 90 psi 4 Press and release the current selection knob until the amps icon is illuminated CAUTION Gas supply pressures not within t...

Page 76: ...pply pressure from high pressure gas cylinders The high quality gas regulators listed below are available from Hypertherm and meet U S Compressed Gas Association CGA specifications In other countries select gas regulators that conform to national or local codes Part number Description 128544 Kit Oxygen 2 stage regulator 128548 Kit Oxygen 1 stage regulator for use with cryogenic liquid nitrogen or ...

Page 77: ...n as the plasma gas air must also be connected to the filter regulator Caution Never use teflon tape Caution When connecting oxygen to the power supply make sure that all hoses hose connections and fittings are acceptable for use with oxygen Installation must be made in accordance with national and local codes WARNING CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION Cutting with oxygen as the plasm...

Page 78: ...50 ft 024767 75 m 250 ft 024766 20 m 65 ft Part number Length Part number Length 024607 3 m 10 ft 024738 25 m 82 ft 024204 4 5 m 15 ft 024450 35 m 115 ft 024205 7 5 m 25 ft 024159 45 m 150 ft 024760 10 m 35 ft 024333 60 m 200 ft 024155 15 m 50 ft 024762 75 m 250 ft 024761 20 m 65 ft Part number Length Part number Length 024210 3 m 10 ft 024739 25 m 82 ft 024203 4 5 m 15 ft 024451 35 m 115 ft 02413...

Page 79: ...bles can cause the torch to malfunction and can shorten the life of the coolant pump See Install and inspect consumables on page 90 for details Refer to Cut charts to choose the correct consumables for your cutting needs 3 Replace consumable parts See Install and inspect consumables on page 90 for details 4 Make sure that the torch is perpendicular to the workpiece DANGER ELECTRIC SHOCK CAN KILL B...

Page 80: ...vision 1 Operation Controls and indicators Control panel descriptions 1 Power switch 2 3 digit display area 3 Current selection knob 4 2 digit plasma display area 5 Plasma gas knob 6 2 digit shield display area 7 Shield gas knob 1 2 3 5 4 6 7 ...

Page 81: ... 1 thru 5 If the system is powered up with the start signal on the 3 digit display will continue to count up When you turn ON the power to the system the displays shows the last process used The user can lock out all inputs current plasma gas and shield gas to the system by pressing and holding both the amps and shield gas control knobs until LOC appears in the 3 digit display The same process unl...

Page 82: ... illuminated fault icon When the fault icon is selected the error code appears in the 3 digit display If the error code is 60 or greater the system automatically selects the fault icon and the error code number flashes in the 3 digit display Press and hold the current selection knob to see the power supply status number for both types of error code 4 Coolant flow When the coolant flow icon is sele...

Page 83: ...sure will automatically be set when you choose a gas Turning the knob increases or decreases the pressure A blinking red dot appears in the bottom right corner of each display when the parameters have been changed from the default setting You can return to the default setting by pressing and releasing the knob until you return to the original gas selection 3 The shield gas pressure is set automati...

Page 84: ...f 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 2 Hold the torch lightly on the metal or just off the metal and drag the torch across the metal The arc transfers once the torch is within 6 mm 1 4 inch of the workpiece CAUTION SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch sp...

Page 85: ...rkpiece before squeezing the trigger switch This method maximizes the life of the consumables See figures below 2 Hold the torch at about a 45º angle to the workpiece pointing away from yourself then slowly roll it to a vertical position This is particularly important when cutting thicker material Make sure that the torch is pointed away from you and the people around you to avoid any danger from ...

Page 86: ...ing the torch 2 Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip and the workpiece Press the trigger to obtain a pilot arc Transfer the arc to the work piece 3 Maintain an approximate 45 angle to the workpiece as you feed into the gouge Push the plasma arc in the direction of the gouge you want to create Keep a small distance between the torch tip and the molten...

Page 87: ...MAXPRO200 Instruction Manual 807700 Revision 1 83 Operation Gouging techniques Straight gouging Straight gouge Weaving gouge ...

Page 88: ...84 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Side gouging Side gouge Weaving gouge ...

Page 89: ...10 7 mm 0 42 inches 5 4 4 mm 0 18 inches Typical gouge profile for 200A O2 Metal removal rate on mild steel 20 5 Kg hr 45 lbs hr Speed 1270 mm min 50 ipm Stand off 12 7 mm 0 5 inch Angle 35º 6 10 4 mm 0 41 inches 7 5 4 mm 0 21 inches 1 2 3 Operating parameters 1 Speed 635 to 1270 mm minute 25 to 50 ipm 2 Angle 35 to 45 degrees 3 Standoff 12 7 to 19 0 mm 0 5 to 0 75 inches Maximum arc stretch 76 mm...

Page 90: ...asing the current of the power supply will decrease width and decrease depth Cutting parameters The cut charts for the MAXPRO200 show the consumable parts cutting speeds and the gas and torch settings required for each process allowing for differences in the lead length These parameters are used for cutting with both mechanized and handheld torches the consumable part numbers listed with each cut ...

Page 91: ...Note consumable part numbers listed above each cut chart are specific to mechanized torches Mild steel 50 A Air Plasma Air Shield 50 A O2 Plasma Air Shield 130 A Air Plasma Air Shield 130 A O2 Plasma Air Shield 200 A Air Plasma Air Shield 200 A O2 Plasma Air Shield 200 A Gouging Air Plasma Air Shield 200 A Gouging O2 Plasma Air Shield 420063 220890 220529 220528 220935 420063 220891 220529 220528 ...

Page 92: ...eld 130 A N2 Plasma N2 Shield 200 A Air Plasma Air Shield 200 A N2 Plasma N2 Shield 200 A Gouging Air Plasma Air Shield 420063 220890 220529 220528 220935 420061 220892 220488 220487 220935 420061 220892 220488 020415 220935 420058 420044 220488 220937 220935 420058 220488 020415 220935 420044 420067 420066 220488 220937 220935 ...

Page 93: ...130 A N2 Plasma N2 Shield 200 A Air Plasma Air Shield 200 A N2 Plasma N2 Shield 200 A Gouging Air Plasma Air Shield 420063 220890 220529 220528 220935 420061 220892 220488 220487 220935 420061 220892 220488 020415 220935 420058 420044 220488 220937 220935 420058 220488 020415 220935 420044 420067 420066 220488 220937 220935 ...

Page 94: ...seated WARNING Always disconnect power to the power supply before inspecting or changing torch consumable parts Use gloves when removing consumables The torch might be hot Apply a thin film of silicone lubricant on each o ring The o ring should look shiny but there should not be any excess or built up lubricant Wipe the internal and external surfaces of the torch with a clean cloth or paper towel ...

Page 95: ... holes Replace the nozzle Center hole Must be round Replace the nozzle when the center hole is no longer round Signs of arcing Replace the nozzle O rings Damage Replace the o ring Lubricant Apply a thin film of silicone lubricant if the o rings are dry Swirl ring General Damage Replace the swirl ring Dirt or debris Clean and inspect for damage and replace if damaged Blocked gas holes Replace the s...

Page 96: ...ipe them off and use compressed air to blow them off before they are installed again This is especially critical for the nozzle retaining cap Quick disconnect maintenance The following steps should be completed every 5 10 times consumables are changed 1 Remove the torch from the quick disconnect assembly 2 Use compressed air to blow off all internal surfaces and the external threads 3 Use compress...

Page 97: ...ect torch Straight torch 1 Shield gas 2 Pilot arc 3 Coolant return 4 Plasma gas 5 Coolant supply 1 Plasma gas 2 Coolant supply also contains the negative lead 3 Shield gas also contains the pilot arc lead 4 Coolant return 1 2 3 4 5 1 2 3 4 5 Torch main body Quick disconnect receptacle 1 2 3 4 ...

Page 98: ...pect consumables on page 90 3 Remove the old water tube 4 Apply a thin film of silicone lubricant on the o ring and install a new water tube The o ring should look shiny but there should not be any excess or built up lubricant 5 Replace consumables See Install and inspect consumables on page 90 WARNING DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE Always disconnect power to the power suppl...

Page 99: ...th respect to the forward motion of the torch Torch to work distance is not correct check cut chart information Cutting speed is not correct check cut chart information Arc current is not correct check cut chart information Damaged or worn consumable parts see Install and inspect consumables on page 90 Short consumable life Causes can be Arc current arc voltage travel speed motion delay gas flow r...

Page 100: ...t and stop on the workpiece The torch should never fire into the air Starting the cut at the edge of the workpiece is acceptable as long as the arc is not fired in the air To start with a pierce use a pierce height that is 1 5 to 2 times the cut height Refer to the cut chart for your process for more information Each cut should end with the arc still attached to the workpiece to avoid arc blow out...

Page 101: ...em is being caused by the plasma system or the drive system a Make a test cut and measure the angle of each side b Rotate the torch 90 in its holder and repeat the process c If the angles are the same in both tests the problem is in the drive system If a cut angle problem persists after mechanical causes have been eliminated see Tips for table and torch check the cut height especially if cut angle...

Page 102: ...luminum Worn or damaged consumables may produce intermittent dross Straightness of the cut surface A typical plasma cut surface is slightly concave The cut surface may become more concave or convex Correct torch height is required to keep the cut surface acceptably close to straight A strongly concave cut surface occurs when the torch to work distance is too low Increase the arc voltage to increas...

Page 103: ... Air 2 68 2 90 2 98 2 95 3 12 3 53 3 98 4 20 4 37 5 02 5 69 200A O2 Air 2 55 2 95 3 11 3 04 3 13 3 44 3 96 4 60 5 15 5 77 6 40 Stainless steel Thickness mm 0 5 0 8 1 1 2 1 5 2 2 5 3 4 5 6 8 10 12 15 20 25 32 38 44 50 50A Air Air 1 45 1 71 1 77 1 68 1 56 1 52 1 50 1 55 1 66 1 71 130A Air Air 2 57 2 70 2 74 2 90 3 19 130A N2 N2 2 56 2 40 2 43 2 40 2 59 2 97 200A Air Air 3 03 2 76 2 76 2 76 2 98 3 35...

Page 104: ...el Thickness inches 018 020 024 030 036 048 060 075 105 125 135 3 16 1 4 5 16 3 8 1 2 5 8 3 4 7 8 1 1 1 4 1 1 2 1 3 4 2 50A Air Air 0 056 0 061 0 066 0 071 0 066 0 061 0 060 0 059 N A 0 063 0 068 0 067 130A Air Air 0 104 0 106 0 108 0 116 0 124 130A N2 N2 0 101 0 093 0 096 0 094 0 105 0 116 200A Air Air 0 119 0 105 0 109 0 109 0 120 0 131 0 135 0 134 0 143 0 152 0 184 200A N2 N2 0 132 0 124 0 116 ...

Page 105: ...tting with both mechanized and handheld torches the consumable part numbers listed with each cut chart are specific to mechanized torches Refer to Hand held cutting and gouging consumable selection on page 87 for the consumables to use for handheld torches for each process The cut chart values in this document are recommended to provide high quality cuts with minimal dross Because of differences b...

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