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powermax

380

Operator Manual

5-1

0

Section 5

MAINTENANCE AND PARTS

In this section:

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

Inspect Consumables......................................................................................................................................5-3

Controls and Indicators ...................................................................................................................................5-4

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

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

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

Torch Consumables...............................................................................................................See Section 4

PAC110T Hand – Torch Assembly..........................................................................................................5-9

Power Supply – Filter Regulator...........................................................................................................5-10

Power Supply – Work Cable.................................................................................................................5-10

Powermax380 Labels ...........................................................................................................................5-11

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Summary of Contents for powermax 380

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

Page 2: ...1 Hypertherm Inc Hanover NH USA www hypertherm com email info hypertherm com Copyright 2001 Hypertherm Inc All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries ...

Page 3: ...l 65 841 2490 Fax 65 841 2489 Technical Service Japan Shinjuku Park Tower 30th Floor 3 7 1 Nishi Shinjuku Shinjuku ku Tokyo 163 1030 Japan 81 03 5326 3142 Tel 81 03 5326 3001 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 33 1 30 37 15 28 Tel 33 1 30 37 15 79 Fax Hypertherm...

Page 4: ...ection 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 risk ...

Page 5: ...actured 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 you alleging that the use of the Hypertherm product alone and n...

Page 6: ... Arc Can Damage Frozen Pipes 1 5 Additional Safety Information 1 5 Warning Label 1 6 Section 1a Sécurité 1a 1 Identifier les consignes de 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 ...

Page 7: ...3 6 Air Hose Connection 3 7 Section 4 Operation 4 1 Controls and Indicators 4 2 Installing Torch Consumables 4 3 Turn On Power 4 4 Adjust Gas Pressure and Current Setting 4 4 Check Indicator Lights 4 5 Hand Torch Operation 4 6 Section 5 Maintenance 5 1 Routine Maintenance 5 2 Inspect Consumables 5 3 Controls and Indicators 5 4 Basic Troubleshooting 5 5 Technical Questions 5 7 Parts 5 8 Torch Consu...

Page 8: ...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 9: ... 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 10: ... 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 11: ...ant 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 o...

Page 12: ...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 13: ...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 14: ...T 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 LES RAYONS DE L ARC PEUVENT BRÛLER LES YEUX ET LA PEAU 1a 4 MISE À LA MASSE ET À LA TERRE 1a 4 SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ 1a 5 LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES 1a 5 LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS 1a 5 PAC...

Page 15: ...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 16: ...s du coupage Laisser la pièce à couper en place ou sur la table de travail le câble de retour connecté lors du coupage Avant de vérifier de nettoyer ou de remplacer les pièces de la torche couper l alimentation ou débrancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de sécurité Avant d enlever le capot du système ou de la source de courant couper l alimentation ...

Page 17: ...fixer le câble de retour à la partie de la pièce qui doit se détacher Table de travail Raccorder la table de travail à la terre conformément aux codes de sécurité locaux ou nationaux appropriés MISE À LA MASSE ET À LA TERRE Alimentation S assurer que le fil de terre du cordon d alimentation est connecté à la terre dans le coffret du sectionneur S il est nécessaire de brancher le cordon d alimentat...

Page 18: ...ter à tout prix le contact électrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs Utiliser un casque de p...

Page 19: ...s 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 ...

Page 20: ...powermax380 Operator Manual 2 1 0 Section 2 SPECIFICATIONS In this section Specifications Power Supply 2 2 Specifications PAC110T Torches 2 3 Symbols and Markings 2 4 ...

Page 21: ... cycle 100 I2 17 A U2 87 V Operating Temperature 4 to 104 F 20 to 40 C Storage Temperature 58 to 131 F 50 to 55 C Power Factor 0 975 Rated Pilot Current 12 A Input Voltage U1 Input Current I1 at 115 V 28 A Rated Output U2 MAX I2 MAX 230 V 14 A Gas Type Air Nitrogen Gas Quality Clean dry oil free 99 995 pure Gas Inlet Pressure and Flow See Setup Section 3 Powermax380 Power Supply Dimensions and Wei...

Page 22: ... 4 inch 6 mm 27A 35 duty cycle Maximum Cutting Capacity 3 8 inch 10 mm 27A 35 duty cycle Severance Cutting Capacity 1 2 inch 12 mm 27A 35 duty cycle Gas Flow 270 scfh 4 5 scfm 60 psi 127 l min 4 2 bar Weight 3 pounds 1 4 kg PAC110T Torch Dimensions PAC110T 8 72 221 mm 8 5 216 mm 3 10 79 mm 1 58 40 mm 1 00 25 mm ...

Page 23: ...he TEST position cooling and cutting gas exiting nozzle Symbols and Markings S Mark The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock IEC Symbols Used The following symbols may appear on the power supply data plate control labels and switches AC AC ON Alternating current AC Inlet gas pressure Consumables are loose or...

Page 24: ... Claims 3 2 Contents of Box 3 2 Locating Power Supply 3 2 115 230 Voltage Configurations 3 2 Input Voltage Selector Switch 3 3 Power Cord Plugs 3 4 Grounding 3 4 Extension Cords 3 5 Work Cable and Clamp 3 5 Plasma Gas Supply 3 6 Additional Gas Filtration 3 6 Gas Supply Connection 3 7 ...

Page 25: ...ront of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor OEM If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Contents of Box Verify items against the illustration shown CAUTION SYSTEM CIRCUIT REQUIREMENTS A circuit capable of 20A 115V or 10A 230V is required f...

Page 26: ...s shown below 230 V 1 PH 120 V 1 PH or Voltage selector switch 1 Turn power OFF 2 Remove power cord from power receptacle 3 Set input voltage Determine correct switch position for the voltage required Voltage selector switch is accessible through slot in rear panel OFF 0 140 140 50 50 100 100 ON OFF CAUTION Do not reposition Voltage Selector Switch with power ON Damage to the power supply will res...

Page 27: ...out a plug on the power cord To operate at 230V obtain a plug that meets national or local electrical codes The plug should be connected to the power cord by a licensed electrician Also note that some 115V receptacles may require a plug that is different from the plug on the power cord To install the required plug refer to figure below The installed 115V plug and cords must conform to national or ...

Page 28: ...ecommended Voltage Phase Cord Gauge Size Length 115 VAC 1 12 AWG 53 ft 16 m 230 VAC 1 14 AWG 133 ft 41 m A Work Cable and Clamp The work clamp must be attached to the workpiece while cutting Ensure that the work clamp and the workpiece make good metal to metal contact Attach the work clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields EMF Do not atta...

Page 29: ... 4 2 bar If gas supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Gas supply Powermax380 Water particle filter Oil filter Oil vapor filter Additional Gas Filtration Use a 3 stage coalescing filtration system as shown when site conditions introduce moisture oil or other contaminants into the air line WARNING Do not all...

Page 30: ...n tape when installing the nipple or adapters Bits of tape can break off and enter the air line and harm the pressure regulator pressure switch and valve Nipple is found in the consumables box located on the left side of the power supply cover 2 Air hose Use an inert gas hose with a 3 8 inch 9 5 mm internal diameter and a 1 4 NPT quick disconnect coupler Connect it to the nipple installed in step ...

Page 31: ... Manual 4 1 0 Section 4 OPERATION In this section Controls and Indicators 4 2 Installing Torch Consumables 4 3 Turn Power ON 4 4 Adjust Gas Pressure and Current Setting 4 4 Check Indicator LEDs 4 5 Hand Torch Operation 4 6 ...

Page 32: ...ssure is below 40 psi 2 8 bar Yellow TORCH CAP LED When illuminated indicates that the torch consumables are loose or not installed Yellow TEMP LED When illuminated indicates that the power supply is out of its operating range AMPS GAS TEST SET Adjustment Knob Adjusts output current between 14 and 27 amps The position allows adjustment of the air pressure Pressure Gauge Indicates gas pressure at t...

Page 33: ...C CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly cut through gloves and skin Make sure power is OFF before changing consumables Installing Torch Consumables Hand tighten only OFF 220016 120504 020382 220013 ...

Page 34: ... and Current Setting Turn Power ON OFF 0 140 140 50 50 100 100 ON ON Set current knob to gas test Pull regulator knob to unlock 0 140 140 50 50 100 100 Set pressure to 60 psi 4 2 bar Push regulator knob to lock Turn current knob away from gas test to stop gas flow ...

Page 35: ...x380 Operator Manual 4 5 0 Check Indicator LEDs AC AC ON See Basic Troubleshooting Section 5 for additional information Power ON system ready System is ready when lights are as shown Temperature Torch parts Gas pressure ...

Page 36: ... on immediately when the torch switch is activated The plasma arc will quickly cut through gloves and skin Keep away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others Safety Trigger Operation Avoid firing the torch when it is not in contact with the workpiece ...

Page 37: ...re moving the torch too fast or without sufficient power Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line Firing the torch unnecessarily reduces nozzle and electrode life Pulling the torch through the cut is easier than pushing it To cut thin material reduce the amps until you get the best quality cut For straight line cuts use a straight edge as a guide To ...

Page 38: ...al 0 Starting a cut from the edge of the workpiece Hold the torch vertical at the edge of the workpiece Start cut at the edge of the workpiece Pause at the edge until the arc has completely cut through the workpiece Then proceed with the cut ...

Page 39: ...int the torch away from yourself and others Piercing Hold the torch so that the nozzle is within 1 16 inch 1 5 mm from the workpiece before firing the torch Fire the torch at an angle to the workpiece then slowly rotate it to an upright position When sparks are exiting from the bottom of the workpiece the arc has pierced through the material When the pierce is complete proceed with the cut ...

Page 40: ...Stainless Steel 27 16 400 3 8 9 0 Stainless Steel 27 8 220 18 ga 1 3 Aluminum 27 192 4875 10 ga 3 4 Aluminum 27 51 1300 1 4 6 0 Aluminum 27 13 345 3 8 9 0 Aluminum 27 8 200 To cut material above 6 mm start torch at edge of material OPERATION 4 10 powermax380 Operator Manual 0 Torch Operation Cut Chart 27 Amp Standard Consumables Torch to work distance for the following cut chart is 1 16 inch 1 5 m...

Page 41: ...utine Maintenance 5 2 Inspect Consumables 5 3 Controls and Indicators 5 4 Basic Troubleshooting 5 5 Technical Questions 5 7 Parts 5 8 Torch Consumables See Section 4 PAC110T Hand Torch Assembly 5 9 Power Supply Filter Regulator 5 10 Power Supply Work Cable 5 10 Powermax380 Labels 5 11 ...

Page 42: ...0 50 50 100 100 PA C 11 0T Check gas pressure Replace damaged power cord or plug Replace damaged torch lead Check pressure hose and connections for leaks Clean the inside of the power supply with air pressure or vacuum Replace damaged labels Check torch cap on safety switch listen for click when the retaining cap is loosened Check consumables for wear and proper installation Check trigger for dama...

Page 43: ...ndness of through hole Center surface Maximum pit depth Replace 1 16 inch 1 6 mm Electrode Max 1 16 inch Part Check For Action External surfaces Damage or debris Replace Gas holes Blocked holes Replace Swirl Ring External surfaces Damage or wear Replace Lubricated Apply a thin film of silicone lubricant Torch O ring ...

Page 44: ...as pressure is below 40 psi 2 8 bar Yellow TORCH CAP LED When illuminated indicates that the torch consumables are loose or not installed Yellow TEMP LED When illuminated indicates that the power supply is out of its operating range AMPS GAS TEST SET Adjustment Knob Adjusts output current between 14 and 27 amps The position allows adjustment of the air pressure Pressure Gauge Indicates gas pressur...

Page 45: ...ltage selector switch position is not set to match the input voltage the POWER ON LED will not illuminate the torch will be disabled and the fan will rotate slowly To clear this fault see Input Voltage Selector Switch Section 3 3 The POWER ON LED is blinking 3 1 Line voltage is either too low or too high The following table lists the operating range of the Powermax380 power supply Have an electric...

Page 46: ... drops below 40 psi after the torch trigger is pressed the GAS PRESSURE LED will blink Check the torch lead and air hose from the gas supply for pinched hoses or obstructions Check that the gas pressure has been set correctly See Plasma Gas Supply Section 3 6 The POWER ON LED is illuminated and the TORCH CAP LED is illuminated 6 1 Torch consumables are loose or removed from the torch Turn power su...

Page 47: ...ir air filtration to power supply See Additional Gas Filtration Section 3 12 Cut quality is not good 12 1 Consumables are worn or the torch is being used incorrectly See Inspect Consumables in this section See Hand Torch Operation Section 4 Technical Questions If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance 1 Call your Hypertherm...

Page 48: ...Replacement Start Switch switch and wire splices 1 4 027254 Trigger Spring 1 5 004764 Gutcha Retaining Ring 1 6 075339 Screws P S 4 X 1 2 PH RND S B 5 7 120976 Torch Main Body with Safety Switch 1 8 058503 O Ring Viton 625 X 070 1 9 128554 Replacement 20 ft 6 1 m Torch Lead 1 Top assembly includes the following consumables See page 4 3 for details of consumable parts 020382 Electrode 1 220013 Swir...

Page 49: ...powermax380 Operator Manual 5 9 0 MAINTENANCE AND PARTS Included with replacement assembly ...

Page 50: ... MAINTENANCE AND PARTS Part Item Number Description Qty 1 060197 Air filter element 1 2 060203 O ring 1 Power Supply Work Cable Part Item Number Description Qty 1 060009 Work Cable with clamp 15 ft 4 6 m 1 Power Supply Filter Regulator ...

Page 51: ...o not touch live electrical Do not touch live electrical Electric shock can kill Electric shock can kill WARNING WARNING AVERTISSEMENT AVERTISSEMENT AVIS AVIS CET CET ENLEVER ENLEVER PAS PAS NE NE MARKING MARKING THIS THIS REMOVE REMOVE NOT NOT DO DO votre entreprise votre entreprise egalement les consignes de securite de egalement les consignes de securite de instructions du fabricant Appliquer i...

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