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Hypertherm POWERMAX 800 Operator'S Manual Download Page 34

3-12

S

ETUP

Operator Manual

TORCH LEAD CONNECTION

To connect the torch lead to the power supply:

1. Align the connector key plug (on torch lead) with the connector receptacle key slot (on power

supply) and push in until pins seat.

2. Turn the connector securing ring 1/4 turn to the left to ensure that the securing ring threads and

the connector receptacle threads are aligned prior to tightening.

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

PAC121MS ON/OFF Pendant Connection

To connect the on/off pendant lead to the PAC121MS machine torch pigtail:

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

and push in until pins seat.

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

PAC121MS Torch ON/OFF Switch Connection Data

The PAC121MS torch lead is supplied with a pigtail so that the on/off pendant may be used.  If you
want to use a different on/off switch configuration, note that the wiring configuration to the 3-socket
female receptacle on the pigtail is as follows:

Machine Torch Pigtail

To
Powermax800
power supply

Torch Lead

WARNING

Do not connect cutting machine interface START signal if using the

ON/OFF pendant! (See page 3-13)

On/Off Pendant

Socket A

White Wire

Socket B

Not Used

Socket C

Black Wire

9-96

Figure 3-14   ON/OFF Pendant Connection

Summary of Contents for POWERMAX 800

Page 1: ...EN50199 EN50192 Plasma Arc Cutting System Operator Manual 802270 Revision 5 ...

Page 2: ...m Inc P O Box 5010 Hanover New Hampshire 03755 5010 Tel 603 643 3441 Fax 603 643 5352 Copyright 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 5HYLVLRQ 1RYHPEHU ...

Page 3: ...anization ETSO Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm U K 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 Hyperth...

Page 4: ... additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the...

Page 5: ...THERM not in strict conformity with HYPERTHERM s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by HYPER THERM HYPERTHERM agrees to indemnify protect and hold harmless Distributors and their custom ers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because ...

Page 6: ...es 1a 2 Prévention des incendies 1a 2 Prévention des chocs électriques 1a 2 Prévention des explosions 1a 3 Protection contre le bruit 1a 4 Mise à la masse et à la terre 1a 4 Rappels de sécurité 1a 4 Prothèses électroniques 1a 4 SECTION 2 DESCRIPTION SPECIFICATIONS 2 1 Introduction 2 2 Specifications 2 3 PAC121 50A Torches 2 4 IEC Symbols Used 2 6 SECTION 3 SETUP 3 1 Upon Receipt 3 2 Claims 3 2 Hoi...

Page 7: ...es 400V CE 5 16 APPENDIX A CHANGING FUSES a 1 APPENDIX B STANDARDS INDEX b 1 APPENDIX C AERATION MANIFOLD c 1 ILLUSTRATIONS Figure 2 1 Powermax800 Hand Plasma Cutting System 2 2 Figure 2 2 Powermax800 Power Supply with Dimensions 2 3 Figure 2 3 PAC121TS Torch with Dimensions 2 4 Figure 2 4 PAC121MS Torch with Dimensions 2 4 Figure 2 5 S Mark Label 2 5 Figure 3 1 Powermax800 Power Supply Hoisting S...

Page 8: ...max800 Operating Indicators and Adjustments 4 3 Figure 4 3 Proper Work Clamp Connection 4 4 Figure 4 4 PAC121TS Torch Safety Trigger Operation 4 5 Figure 4 5A Consumables 4 7 Figure 4 5B Consumables CE Compliance 4 7 Figure 4 6 Starting a Cut 4 8 Figure 4 7 Cutting a Circle 4 9 Figure 4 8 Dragging the Torch 4 9 Figure 4 9 Piercing 4 10 Figure 4 10 Gouging 4 11 Figure 5 1 Filter Assembly 5 2 Figure...

Page 9: ...body workpiece or the water in a water table when operating the plasma system When using a water table be sure that it is correctly connected to earth ground Operating the plasma system completes an electrical circuit between the torch and the workpiece and anything touching the workpiece The workpiece is part of the electrical circuit WARNING Instant On Torches Instant on torches produce a plasma...

Page 10: ...an air supplied helmet 01 97 Fire Prevention Make fire extinguishers available in the cutting area Remove all combustible materials from the immediate cutting area to a distance of at least 35 feet 10 m Quench freshly cut metal or allow metal to cool before handling it or bringing it into contact with combustible materials Never use a plasma system to cut containers with potentially flammable mate...

Page 11: ...amine hoses at regular intervals for leaks wear loose connections or other hazard Replace hose that is damaged in any way Electric Shock Prevention continued Before changing the torch parts disconnect the main power or unplug the power supply After changing torch parts and replacing the retaining cap plug in the power supply again Never bypass or shortcut the safety interlocks Before removing a po...

Page 12: ...ose as possible to work cable Do not wrap the torch lead or work cable around your body Stay as far away from the power supply as possible Hoses continued Keep hose lengths to a minimum to prevent damage reduce pressure drop and to prevent possible flow restrictions Prevent kinking by laying out hoses as straight as possible between termination points Coil any excess hose and place it out of the w...

Page 13: ...s suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais couper de...

Page 14: ...et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du coupage Laisser la pièce à couper en place ou sur la table de travail le câble de retour connecté lors du coupage Avant de vérifier de nettoyer ou de remplacer les pièces de la torche couper l alimentation ou débrancher la prise de courant Ne jamais contourner ou court circuiter l...

Page 15: ...er le câble de retour à la partie de la pièce qui doit se détacher Table de travail Raccorder la table de travail à la terre conformément aux codes de sécurité locaux ou nationaux appropriés MISE À LA MASSE ET À LA TERRE Alimentation S assurer que le fil de terre du cordon d alimentation est connecté à la terre dans le coffret du sectionneur S il est nécessaire de brancher le cordon d alimentation...

Page 16: ...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 prote...

Page 17: ...Manual In this section Introduction 2 2 Specifications 2 3 Power Supply 2 3 PAC121 50A Torches 2 4 PAC121TS Hand Torch Assembly 2 4 PAC121MS Machine Torch Assembly 2 4 S Mark 2 5 IEC Symbols Used 2 6 Section 2 DESCRIPTION SPECIFICATIONS 9 96 ...

Page 18: ...lean dry and oil free When properly set and maintained the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality The Powermax800 can also cut with nitrogen when extended electrode life is a priority This instruction manual provides information for the user to set up and operate the system an...

Page 19: ...d in an ambient temperature above 86 F 30 C may show some decrease in duty cycle Apparent Input Power S1 10 4kVA U1 I1 Input Voltage U1 Input Current I1 6 kw Output 208V 50A 240V 43A 480V 25A 1φ 60 Hz 208V 29A 240V 25A 480V 13A 3φ 60 Hz 200V 52A 230V 45A 400V 30A 1φ 50 60 Hz 200V 30A 230V 26A 400V 16A 3φ 50 60 Hz 400V CE 16A 3φ 50 60 Hz 600V 11A 3φ 60 Hz Dimensions and Weight Depth 23 1 590 mm Wid...

Page 20: ...y PAC121TS 3 4 20 mm 50 duty cycle Maximum 50A Cutting Capacity PAC121MS 3 8 10 mm 50 duty cycle Maximum 35A Cutting Capacity PAC121MS 1 4 6 mm 100 duty cycle Maximum current at 50 duty cycle 50 amps Gas Flow 320 scfh 5 3 scfm at 70 psi 150 l min at 4 8 bar Gouging Capability metal removal rate 6 3 pounds 2 9 kg hr Weight PAC121TS 4 5 pounds 2 kg with 25 ft 7 6 m lead 7 pounds 3 2 kg with 50 ft 15...

Page 21: ...d Figure 2 5 7 99 Figure 2 5 S Mark Label WARNING The voltage between the tip of the torch and the workpiece will exceed 113VDC if shielded consumable parts are not installed in the torch If using the 400V CE power supply the PAC121TS torch must be operated with shielded parts to maintain the S mark and CE low voltage compliance for hand held applications See Section 5 Consumable Parts For CE Comp...

Page 22: ...put power connection The terminal for the external protective earth conductor An inverter based power source Anode work clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle Power is on Power is off Volt amp curve drooping characteristic IEC SYMBOLS USED 9 96 ...

Page 23: ...Single Phase 208 240 480V 3 7 Single Phase 200 230 400V 3 7 Three Phase 208 240 480V and 600V 3 8 Three Phase 200 230 400V 3 8 Three Phase 400V CE 3 8 Power Requirements 3 9 Line Disconnect Switch 3 9 Grounding Requirements 3 9 Work Cable and Clamp 3 10 Gas Supply Requirements 3 10 Cylinder or Shop Compressed Air Supply 3 10 Additional Air Filtration 3 11 Nitrogen Supply 3 11 Gas Supply Connection...

Page 24: ...max800 read the Safety section of this manual CLAIMS Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance call Customer Service at 1 800 643 0030 in the U S and Canada or your authorized Hypertherm distributor Claims for defective...

Page 25: ...upply by one handle see Fig 3 1 it is not designed to support the weight of the power supply Failure to heed this warning could result in personal injury and damage to the power supply 1 Use a hoisting strap rated for a minimum hoisting weight of 200 pounds 91 kg Approved hoisting straps have attached labels with ratings 2 Ensure the power supply cover is secured prior to hoisting 3 Route strap be...

Page 26: ...lso Single Phase and Three Phase Power Cords 208 240 480V Three Phase Power Cords 600V later in this section WARNING SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position In the U S use a lock out tag out procedure until the ser...

Page 27: ...pply cannot be configured for alternate voltages See also Single Phase and Three Phase Power Cords 200 230 400V later in this section WARNING SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position In the U S use a lock out tag ou...

Page 28: ... and a 4 conductor SO type cord for three phase power supplies The cord should be installed only by a licensed electrician Input Phase Input Recommended Power Cord Gauge Size AWG Voltage Current to 10 ft 10 25 ft 25 50 ft 50 100 ft 100 150 ft 208 VAC 1 50A 8 8 8 6 6 240 VAC 1 43A 8 8 8 8 6 480 VAC 1 25A 10 10 10 10 8 208 VAC 3 29A 10 10 10 8 8 240 VAC 3 25A 10 10 10 10 8 480 VAC 3 13A 12 12 12 12 ...

Page 29: ...the ground wire to the stud marked above the terminal block Single Phase 200 230 400V Remove the rear panel Fig 3 2 and connect the power cable to terminal block TB1 as shown in Fig 3 9B Connect the ground wire to the stud marked above the terminal block 3 96 WARNING SHOCK HAZARD Always turn off power unplug cord from wall and wait 5 minutes before removing any power supply cover If power supply i...

Page 30: ...power cable to terminal block TB1 as shown in Fig 3 10B Connect the ground wire to the stud marked above the terminal block 3 96 Figure 3 10A Three Phase Power 208 240 480V Conductor Color Ground Green L3 Red L2 White L1 Black Black Green TB1 Red White Figure 3 10B Three Phase Power 200 230 400V Conductor Color Ground Green Yellow L3 W Black L2 V Blue L1 U Brown Brown Blue Black Green Yellow TB1 C...

Page 31: ...amps 35 amp 240 VAC 3 25 amps 35 amp 400 VAC 3 16 amps 20 amp 480 VAC 3 13 amps 20 amp 600 VAC 3 11 amps 20 amp GROUNDING REQUIREMENTS To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax800 must be properly grounded The power supply must be properly grounded through the power cord according to your local or national electrical codes The power supp...

Page 32: ...ners A high pressure regulator on either type of supply must be used and must be capable of delivering the following 320 scfh 5 3 scfm 150 l min at a pressure of 90 psi 6 2 bar to the filter on the power supply The filter is mounted at the rear of the Powermax800 power supply See Fig 3 13 WARNING Do not allow the gas inlet pressure to the filter on the power supply to exceed 120 psi 8 2 bar The pl...

Page 33: ...PPLY CONNECTION Use a 3 8 inch ID inert gas hose to connect the gas supply air or nitrogen to the filter at the rear of the power supply To connect the hose to the power supply install a 1 8 NPT nipple to the filter block as shown in Fig 3 13 Apply liquid pipe sealant to the threads to ensure a leak free installation The 1 8 NPT nipple and other adapters come with the consumable parts kit CAUTION ...

Page 34: ...1 Align the pendant lead connector key plug with the connector receptacle key slot on the pigtail and push in until pins seat 2 Turn the connector securing ring to the right to tighten PAC121MS Torch ON OFF Switch Connection Data The PAC121MS torch lead is supplied with a pigtail so that the on off pendant may be used If you want to use a different on off switch configuration note that the wiring ...

Page 35: ...ion The machine interface option is also available as an upgrade kit Plug the machine interface cable into the connector on the rear panel See Fig 3 16 to hook up the machine interface cable to the cutting machine WARNING Do not connect cutting machine interface START signal if using an ON OFF pendant Signal Type Notes Rear panel sockets Cable wires START start plasma Input Normally open 24VAC ope...

Page 36: ...al or national safety procedures 1 Disconnect power from Powermax800 see warning above 2 Remove the 22 screws that attach Powermax800 cover to the chassis Remove the cover 3 Feed cable through strain relief in the rear of Powermax800 See Fig 3 17 Figure 3 18 Machine Interface Board Connections for Arc Voltage Figure 3 17 Feeding Arc Voltage Cable to Machine Interface Board 208 240 480V power suppl...

Page 37: ...4 2 Operating Instructions 4 3 Pilot Arc Controller Option 4 4 PAC121TS Safety Trigger Operation 4 5 Operating Tips 4 6 Changing Consumable Parts 4 6 Cutting 4 8 Piercing 4 10 Gouging 4 11 Cut Chart 50A Standard Consumables 4 12 Cut Chart 40A Consumables 4 13 Common Cutting Faults 4 14 10 96 ...

Page 38: ...perating limits Green GAS PRESSURE LED When illuminated indicates that the gas pressure is within operating limits GAS TEST Switch When pushed in allows the operator to view and adjust pressure setting AMPS Output Adjustment Knob Adjusts output current between 20 and 50 amps Pressure Regulator Regulates input gas pressure to power supply Pressure Gauge Indicates gas pressure at power supply ON I O...

Page 39: ...the gas pressure REGULATOR for a reading of 70 psi 4 8 bar on the PRESSURE GAUGE To adjust regulator pressure Pull the REGULATOR CAP out Push the GAS TEST switch in Turn the REGULATOR CAP while still holding in the GAS TEST switch After adjustment to 70 psi 4 8 bar release the GAS TEST switch Push the REGULATOR CAP back in Note If using 50 ft 15 2 m torch leads adjust pressure to 75 psi 5 bar 5 Ad...

Page 40: ...to stop the arc The arc will also extinguish when transfer to the workpiece is no longer sensed Pilot Arc Controller Option In power supplies with the pilot arc controller option the torch will return to a pilot arc after finishing a cut if the torch switch remains pressed After a short delay the pilot arc will then go out if no arc trans fer is sensed The pilot arc controller option is especially...

Page 41: ...ety On position In this position the trigger cannot be pulled back so that the torch cannot be accidentally fired Start pushing the safety forward Do not pull back on the trigger now wait until the safety reaches the Safety Off position as shown in step 3 1 2 Safety Off position In this position the trigger can be pulled back so that the torch can be fired 3 Release the safety to return to the Saf...

Page 42: ... the center of the electrode has a pit more than 1 16 inch 1 6 mm deep replace it 6 Inspect the swirl ring It should be clean and the holes along the side should not be plugged If the swirl ring is damaged replace it with a new one 7 Inspect the O ring on the torch It should be lubricated and undamaged If it is dry lubricate it with a thin film of the lubricant provided in the spare parts kit If i...

Page 43: ... Shields 120601 120602 Deflector 120303 Gouging Shield 120608 Deflector 120303 Shielded Nozzles 120282 Retaining Cap 120301 Shields 120601 120602 Shielded 120281 Gouging 120301 Electrodes 120573 Air 020480 N2 Swirl Ring 020361 PAC121 Torch O Ring 044016 Figure 4 5B Consumables CE Compliance for Hand Torch Applications Figure 4 5A Consumables 7 99 020395 Nozzles 120282 50A 120438 40A Gouging Shield...

Page 44: ...ly penetrate the workpiece Hold the torch lightly on the metal or just off the metal Holding the torch firmly to the workpiece causes the shield or nozzle to stick and makes smooth cutting difficult The arc transfers to the workpiece once the torch is within 1 8 inch 3 mm of the workpiece Pulling the torch through the cut is easier than pushing it Hold the torch nozzle at a vertical position and w...

Page 45: ...OPERATION 4 9 Operator Manual Figure 4 8 Dragging the Torch Figure 4 7 Cutting a Circle ...

Page 46: ...tion 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 sparks and hot metal Fig 4 9 When the pierce is complete proceed with the cut Start the cut at an angle rather than in an upright position This method permits the hot metal to escape to one side rather than splashing back against the...

Page 47: ...kin is not covered Install the gouging nozzle and shield just as you would install a standard cutting nozzle and shield See Changing Consumable Parts earlier in this section Adjust the air pressure to 50 55 psi 3 4 3 8 bar with air flowing from the torch Note that this is lower than the cutting pressure Tilt the torch approximately 45 from the surface to be gouged and feed into the gouge Multiple ...

Page 48: ...ess Steel 50 110 200 5080 1 8 3 0 Stainless Steel 50 115 105 2670 0 5 1 4 6 4 Stainless Steel 50 117 36 915 1 0 3 8 9 5 Stainless Steel 50 121 22 560 2 0 1 8 3 0 Aluminum 50 108 170 4320 0 5 1 4 6 4 Aluminum 50 117 50 1270 1 0 3 8 9 5 Aluminum 50 123 27 690 2 0 WARNING The voltage between the tip of the torch and the workpiece will exceed 113VDC if shielded consumable parts are not installed in th...

Page 49: ... 40 115 35 890 2 0 3 8 9 5 Mild steel 40 124 15 380 2 5 27 ga 0 4 Stainless Steel 40 114 250 6350 24 ga 0 6 Stainless Steel 40 102 200 5080 16 ga 1 5 Stainless Steel 40 110 125 3180 10 ga 3 4 Stainless Steel 40 111 60 1520 0 5 1 4 6 4 Stainless Steel 40 118 22 560 2 0 3 8 9 5 Stainless Steel 40 123 12 305 2 5 1 16 1 5 Aluminum 40 104 200 5080 1 8 3 0 Aluminum 40 123 100 2540 0 6 3 8 9 5 Aluminum 4...

Page 50: ...t or plasma arc can remain on in minutes within a 10 minute period is affected by many factors When the current is set at 50 amps the Powermax800 has a 50 duty cycle at a temperature of 40 C 104 F At these conditions the plasma arc can remain on 5 minutes out of every 10 minutes without causing the tempera ture sensors to disable the unit The duty cycle increases to 100 at a temperature of 40 C 10...

Page 51: ...5 5 PAC121MS Torch Parts Removal and Replacement 5 6 Removal 5 6 Replacement 5 6 Basic Troubleshooting 5 8 Technical Questions 5 10 Parts 5 11 Consumable Parts 5 11 Hand Consumable Spare Parts Kit 5 11 Machine Consumable Spare Parts Kit 5 11 Consumable Parts For CE Compliance 5 12 Consumable Spare Parts Kit 5 12 PAC121TS Torch Assembly 5 13 PAC121MS Torch Assembly 5 14 Powermax800 Field Upgrade Ki...

Page 52: ... the filter element 1 Shut off the gas supply and disconnect the gas supply hose from the filter assembly before proceeding 2 Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl 3 Unscrew the filter bowl 4 Unscrew the filter element See Powermax800 Field Upgrade Kits and Optional Parts later in this section for part number in...

Page 53: ...he service or maintenance work is complete In other countries follow appropriate local or national safety procedures 3 96 Figure 5 2 Air Filter Removal Cooling Air Filter 1 Turn the Powermax800 power switch to the OFF 0 position unplug the power cable from the wall receptacle and disconnect the gas supply See warning above 2 Remove the 22 screws that secure the power supply cover to the chassis 3 ...

Page 54: ...ing the plunger nut with a 1 4 6mm wrench or nut driver and removing the plunger screw Fig 5 3 6 Disconnect the torch main body and torch lead gas fittings using 5 16 8mm and 7 16 11mm open end wrenches 7 Replace the new torch main body by reversing these instructions Note When connecting the plunger wire be certain to keep the plunger wire terminal at the proper angle as shown in the Fig 5 3 inse...

Page 55: ...he handle 4 Remove the torch switch by cutting the two splices at the torch lead violet wires 5 Replace the torch switch by crimping the switch wires and the violet wires from the torch lead together with the splices 6 Install the torch switch back into the handle Be certain that the torch switch slides into position above the safety trigger and that trigger movement activates the switch pushbutto...

Page 56: ...g the red wires from the torch lead to the torch main body Note for steps 7 and 8 Disconnect wires by pulling on terminals Do not pull on wires 7 Disconnect the 2 lead terminals 4 white wires in each terminal from the 2 black plunger wire terminals of the torch main body 8 Disconnect the 2 lead terminals blue wire in each terminal from the 2 white wires of the cap sensor microswitch 9 Disconnect t...

Page 57: ... with silicone 8 Screw the torch position sleeve and the torch sleeve together 9 When the nozzle electrode and swirl ring are properly in place replace the retaining cap with the shield When the retaining cap is tightened the microswitch will click indicating that the torch main body has been replaced correctly 10 Align the connector plug key on torch lead with the connector receptacle key slot on...

Page 58: ... supply Verify that the gas is turned on and connected to the power supply 2 2 Gas pressure is too low Set gas supply pressure to 90 psi 6 2 bar Verify that there are no leaks in the gas supply line 3 1 Power supply voltage links are incorrect See voltage configuration settings in Section 3 3 2 Line voltage is too low The following table represents the operating range of the Powermax800 power supp...

Page 59: ...rage rating See Power Requirements in Section 3 Check power cable for a short circuit or loose connection 6 1 One of the internal thermostat switches has opened due to overheating Leave power supply on to allow fan to cool power supply down then shut down and restart Clean internal air filter if installed See Cooling Air Filter Removal Cleaning and Replacement earlier in this section 7 1 The five ...

Page 60: ...ressure if necessary 8 3 The gas filter at the rear of the supply contains excessive moisture Drain filter bowl and clean filter See Routine Maintenance earlier in this section 9 1 The gas filter at the rear of the supply contains excessive moisture Drain filter bowl and clean filter See Routine Maintenance earlier in this section 10 1 Power supply voltage links are incorrect See voltage configura...

Page 61: ...ded 3 120281 Nozzle 50A Gouging 1 120305 Nozzle Pipe Saddle Extended 1 120601 Shield T torch 1 120608 Shield Gouging 1 120303 Deflector 1 044016 O Ring 3 015152 Nipple 1 8 NPT QDisc Steel 1 015570 Bushing Reducer 1 4 X 1 8 Brass 1 015604 Reducer 1 4 FPT X 1 8 NPT Brass 1 027055 Lubricant Silicone 1 4 Oz Tube 1 Machine Consumable Spare Parts Kit 128030 Part Number Description Quantity 001285 Box Co...

Page 62: ...T torch 1 120602 Shield M torch 1 120608 Shield Gouging 1 044016 O Ring 3 015152 Nipple 1 8 NPT QDisc Steel 1 015570 Bushing Reducer 1 4 X 1 8 Brass 1 015604 Reducer 1 4 FPT X 1 8 NPT Brass 1 027055 Lubricant Silicone 1 4 Oz Tube 1 Note See page 5 11 for a list of consumable parts for non CE countries 120281 Nozzles 120282 Retaining Cap 120301 Gouging 120301 Shields 120601 120602 Gouging Shield 12...

Page 63: ...120283 Shield PAC121 50A 120301 Cap Retaining 120556 Torch Main Body with Switch PAC121T 044016 O Ring BUNA 90 Duro 614X 070 129001 Torch Lead 25 ft 7 6 m 129002 Torch Lead 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown Used only in 083003 Used only in 083004 Note See page 5 11 or 5 12 for detail of consumable parts Figure 5 7 PAC121TS Torch Assembly and Leads Handle 001288 Handle 001288 Tr...

Page 64: ...ail 35 ft 10 6 m 128127 Torch Lead no pigtail 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown 075321 Socket Cap 4 40 X 1 2 HX SS 075322 M S 4 40 X 1 4 SL SZ 120282 Nozzle PAC121 50A Shield 120326 Shield PAC121M Machine Torch 120301 Cap Retaining 120558 Torch Main Body w Switch PAC121M 044016 O Ring BUNA 90 Duro 614X 070 Note See page 5 11 or 5 12 for detail of consumable parts 12 97 Screw 07...

Page 65: ...ax800 Link Box 128032 Kit Powermax800 600V 008809 Fuse 1A 600V 13 32 X 1 1 2 Slo Used on 208 240 480V power supplies 008958 Fuse 1A 500V 10mm X 38mm Slo Used on 200 230 400V and 400V CE power supplies 023206 Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits POWER SUPPLIES 208 240 480V 1φ 3φ 60 HZ Part For With Pilot Arc With...

Page 66: ...rt For With Pilot Arc With Machine Number Torch Type Control Interface 083018 Hand No No 083021 Hand Yes No 083024 Machine No Yes 083027 Machine Yes Yes Note Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations 9 96 ...

Page 67: ... is complete In other countries follow appropriate local or national safety procedures 1 Turn the Powermax800 power switch to the OFF 0 position unplug the power cable from the wall receptacle and disconnect the gas supply See warning above 2 Remove the 22 screws that secure the power supply cover to the chassis 3 Remove the cover and find F1 and F2 power fuses Fig a 1 4 Remove and check the fuses...

Page 68: ...n Fuel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 10 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 470 Atlantic A...

Page 69: ...n 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 every six inches 150 mm in the distribution lines Cap the e...

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