Hypertherm powermax1650 Operator'S Manual Download Page 105

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MAINTENANCE AND PARTS

powermax

1650

Operator Manual

5-11

Accessories

Power Supply Parts

128788

Stationary mounting kit

128647

011092

Optional air filtration kit

Replacement filter for optional air filtration kit

027668

Plasma cutting guide – deluxe

127102

Plasma cutting guide – basic

027684

Replacement bushing for the plasma cutting guide assembly

127100

Powermax1650 dust cover

123655

50 ft (15M) work cable with clamp and strain-relief

023206

CNC interface cable

220049

Gouging heat shield for hand torch

128650

On/off pendant for machine torch, 25 ft (7.5 m)

128651

On/off pendant for machine torch, 50 ft (15 m)

128652

On/off pendant for machine torch, 75 ft (22.9 m)

024548

Leather torch lead sheathing

128888

FineCut kit: Powermax1000/1250/1650

128889

FineCut kit: Powermax1000/1250/1650 CE

804470

Powermax1650 service manual

128740

Cover assembly, CSA (14 screws included)

128762

Cover assembly, CE (14 screws included)

075533

Cover screws (Individual cover screw)

128627

011092

Air filter bowl with fittings

Replacement filter element

129654

ETR door assembly

129405

Consumable box

123654

20 ft ground clamp with cable and strain-relief

128750

Kit: Powermax1650 labels, CSA

128758

Kit: Powermax1650 labels, CE

Summary of Contents for powermax1650

Page 1: ...SER IES G3 _ 4 0 5 0 50 60 AC 70 80 V BAR 6 0 PSI AMPS 30 40 100 80 60 Plasma Arc Cutting Gouging System Operator Manual 804480 Revision 4 powermax1650 ...

Page 2: ...______________ Distributor _____________________________________________ ________________________________________________________ ________________________________________________________ Maintenance notes ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________...

Page 3: ...4 November 2013 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2013 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 4: ...349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit A 5th Floor Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 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 Tec...

Page 5: ...electro magnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people arou...

Page 6: ...ing of workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other e...

Page 7: ...reasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above ...

Page 8: ...d use installation site When Hypertherm products are shipped to one country for export to another country the product must be configured and certified properly for the end use site Higher level systems When a system integrator adds additional equipment such as cutting tables motor drives motion controllers or robots to a Hypertherm plasma cutting system the combined system may be considered a high...

Page 9: ...iability whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim Insurance At all times you will have and maintain insurance in such quan...

Page 10: ...WARRANTY vi Hypertherm ...

Page 11: ...a 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 L électricité statique peut endommager les cartes de circuits imprimés 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les y...

Page 12: ...nos 1b 7 Un arco plasma puede dañar tubos congelados 1b 7 Símbolos y marcas 1b 8 Etiquetas de advertencia 1b 9 Información sobre la colección de polvo seco 1b 11 Section 2 Specifications Power supply 2 2 Duty cycle 2 3 Dimensions and weight 2 3 T100 torches 2 4 Torch dimensions 2 5 Symbols and markings 2 6 S mark 2 6 CE mark 2 6 IEC symbols used 2 6 Section 3 Setup Upon receipt 3 2 Claims 3 2 Cont...

Page 13: ...mic sensing retaining cap 4 6 Unshielded 4 6 Set the mode switch 4 7 Turn ON the power 4 7 Check the indicator lights 4 7 Adjust the gas pressure and current setting 4 8 Hand torch operation 4 9 Safety trigger operation 4 9 Attach the work clamp 4 10 Start a cut from the edge of the workpiece 4 10 Hand torch cutting technique 4 11 Piercing 4 12 Gouging 4 13 Cut charts 4 14 Section 5 Maintenance an...

Page 14: ...TABLE OF CONTENTS 0 x powermax1650 Operator Manual ...

Page 15: ...c fumes can cause injury or death 1 4 A plasma arc can cause injury and burns 1 5 Arc rays can burn eyes and skin 1 5 Grounding safety 1 6 Compressed gas equipment safety 1 6 Gas cylinders can explode if damaged 1 6 Noise can damage hearing 1 7 Pacemaker and hearing aid operation 1 7 A plasma arc can damage frozen pipes 1 7 Additional safety information 1 7 Symbols and markings 1 8 Warning labels ...

Page 16: ... in this manual that may result in minor injury or damage to equipment if not followed correctly Fire Prevention Be 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 fla...

Page 17: ... 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 or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece i...

Page 18: ...he 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 TOXIC FUMES CAN CAUSE INJURY OR DEATH Duration of cutting ...

Page 19: ...ed by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant 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 ...

Page 20: ...r use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete W...

Page 21: ...ndards Institute 1430 Broadway New York NY 10018 3 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O ...

Page 22: ...Laboratories Incorporated UL or TÜV CE marking The CE marking signifies the 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 fil...

Page 23: ...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 qualified personnel and children away 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protect...

Page 24: ...s 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 operate in closed spaces Remove fumes...

Page 25: ...initions 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 designed to the w...

Page 26: ...1 12 Hypertherm 11 08 SAFETY ...

Page 27: ...ent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 6 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages 1a 6 Le bruit peut provoquer des problèmes auditifs 1a 7 Pacemakers et prothèses audit...

Page 28: ... de sécurité ATTENTION précèdent les directives associées dans le manuel qui si elles ne sont pas suivies scrupuleusement peuvent entraîner des blessures secondaires ou endommager l équipement 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 ...

Page 29: ...les instructions du présent manuel et conformément aux codes électriques locaux et nationaux Inspecter fréquemment le cordon d alimentation primaire pour s assurer qu il n est ni endommagé ni fendu Remplacer immédiatement un cordon endommagé Un câble dénudé peut tuer Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du cou...

Page 30: ...s et réglementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT Le niveau de qualité de l air dans tout lieu de travail dépend des variables propres au site comme Type de table humide sèche sous l eau Composition du matériau fini de la surface et composition des revêtements Volume de matériau enlevé Durée du coupage ou du gougeage Dimensions volume d air v...

Page 31: ...t Gants à crispin chaussures et casque de sécurité Vêtements ignifuges couvrant toutes les parties exposées du corps Pantalon sans revers pour éviter que des étincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la trans...

Page 32: ... connectée pour utilisation Éviter à tout prix le contact électrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Câble de retour Bien fixer le câble de retour ou de masse à la pièce à couper ou à la tabl...

Page 33: ...ques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un médecin avant de s approcher d un lieu où s effectue le coupage ou le gougeage plasma Pour réduire les risques associés aux champs magnétiques Garder loin de soi et du même côté du corps le câble de retour et le fa...

Page 34: ... Laboratories Incorporated UL ou TÜV Marque CE La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes applicables Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque signalétique ou à proximité ont été mises à l essai de conformité à la directive européenne sur la basse tension et la compatibilité électromagnétique eur...

Page 35: ...ating 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 operate in closed spaces Remove fumes with ventilation 6 Become trained Only qualified perso...

Page 36: ...gants isolants Remplacer les gants s ils sont humides ou endommagés 3 2 Se protéger contre les chocs en s isolant de la pièce et de la terre 3 3 Couper l alimentation avant d entretenir Ne pas toucher les pièces sous tension 4 Les fumées du plasma peuvent être dangereuses 4 1 Ne pas inhaler les fumées 4 2 Utiliser une ventilation forcée ou par aspiration à la source pour éliminer les fumées 4 3 Ne...

Page 37: ...s du bâtiment locaux Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que déflagration autorité compétente adopté par référence valeur du pire cas indice de déflagration et autres termes Note 1 L interprétation d Hypertherm de ces nouvelles exigences est que sauf évaluation particulière du site pour déterminer que toute la poussière produite n...

Page 38: ...11 08 1a 12 Hypertherm SÉCURITÉ ...

Page 39: ...usar lesiones o muerte 1b 4 El arco de plasma puede causar lesiones y quemaduras 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel 1b 5 Seguridad de toma a tierra 1b 6 Seguridad de los equipos de gas comprimido 1b 6 Los cilindros de gas pueden explotar si están dañados 1b 6 El ruido puede deteriorar la audición 1b 7 Operación de marcapasos y de audífonos 1b 7 Un arco plas...

Page 40: ... muerte Los mensajes de seguridad de CUIDADO o PRECAUCIÓN preceden mensajes relacionados con instrucciones en el manual que puede resultar en lesiones menores o daño a equipo si no se siguen correctamente Prevención ante el fuego Asegúrese de que el área sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables colocándolos a por lo meno...

Page 41: ...A MUERTE Instale este equipo y conéctelo a tierra según el manual de instrucciones y de conformidad con los códigos locales y nacionales Inspeccione el cordón de alimentación primaria con frecuencia para asegurarse de que no esté dañado ni agrietado Si el cordón de alimentación primaria está dañado reemplácelo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la ...

Page 42: ...ar de trabajo cumpla con todas las normas y reglamentos locales y nacionales HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables específicas al sitio tales como Diseño de mesa mojada seca bajo agua La composición del material el acabado de la superficie y la composición de los recubrimientos Volumen que se quita...

Page 43: ...iación ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro Roipa de combustión retardada y que cubra todas las partes expuestas Pantalones sin dobladillos para impedir que recojan chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar Área de cort...

Page 44: ...ros a calor excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa de traba...

Page 45: ...OS CONGELADOS Los campos magnéticos producidos por las elevadas corrientes pueden afectar la operación de marcapasos y de audífonos Las personas que lleven marcapasos y audífonos deberán consultar a un médico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magnéticos Mantenga el cable de trabajo y la manguera de la an...

Page 46: ...rwriters Laboratories Incorporated UL ó TÜV Marcas CE Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares aplicables Europeos Sólo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo la Compatibilidad Electromagnético Europea EMC...

Page 47: ...ersons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l opérateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de sécurité peut entraîner la mort 1 Les étincelles de coupage...

Page 48: ...Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Protéjase del electrochoque 3 1 Colóquese guantes aislantes No utilice guantes dañados o mojados 3 2 Aíslese de la pieza de trabajo y de la tierra 3 3 Antes de trabajar en una máquina desconecte el enchufe de entrada o la potencia primaria 4 La inhalación de los humos provenientes del área de corte puede ser nociva para...

Page 49: ...igos de construcción locales Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como deflagración AHJ adoptada por referencia el valor Kst índice de deflagración y otros términos Nota 1 La interpretación de Hypertherm de estos nuevos requisitos es que a no ser que se haya completado una evaluación específica del sitio para determinar que todo polvo generado no es c...

Page 50: ...11 08 SEGURIDAD 1b 12 Hypertherm ...

Page 51: ...on 2 SPECIFICATIONS In this section Power supply 2 2 Duty cycle 2 3 Dimensions and weight 2 3 T100 torches 2 4 Torch dimensions 2 5 T100 hand torch 2 5 T100M 2 machine torch 2 5 Symbols and markings 2 6 S mark 2 6 CE mark 2 6 IEC symbols 2 6 ...

Page 52: ...I1eff I1 X used to determine 480 VAC 3PH 22 20 rating of power cord 600 VAC 3PH 21 19 U1 Volts AC rms Harmonic power factor Displacement power factor Power factor 200 208 VAC 3PH 0 94 0 98 230 240 VAC 3PH 0 94 0 98 380 415 VAC 3PH 0 94 0 99 480 VAC 3PH 0 94 0 99 600 VAC 3PH 0 78 0 99 Rsce Short Circuit Ratio CE model only U1 Volts AC rms 3PH Rsce 400 VAC 191 230 VAC 142 This equipment conforms to ...

Page 53: ...mensions and weight Weight of power supply without torch 128 lb 58 06 kg 26 4 in 671 mm 16 8 in 427 mm 25 8 in 655 mm Duty cycle Duty cycle is the percentage of time during a 10 minute period that the power supply can cut continuously The diagram below depicts an 80 duty cycle 8 minutes cutting 2 minutes resting ...

Page 54: ...nded pierce capacity up to 1 2 inch 13 mm Maximum pierce capacity 3 4 inch 19 mm Severance with an edge start 1 3 4 inch 45 mm at low speed Gouging capability Metal removal rate on mild steel 24 pounds 10 8 kg hour Weight T100 7 2 pounds 3 3 kg with 25 ft 7 5 m lead 13 9 pounds 6 3 kg with 50 ft 15 m lead 20 6 pounds 9 4 kg with 75 ft 22 5 m lead T100M 2 8 3 pounds 3 8 kg with 25 ft 7 5 m lead 11 ...

Page 55: ...owermax1650 Operator Manual 2 5 T100 hand torch 8 9 226 mm 4 2 107 mm 1 5 38 mm 1 00 25 mm T100M 2 machine torch 15 47 393 mm 1 00 25 mm 1 38 35 mm 2 35 60mm 8 203 mm 32 pitch 125 3 2 mm width 2 55 65 mm Torch dimensions ...

Page 56: ... near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE mark IEC Symbols Used The following symbols may appear on the power supply data plate control labels and switches O l Direct current DC The terminal for...

Page 57: ...3 5 Grounding 3 6 Power cords 3 6 Three phase power cord and plug installation 3 7 Power cord installation 3 7 Torch installation 3 8 Plasma gas supply 3 10 Additional gas filtration 3 10 Gas supply installation 3 11 T100M 2 torch alignment 3 11 ON OFF pendant connection 3 12 Machine interface connection 3 12 Arc voltage 3 13 Changing XFER start machine motion from dry contact closure to voltage s...

Page 58: ...laims 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 the nearest Hypertherm office listed in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm...

Page 59: ...lb 68 kg Always lift the power supply by TWO handles using two people or a hoist Do not lift the power supply by ONE handle The handle can break resulting in injury and damage Hoist Cover in place Approved hoisting strap Keep power supply as horizontal as possible Lifting the power supply ...

Page 60: ... supply so that the operator can turn off the power supply quickly in an emergency Locate the switch so it is easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses rated per local and national electrical codes CSA model Three phase Input voltage 200 208 230 240 400 480 600 Input current at 16kw output 5...

Page 61: ...drive to the maximum output see table below Use unshielded consumables if you experience difficulty cutting thicker material CSA power supplies only CSA power supplies 3 Phase 50 60 hz 200 600 VAC 480 VAC recommended for best performance CE power supplies 3 Phase 50 60 hz 230 400 VAC 400 VAC recommended for best performance Engine drive rating Powermax1650 output current Performance 30 kw 100 A Fu...

Page 62: ...ertified by local and national codes The cord should be installed by a licensed electrician Refer to the length requirements listed below Note The unit was tested with a 2 m power cord to verify EMC standard EN50199 compliance Recommended extension cord gauge size AWG mm2 10 ft 3 m 10 25 ft 3 7 5 m 25 50 ft 7 5 15 m 50 100 ft 15 30 m 100 150 ft 30 45 m CSA model Input voltage Phase AWG mm2 AWG mm2...

Page 63: ...electrical codes The plug must be connected to the power cord by a licensed electrician L1 10 Ground PE L2 6 152 mm 9 5 241 mm Route power cord through strain relief and tighten Power switch Ground PE L1 L3 Strain relief Strain relief inserts 2 1 Strip and prepare the power cord wires as shown below Power cord installation 2 Connect the power cord to the power switch Note On CE power supplies L1 L...

Page 64: ...h installation 1 Turn OFF the power 2 Remove the power cord from the power receptacle 3 Open the Easy Torch Removal ETR door and route the lead through the end cap _ 4 0 5 0 50 60 AC 70 80 V BAR 6 0 PSI AMPS 30 40 100 80 60 OFF ON ETR door End cap ...

Page 65: ...ick release collar and insert the lead s gas fitting 6 Slide the quick release collar foward to lock the gas fitting in place Make sure that the gas fitting is secure 7 Make sure that the red dot on the connector is on top then plug in the electrical connector Close the ETR door Quick release collar ...

Page 66: ...ty is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Gas supply Powermax1650 Filter kit 128647 Additional gas filtration Use Hypertherm filter kit part number 128647 when site conditions introduce moisture oil or other particulates into the air line A 3 stage coalescing filtration system as shown should be used in extreme conditions...

Page 67: ...del provides a G1 4 adapter in the CE kit Use liquid pipe sealant on the threads Nipple Adapter is found in the consumables box located on the side of the power supply cover 2 Air hose Use an inert gas hose with a 3 8 inch 9 5 mm internal diameter Connect it to the gas fitting installed in step 1 Adjust the air pressure according to the procedure in Section 4 Operation Torch CAUTION Never use PTFE...

Page 68: ...For the machine torch T100 inputs for arc start are available through the machine interface connection on the rear of the power supply Plug the Hypertherm remote pendant see Section 5 Maintenance and parts for part numbers into the connector on the rear panel Signal Start start plasma XFER start machine motion Type Input Output Notes Normally open 18VDC open circuit voltage at START terminals REqu...

Page 69: ... following applicable local and national codes WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring removal of the power supply cover must be performed by a qualified technician 1 Disconnect the power from the power supply 2 Remove the screws that attach the power supply cover to the chassis Remove the cover 3 Route the cable through the ...

Page 70: ... type 1 4 inch faston terminal ends to connect to J15 and J16 Signal Arc voltage torch height control Type Output Notes Full arc voltage No voltage divider 300 VDC maximum Signal not available on rear panel connector J15 VDC J16 VDC 5 Tighten the strain relief 6 Replace the cover ...

Page 71: ...le which has an opto coupler built in Shown below are typical connections for a high side drive arrangement Driving a relay coil Notes 1 Customer supplied 24 VDC relay coil 240 ohms 2 Must use suppression diode 1A 100V such as IN4002 through IN4004 type across coil 3 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider Move the black BLK wire to ground GND...

Page 72: ...o ground GND and add a jumper wire as shown Notes 1 Customer supplied isolated input module 2 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider J16 J15 J19 GND 24VDC BLK YEL RED WHT XFER START BLK 5 V div 6 V div 4 3 14 12 13 Shield Start Signal Isolated input module ...

Page 73: ...l 240 ohms 2 Customer supplied 24 VDC power source 3 Must use suppression diode 1A 100V such as IN4002 through IN4004 type across coil 4 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider J16 J15 J19 GND 24VDC BLK YEL RED WHT XFER START Start Signal 5 V div 6 V div 4 3 14 12 13 Shield 24 VDC ...

Page 74: ...ce Notes 1 Customer supplied isolated input module 2 Customer supplied 24 VDC power source 3 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider J16 J15 J19 GND 24VDC BLK YEL RED WHT XFER START Start signal 5 V div 6 V div 4 3 14 12 13 Shield 24 VDC Isolated input module ...

Page 75: ...0M 2 consumable configurations 4 5 Shielded 4 5 FineCut 4 6 Ohmic sensing retaining caps 4 6 Unshielded 4 6 Set the mode switch 4 7 Turn ON the power 4 7 Check the indicator lights 4 7 Adjust the gas pressure and current setting 4 8 Hand torch operation 4 9 Safety trigger operation 4 9 Attach the work clamp 4 10 Start a cut from the edge of the workpiece 4 10 Hand torch cutting technique 4 11 Pier...

Page 76: ...n illuminated indicates that there is acceptable gas pressure for torch operation Yellow torch cap LED When illuminated indicates that the retaining cap is loose or not installed NOTE This condition must be corrected and the power turned OFF and then ON again to clear the LED Yellow temperature LED When illuminated indicates that the power supply temperature has exceeded its operating limit Red fa...

Page 77: ...The plasma arc will quickly burn through gloves and skin Make sure the power is OFF before changing the consumables Install the consumables Note Hand tighten only Retaining cap Nozzle Electrode Swirl ring Shield 2 1 The instructions for hand torches are shown below If you are using a machine torch you may need to install it on the cutting table prior to installing the consumables ...

Page 78: ...0928 80A 220051 220037 FineCut O ring 058519 220327 120926 220329 120928 220325 120979 For use with CE systems The 220327 swirl ring is intended for manual cutting with FineCut consumables 30A 50A Shielded Unshielded The unshielded consumables available for the T100 hand torch only for use with non CE systems are the same as those used for the T100M 2 See the illustrations later in this section ...

Page 79: ...120977 220063 220048 100A O ring 058519 120977 220059 120928 60A 80A 220051 220037 T100M 2 consumable configurations Shielded 120930 120932 120928 220047 220011 220048 100A 40A O ring 058519 120930 120931 120928 60A 220051 220037 120930 120927 120928 80A 120925 120926 ...

Page 80: ...120925 120926 220061 220206 Ohmic sensing retaining caps 100A 40A 80A In CE countries unshielded consumables may only be used in mechanized torch applications Maintain a torch to work distance of approximately 1 8 inch 3mm Use an ohmic sensing cap when a compatible torch height contoller is installed FineCut O ring 058519 120925 120926 220329 120928 220325 120979 220404 220061 30A 50A ...

Page 81: ...or non transfered arc operation Turn ON the power Position the power switch to ON I as shown Note The cooling fan is automatic and will only operate when needed Check that the power ON lamp is illuminated Check the indicator lights AC V Check that the remaining indicator lamps are NOT illuminated See Section 5 Maintenance and parts for details Check that the gas pressure LED illuminates green ...

Page 82: ... knob to gas test Pull the regulator knob to unlock it 15 50 ft 4 5 15 m 15 25 ft 4 5 7 5 m 35 50 ft 12 15 m 6 0 BAR 5 0 4 0 PSI 80 70 50 60 AMPS 60 40 80 25 Push the regulator knob to lock it Set the cutting current 30 amps minimum Set the pressure as shown above based on the cutting mode and torch lead length 2 1 3 4 5 ...

Page 83: ...USE INJURY AND BURNS The plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn 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 Never use with the pendant switch 2 3 1 ...

Page 84: ...work clamp to the portion that will fall away Start a cut from the edge of the workpiece Hold the torch vertical at the edge of the workpiece Start cutting from the edge of the workpiece Pause at the edge until the arc has completely cut through the workpiece Then proceed with the cut Attach the work clamp WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle...

Page 85: ...e torch through the cut than to push 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 cut circles use a template or the Hypertherm plasma cutting guide part number 027668 Postflow After the torch trigger switch is released the gas will continue to flow for 30 seconds to cool the torch and consumables Note The torch ...

Page 86: ...e Point the torch away from yourself and others Piercing Hold the torch so that the nozzle is within 1 8 in 3 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 87: ...elf and others Gouging Hold the torch so that the nozzle is within 1 16 in 1 5 mm from the workpiece before firing the torch Hold the torch at a 45 angle to the workpiece Pull the trigger to obtain a pilot arc Transfer the arc to the work piece Maintain an approximate 45 angle to the workpiece Feed into the gouge Direction of travel 45 Note A heat shield is available for added hand and torch prote...

Page 88: ...el speed Inches mm IPM mm min IPM mm min 100 153 0 5 1 4 6 4 208 5283 135 3429 155 0 5 3 8 9 5 119 3022 77 1955 159 1 0 1 2 12 7 88 2235 57 1447 160 1 0 5 8 15 9 61 1549 40 1016 161 1 5 3 4 19 0 47 1193 26 660 163 NA 1 25 4 28 711 18 457 167 1 1 4 31 8 19 482 12 305 Arc current Arc voltage Pierce delay Material thickness Maximum travel speed Optimum travel speed Inches mm IPM mm min IPM mm min 100...

Page 89: ...travel speed Inches mm IPM mm min IPM mm min 80 132 0 25 3 16 4 8 216 5486 140 3556 134 0 50 1 4 6 4 161 4089 105 2667 137 3 8 9 5 94 2388 61 1549 140 1 2 12 7 60 1524 39 991 145 1 0 5 8 15 9 40 1016 26 660 148 N A 3 4 19 0 31 787 20 508 150 7 8 22 2 23 584 15 381 156 1 25 4 16 406 10 254 Mild steel Arc current Arc voltage Pierce delay Material thickness Maximum travel speed Optimum travel speed I...

Page 90: ...ed Inches mm IPM mm min IPM mm min 60 134 0 16 Ga 1 5 627 15926 502 12751 134 10 Ga 3 4 264 6706 211 5359 138 0 25 1 4 6 4 132 3353 86 2184 141 0 75 3 8 9 5 63 1600 41 1041 141 1 50 1 2 12 7 42 1067 27 686 147 5 8 15 9 31 787 20 512 153 3 4 19 0 22 559 14 363 Arc current Arc voltage Pierce delay Material thickness Maximum travel speed Optimum travel speed Inches mm IPM mm min IPM mm min 60 135 0 1...

Page 91: ...GA 0 5 638 16205 415 10541 148 22 GA 0 8 500 12700 325 8255 149 18 GA 1 3 312 7925 203 5156 152 16 GA 1 5 176 4470 114 2896 40 144 0 25 14 GA 1 9 640 16256 221 5613 146 0 50 10 GA 3 4 151 3835 98 2489 147 0 75 3 16 4 7 97 2464 63 1600 149 1 00 1 4 6 4 74 1880 48 1219 Arc current Arc voltage Pierce delay Material thickness Maximum travel speed Optimum travel speed Inches mm IPM mm min IPM mm min 25...

Page 92: ...Inches mm IPM mm min 50 63 10 Ga 3 4 80 1905 40 73 10 Ga 3 4 60 1524 45 63 12 Ga 2 7 100 3174 40 72 12 Ga 2 7 80 1905 65 14 Ga 1 9 150 3810 64 16 Ga 1 5 150 3810 64 18 Ga 1 2 150 3810 65 20 Ga 0 9 150 3810 30 66 24 Ga 0 6 150 3810 Stainless steel FineCut consumables Torch to work distance for the following cut chart is 0 08 inches 2 032 mm for mild steel and 0 010 inches 0 254 mm for stainless ste...

Page 93: ... speed Inches mm IPM mm min IPM mm min 100 136 0 5 1 4 6 4 210 5334 137 3479 139 0 5 3 8 9 5 122 3098 79 2006 142 1 0 1 2 12 7 91 2311 59 1498 146 1 0 5 8 15 9 57 1447 37 939 150 1 5 3 4 19 0 43 1092 28 711 155 NA 1 25 4 26 660 17 431 160 1 1 4 31 8 16 406 10 254 Arc current Arc voltage Pierce delay Material thickness Maximum travel speed Optimum travel speed Inches mm IPM mm min IPM mm min 100 13...

Page 94: ...rial thickness Maximum travel speed Optimum travel speed Inches mm IPM mm min IPM mm min 25 125 26 GA 0 5 550 13970 353 8966 128 22 GA 0 8 484 12294 315 8001 130 18 GA 1 3 238 6045 155 3937 131 16 GA 1 5 167 4242 109 2769 40 129 0 25 14 GA 1 9 326 8280 212 5385 Arc current Arc voltage Pierce delay Material thickness Maximum travel speed Optimum travel speed Inches mm IPM mm min IPM mm min 25 125 1...

Page 95: ... 2 Inspect the consumables 5 3 Filter element replacement 5 4 Controls and indicators 5 5 Basic troubleshooting 5 6 System circuit diagram 5 9 Technical questions 5 10 Parts 5 10 Torch parts 5 10 Power supply parts 5 11 Accessories 5 11 powermax1650 Operator Manual 5 1 0 ...

Page 96: ... the gas pressure Replace power cord or plug if damaged Replace torch lead if damaged Check the pressure hose filter element and connections for leaks Clean the inside of the power supply with air pressure or vacuum Replace damaged labels Check the torch cap on safety switch observe that red fault LED and yellow torch cap LED illuminate when cap is loosened Check the consumables for wear and prope...

Page 97: ...e Maximum pit depth Replace 1 32 inch 0 8 mm Electrode Part Check for Action External surfaces Damage or debris Replace Central bore I D Does electrode slide easily Replace Gas holes Blocked holes Replace Swirl ring External surfaces Damage or wear Replace Dry surface Apply a thin film of silicone grease part number 027055 Torch o ring Max 1 32 inch 0 8 mm ...

Page 98: ...ng If the o ring shows signs of wear or otherwise needs replacement verify that you have the correct o ring for the filter Each filter has a label on one side of the filter body For AF30 filters use part number 011105 For NAF3000 filters use part number 011094 2 Use a screwdriver to remove the filter element from the filter housing Then install the new filter element Note Do not allow the filter e...

Page 99: ...ing and fault Red lamps are illuminated 2 1 The gas supply is turned OFF or not connected to the power supply Check that the gas is turned on and is connected to the power supply 2 2 The gas supply pressure is too low Set the incoming gas supply pressure to 90 120 psig 6 2 8 3 bar Check that there are no leaks in the gas supply line 2 3 Operating gas pressure is set too low for the selected mode A...

Page 100: ...s not connected to the workpiece the work clamp is broken or there is a loose connection within power supply Connect or repair the work clamp 6 2 The work clamp is not making good metal to metal contact Clean the area where the clamp contacts the workpiece 6 3 The torch is too far from the workpiece Move the torch closer to the workpiece and start the torch again See Section 4 Torch operation 4 Th...

Page 101: ...nsumables in this section See Section 4 Hand torch operation 7 The arc blows out but re ignites when the torch switch is pressed again 7 1 The consumable parts are worn or damaged Inspect and change the consumables as necessary See Inspect the consumables in this section See Section 4 Torch operation 7 2 The gas pressure is incorrect Adjust the operating gas pressure See Section 4 Check and adjust...

Page 102: ...ignal is ON when the ON OFF switch is activated Turn the start signal OFF Turn the power OFF and then ON again 12 The power ON green and fault red lamps are illuminated for 10 seconds after the trigger is activated 12 1 The consumables are stuck or jammed Turn the power OFF and check the consumables Basic troubleshooting continued Problem Cause Solution 5 8 powermax1650 Operator Manual 2 MAINTENAN...

Page 103: ... Input PE Q1 Boost IGBT 70 50 STATUS GAS 45 60 55 65 75 80 85 CPA NORMAL GOUGE CURRENT DOWN MID UP AC V System circuit diagram Designator Component D1 Input diode bridge D2 Output diode bridge L1 Boost inductor L2 Output inductor M1 Fan PCB1 EMI filter board PCB2 Power board PCB3 Control board PS1 Pressure sensor Q1 Boost IGBT Q2 Inverter IGBT Q3 Pilot arc IGBT S1 On off switch J1 Connector TS1 TS...

Page 104: ...mm no gear rack 50 ft 15 m 059336 T100M 2 machine torch 35 mm no gear rack 75 ft 22 9 m 027055 Silicone grease 1 4 oz tube 015337 Quick disconnect nipple 1 4 NPT steel CSA 015145 Adapter 1 4 NPT x G1 4 BSPP brass CE 058519 Torch o ring 128644 T100 hand torch handle replacement kit 5 screws included 075586 T100 hand torch handle screw 5 required 220061 Shield cap T60M T80M ohmic contact 220206 Shie...

Page 105: ...nd torch 128650 On off pendant for machine torch 25 ft 7 5 m 128651 On off pendant for machine torch 50 ft 15 m 128652 On off pendant for machine torch 75 ft 22 9 m 024548 Leather torch lead sheathing 128888 FineCut kit Powermax1000 1250 1650 128889 FineCut kit Powermax1000 1250 1650 CE 804470 Powermax1650 service manual 128740 Cover assembly CSA 14 screws included 128762 Cover assembly CE 14 scre...

Page 106: ...MAINTENANCE AND PARTS 0 5 12 powermax1650 Operator Manual ...

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