Hypertherm powermax900 Page 67 Operator'S Manual Download | Manualshive

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Operator Manual

5-12

M

AINTENANCE

/P

ARTS

Powermax900 Field Upgrade Kits and Optional Parts

Part Number

Description

028714 .............................. On/Off Pendant with Lead, 25 ft (7.6 m) (Also comes standard with most

machine torch system configurations. See note below.)

128061 .............................. On/Off Pendant with Lead, 50 ft (15.2 m)
128062 .............................. On/Off Pendant with Lead, 75 ft (23 m)
128316 .............................. Kit: Powermax900 Power Unit Wheels
128317 .............................. Kit: Powermax900 Pilot Arc Controller
128241 .............................. Kit: Powermax900 Machine Interface, 208/240/480V
128242 .............................. Kit: Powermax900 Machine Interface, 200/230/400V
128286 .............................. Kit: Powermax900 Machine Interface, 400V CE
028907 .............................. Work Cable, 50 ft (15.2 m)
028908 .............................. Kit: Powermax900, Cooling Air Filter
011079 .............................. Filter Element
129019 .............................. Jumper:Powermax900 Link Box
128312 .............................. Kit: Powermax900 600V Conversion
128313 .............................. Kit: Powermax900 CE 230V Conversion
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.)

024548 .............................. Leather Cable Covers, 25 ft (7.6 m)
109068 .............................. Toroid (Used only on 400V CE power supply linecord assemblies.)

POWER SUPPLIES - 208/240/480V, 1

φ

/3

φ

, 60 HZ

Part

For

With Pilot Arc

With Machine

Number

Torch Type

Control

Interface

083063

Hand

No

No

083076

Hand

Yes

No

083077

Machine

No

Yes

083078

Machine

Yes

Yes

POWER SUPPLIES - 200/230/400V, 1

φ

/3

φ

, 50/60 HZ

Part

For

With Pilot Arc

With Machine

Number

Torch Type

Control

Interface

083065

Hand

No

No

083082

Hand

Yes

No

083083

Machine

No

Yes

083084

Machine

Yes

Yes

Note: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations.

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Summary of Contents for powermax900

Page 1: ......

Page 2: ...c All Rights Reserved HYPERTHERM and POWERMAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Revision 2 November 2013 beginning with serial number 900 010000 Hypertherm Inc Hanover NH USA http www hypertherm com email info hypertherm com ...

Page 3: ...al Support Organization 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 5...

Page 4: ...f 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 cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment must be routinely maintained accordi...

Page 5: ...THERM HYPERTHERM agrees to indemnify protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their custom ers because of the use in or about the construction or operation of Equipment or any design system formula combination article or material which infringes or alleges to infringe on any pa...

Page 6: ...NS DE SÉCURITÉ 1a 2 LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION 1a 2 DANGER AVERTISSEMENT PRÉCAUTION 1a 2 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 1a 3 LES CHOCS ÉLECTRIQUES PEUVENT être fatals 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES 1a 4 MISE À LA MASSE ET À LA TERRE 1a 4 LES RAYONS DE L ARC PEUVENT BRÛLER LES YEUX ET LA PEAU 1a 4 SÉCURITÉ DES BOUTEILLES DE ...

Page 7: ...PAC125M ON OFF Pendant Connection 3 12 PAC125M Torch ON OFF Switch Connection Data 3 12 PAC125M Torch Alignment 3 12 MACHINE INTERFACE WITH PAC125M 3 13 Arc Voltage 3 14 SECTION 4 OPERATION 4 1 CONTROLS AND INDICATORS 4 2 OPERATING INSTRUCTIONS 4 3 Pilot Arc Controller Option 4 4 PAC125T Safety Trigger Operation 4 5 OPERATING TIPS 4 6 Changing Consumable Parts 4 6 Cutting 4 8 Piercing 4 10 Gouging...

Page 8: ...no pigtail 5 11 PAC125M Torch Assembly and 25 ft 7 6 m Lead 083068 w pigtail 083072 no pigtail 5 11 PAC125M Torch Assembly and 35 ft 10 6 m Lead 083070 w pigtail 083074 no pigtail 5 11 PAC125M Torch Assembly and 50 ft 15 2 m Lead 083071 w pigtail 083075 no pigtail 5 11 Powermax900 Field Upgrade Kits and Optional Parts 5 12 POWER SUPPLIES 208 240 480V 1F 3F 60 HZ 5 12 POWER SUPPLIES 200 230 400V 1F...

Page 9: ...11 Figure 3 13 ON OFF Pendant Connection 3 12 Figure 3 14 Aligning the Machine Torch with Square 3 13 Figure 3 15 Machine Interface Cable and Signals 3 13 Figure 3 16 Feeding Arc Voltage Cable to Machine Interface Board 3 14 Figure 3 17 Machine Interface Board Connections for Arc Voltage 3 14 Figure 4 1 Powermax900 Controls and Indicators 4 2 Figure 4 2 Powermax900 Operating Indicators and Adjustm...

Page 10: ...e or Explosion 1 2 Electric Shock Can Kill 1 3 Cutting Can Produce Toxic Fumes 1 3 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 Additional Safety Information 1 5 ...

Page 11: ... OR EXPLOSION 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 flammable materials inside they must be emptied and properly cleaned first Ventilate p...

Page 12: ...y and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows...

Page 13: ...her surfaces with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs GROUNDING SAFETY Input Power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connect ing the power cord to the power supply be sure to conne...

Page 14: ...ne side away from your body Route the torch leads as close as 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 A...

Page 15: ...SAFETY 1 6 Hypertherm Plasma Systems 8 99 ...

Page 16: ...TRIQUES PEUVENT ÊTRE FATALS 1a 3 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES 1a 4 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 AUD...

Page 17: ...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 18: ...er 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 circuite...

Page 19: ...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 20: ...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 21: ...SÉCURITÉ 1a 6 08 99 HYPERTHERM Systèmes plasma ...

Page 22: ...rator Manual In this section Introduction 2 2 Specifications 2 3 Power Supply 2 3 PAC125 Torches 2 4 PAC125T Hand Torch Assembly 2 4 PAC125M Machine Torch Assembly 2 4 S Mark 2 5 IEC Symbols Used 2 6 Section 2 SPECIFICATIONS ...

Page 23: ...an 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 Powermax900 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 and ...

Page 24: ...ted in an ambient temperature above 86 F 30 C may show some decrease in duty cycle Apparent Input Power S1 12 5kVA U1 I1 Input Voltage U1 Input Current I1 6 6 kw Output 208V 55A 240V 47A 480V 28A 1φ 50 60 Hz 208V 32A 240V 28A 480V 15A 3φ 50 60 Hz 200V 57A 230V 50A 400V 33A 1φ 50 60 Hz 200V 33A 230V 29A 400V 18A 3φ 50 60 Hz 230V CE 29A 400V CE 18A 3φ 50 60 Hz 600V 12A 3φ 60 Hz Dimensions and Weight...

Page 25: ...ting 70 psi 4 8 bar flowing PAC125 TORCHES Maximum 55A Cutting Capacity PAC125T 7 8 22 mm 50 duty cycle Maximum 55A Cutting Capacity PAC125M 1 2 13 mm 50 duty cycle Maximum 39A Cutting Capacity PAC125M 3 8 9 5 mm 100 duty cycle Maximum current at 50 duty cycle 55 amps Gouging Capability metal removal rate 6 3 pounds 2 9 kg hr Weight PAC125T 4 5 pounds 2 kg with 25 ft 7 6 m lead 7 pounds 3 2 kg wit...

Page 26: ...rmax900 conforms to standard EN50192 The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The hand torches must have shielded consumable parts to maintain S mark compliance ...

Page 27: ... 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 ...

Page 28: ...Phase Non CE 3 7 Three Phase CE 3 8 Power Requirements 3 8 Line Voltage Disconnect Box 3 8 Grounding Requirements 3 9 Work Cable and Clamp 3 9 Gas Supply Requirements 3 10 Cylinder or Shop Compressed Air Supply 3 10 Additional Air Filtration 3 10 Nitrogen Supply 3 10 Gas Supply Connection 3 11 Torch Lead Connection 3 11 PAC125M ON OFF Pendant Connection 3 12 PAC125M Torch ON OFF Switch Connection ...

Page 29: ...rmax900 3 Before setting up and operating the Powermax900 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 listed in the front of this manual or your authoriz...

Page 30: ...uld result in personal injury and damage to the power supply 1 Use a hoisting strap rated for 4x the full weight 2 Ensure the power supply cover is secured prior to hoisting 3 Route strap between both handles as shown in Fig 3 1 4 Bring the strap ends together over the center of the power supply and connect them to the hoisting machine 5 Hoist and lower the power supply slowly and smoothly avoid j...

Page 31: ...ching to the 400 or 480V configuration secure unused link box jumper in the clip located in the link box If using the 600V transformer option kit configure the 3φ Powermax900 for 480V Fig 3 5 See also Power Cords 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...

Page 32: ...al Figure 3 3 200V or 208V Configuration Figure 3 4 230V or 240V Configuration Figure 3 5 400V or 480V Configuration TB3 Link Box 200V or 208V 230V or 240V TB2 TB2 Black White TB3 Black White TB3 TB2 400V or 480V Black White ...

Page 33: ...local codes Prepare the power cord wires as shown in Fig 3 6 for non CE power supplies or Fig 3 6a for CE power supplies Note that all 4 wires must loop through the toroid in the CE power supply Cap or tin the conductor leads and use a 10 terminal on the ground wire The cord should be installed only by a licensed electrician 208 240 480 600V Power Supplies Input Phase Input Recommended Power Cord ...

Page 34: ...below Connect the ground wire to the stud marked above the terminal block Single Phase Three Phase Non CE 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 servic...

Page 35: ... switch should be located on a wall near the power supply and should be easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses according to the power requirements listed below Input Input Current Recommended Voltage Phase 6 6 kw Output Slow Blow Fuse Size 200 VAC 1 57 amps 70 amp 208 VAC 1 55 amps 70 amp...

Page 36: ...ust comply with local electrical requirements Do not use a 2 wire service Refer to Grounding in the Safety section Three phase service must be of the 4 wire type with a green yellow wire for protec tive earth ground It must comply with local electrical requirements Refer to the Standards Index in the Appendix section for other electrical codes WORK CABLE AND CLAMP The work clamp must be attached t...

Page 37: ... bowl for other safety warnings Air Supply Quality The cylinder or shop compressed air supply must be clean dry and oil free If air supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Additional Air Filtration Use a three stage coalescing filtration system as shown in Fig 3 11 when site conditions introduce moisture oil...

Page 38: ...e pressure regulator pressure switch and valve Figure 3 12 Rear Panel Gas Supply Connection to Filter Filter 1 8 NPT Nipple or adapter Gas Supply Hose Connection TORCH LEAD CONNECTION To connect the PAC125T or PAC125M torch lead to the power supply 1 Align the connector key plugs on the torch lead with the connector receptacle key slots on the power supply and push in until the pins seat 2 Turn th...

Page 39: ...ff 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 Powermax900 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 So...

Page 40: ... 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 open circuit voltage at START terminals Requires dry contact closure to activate 3 4 Green Black XFER start machine motion Output Normally open Dry contact closure when ...

Page 41: ...r local safety procedures 1 Disconnect power from the power supply 2 Remove the screws that attach the power supply cover to the chassis Remove the cover 3 Feed the cable through the strain relief at the rear of power supply See Fig 3 16 Figure 3 17 Machine Interface Board Connections for Arc Voltage Figure 3 16 Feeding Arc Voltage Cable to Machine Interface Board 208 240 480V power supply shown S...

Page 42: ...4 2 Operating Instructions 4 3 Pilot Arc Controller Option 4 4 PAC125T 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 35A Consumables 4 13 Common Cutting Faults 4 14 10 96 ...

Page 43: ...at the power supply temperature has exceeded operating 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 the pressure setting AMPS Output Adjustment Knob Adjusts output current between 20 and 55 amps Pressure Regulator Regulates input gas pressure to power supply Pressure G...

Page 44: ...the gas pressure REGULATOR to read 70 psi 4 8 bar on the PRESSURE GAUGE 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 Adjust the AMPS knob to the desired sett...

Page 45: ...10 The torch will continue to release gas after the arc is extinguished This gas postflow will con tinue for approximately 15 seconds but can be halted by quickly depressing and then releasing the trigger To reinitiate the arc while in postflow press and hold the trigger Pilot Arc Controller Option In power supplies with the pilot arc controller option the torch will return to a pilot arc after fi...

Page 46: ...low the steps below Safety On position In this position the trigger cannot be pulled back and the torch cannot fire To fire the torch start pushing the safety forward Do not pull back on the trigger until the safety reaches the Safety Off position 1 2 Safety Off position In this position the trigger can be pulled back and the torch can fire 3 Release the safety to return to the Safety On position ...

Page 47: ...center of the electrode has a pit more than 1 16 inch 1 6 mm deep replace it 7 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 8 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 consumable parts kit If i...

Page 48: ...e allows the torch tip to be dragged directly on the workpiece Gouging For metal removal without cutting Use for weld removal or setup Nozzle shield may be placed directly on the workpiece Non Shielded Extended For increased visibility and access for special applications The nozzle is not shielded Maintain a torch to work distance of approximately 1 8 3 mm when cutting above 40A to avoid accelerat...

Page 49: ... 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 4 inch 6 mm of the workpiece Pulling the torch through the cut is easier than pushing it Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line Fig 4 8 By lightly dragging the...

Page 50: ...OPERATION 4 9 Operator Manual Figure 4 8 Dragging the Torch Figure 4 7 Cutting a Circle ...

Page 51: ...y rotate it to an upright 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 sparks and hot metal Fig 4 9 This method permits the hot metal to escape to one side rather than splashing back against the nozzle This will protect the operator from the sparks and extend the life of th...

Page 52: ...ing 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 Start a transferred arc by holding the torch pependicular to the workpiece As soon as the arc transfers tilt the torch approximately 45 from the surface to be gouged and feed into the gouge Mul...

Page 53: ...r e t a M m m n i r o a g l a i r e t a M c r A t n e r r u C t n e r r u C t n e r r u C t n e r r u C t n e r r u C A A A A A c r A e g a t l o V e g a t l o V e g a t l o V e g a t l o V e g a t l o V V V V V V d e d n e m m o c e R d e e p S l e v a r T d e e p S l e v a r T d e e p S l e v a r T d e e p S l e v a r T d e e p S l e v a r T n i m m m m p i e c r e i P y a l e D y a l e D y a l ...

Page 54: ... n e r r u C t n e r r u C t n e r r u C t n e r r u C t n e r r u C A A A A A c r A e g a t l o V e g a t l o V e g a t l o V e g a t l o V e g a t l o V V V V V V d e d n e m m o c e R d e e p S l e v a r T d e e p S l e v a r T d e e p S l e v a r T d e e p S l e v a r T d e e p S l e v a r T n i m m m m p i e c r e i P y a l e D y a l e D y a l e D y a l e D y a l e D S S S S S a g 6 2 5 0 l e...

Page 55: ...or plasma arc can remain on in minutes within a 10 minute period is affected by many factors When the current is set at 55 amps the Powermax900 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 104 ...

Page 56: ...roubleshooting 5 4 Technical Questions 5 7 Parts 5 8 Consumable Parts Kits 5 8 Hand Consumable Parts Kit 5 8 Machine Consumable Parts Kit 5 8 Consumable Parts Kit CE 5 8 Consumable Configurations 5 9 PAC125T Torch Assembly 5 10 PAC125M Torch Assembly 5 11 Powermax900 Field Upgrade Kits and Optional Parts 5 12 Power Supplies 208 240 480V 5 12 Power Supplies 200 230 400V 5 12 Power Supplies 400V CE ...

Page 57: ...ean 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 Powermax900 Field Upgrade Kits and Optional Parts later in this section for part number...

Page 58: ... procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures Figure 5 2 Air Filter Removal Cooling Air Filter 1 Turn the Powermax900 power switch to the OFF 0 position unplug the power cable from the wall receptacle and disconnect the gas supply 2 Remove the screws that secure the power supply cover to the chassis 3 Remove t...

Page 59: ...rify 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 3a 1 Power supply voltage links are incorrect See voltage configuration settings in Section 3 3a 2 Line voltage is extremely low The following table represents the operating range of the Powermax900 power suppli...

Page 60: ... is too low Line voltage is between 15 and 20 below nominal Have an electrical technician check incoming power 3d 1 Line voltage is too high LIne voltage is greater than 15 of nominal Have an electrical technician check incoming power 3d 2 Torch cap is not engaging microswitch Verify that the torch consumables are installed correctly and that a click is heard when the retaining cap is screwed down...

Page 61: ...ion 3 4 5 Line voltage is too high See table on previous page 5 1 The power supply has exceeded the capacity of the fuse Check the fuse for proper amperage 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 shu...

Page 62: ...ary See Operating Tips in Section 4 8 2 The gas pressure is incorrect Adjust the gas pressure Incoming gas pressure is 90 psi 6 2 bar at a flow of 360 scfh 170 l m Pressure at unit in TEST mode is 70 psi 4 8 bar for lead length of 25 feet 7 6 m and 75 psi 5 bar for lead length of 50 feet 15 2 m See Operating Instructions in Section 4 to adjust gas pressure if necessary 8 3 The gas filter at the re...

Page 63: ...20574 Electrode Extended 3 120577 Nozzle 55A Shielded 3 120606 Nozzle 35A Extended 3 120602 Shield PAC125M Machine Torch 1 120303 Deflector 1 044016 O Ring 3 015152 Nipple 1 8 NPT QDisc Steel 1 015604 Reducer 1 4 FPT X 1 8 NPT Brass 1 027055 Lubricant Silicone 1 4 Oz Tube 1 Machine Consumable Parts Kit 128288 Hand Consumable Parts Kit 128287 Consumable Parts Kit CE 128289 Part Number Description Q...

Page 64: ...Torch Nozzle 120577 Retaining Cap 120600 Shielded Machine Torch 55A Cutting Shield 120602 Shield 120608 Nozzle 120607 Retaining Cap 120600 Shielded 55A Gouging Unshielded 55A Cutting Deflector 120303 Nozzle 120578 55A Retaining Cap 120600 Electrode 120574 Deflector 120303 Nozzle 120606 35A Retaining Cap 120600 Unshielded 35A Cutting Consumable Configurations In CE countries use unshielded consumab...

Page 65: ...ield 120601 Shield PAC121T 120600 Cap Retaining 120570 Torch Main Body with Switch PAC125T 044016 O Ring BUNA 90 Duro 614X 070 129352 Torch Lead 25 ft 7 6 m 129353 Torch Lead 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown Used only in 083066 Used only in 083067 Note See page 5 8 or 5 9 for detail of consumable parts Figure 5 5 PAC125T Torch Assembly and Leads Handle 001288 Handle 001288 Tri...

Page 66: ...44 Torch Lead no pigtail 35 ft 10 6 m 129345 Torch Lead no pigtail 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown 027599 Snap Ring 120577 Nozzle PAC125 55A Shield 120602 Shield PAC121M Machine Torch 120600 Cap Retaining 120583 Torch Main Body w Switch PAC125M 044016 O Ring BUNA 90 Duro 614X 070 Note See page 5 8 or 5 9 for detail of consumable parts Snap Ring 027599 O Ring 044016 Torch Slee...

Page 67: ...Kit Powermax900 CE 230V Conversion 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 024548 Leather Cable Covers 25 ft 7 6 m 109068 Toroid Used only on 400V CE p...

Page 68: ...rt For With Pilot Arc With Machine Number Torch Type Control Interface 083064 Hand No No 083079 Hand Yes No 083080 Machine No Yes 083081 Machine Yes Yes Note Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations 9 99 ...

Page 69: ...Operator Manual 5 14 MAINTENANCE PARTS ...

Page 70: ...e In other countries follow appropriate local or national safety procedures 1 Turn the Powermax900 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 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 Replace if ne...

Page 71: ...ms 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 Avenue Boston MA ...

Page 72: ...tive 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 ends of ...

Page 73: ...APPENDIX B Operator Manual ...

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