Hypertherm powermax 350 Operator'S Manual Download

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EN50199
EN50192

Plasma Arc
Cutting System

Operator Manual
802900 Rev. 0

Summary of Contents for powermax 350

Page 1: ...EN50199 EN50192 Plasma Arc Cutting System Operator Manual 802900 Rev 0 ...

Page 2: ...10 Hanover New Hampshire 03755 5010 Tel 603 643 3441 Fax 603 643 5352 http www hypertherm com Copyright 1997 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 Revision 0 July 1997 ...

Page 3: ...rganization 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 Hyper...

Page 4: ...ke 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 t...

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: ... sécurité 1a 2 Protection des yeux 1a 2 Protection de la peau 1a 2 Prévention des vapeurs toxiques 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 SPECIFICATIONS 2 1 Introduction 2 2 Specifications 2 2 Power Suppl...

Page 7: ...onsumable Parts 5 8 PAC110 Torch Assembly and 15 Ft 4 5 M Torch Lead 25A 5 9 PAC110 Torch Assembly and 25 Ft 7 6 M Torch Lead 25A 5 9 ILLUSTRATIONS Figure 2 1 Powermax350 Hand Plasma Cutting System 2 3 Figure 2 2 PAC110 Torch with Dimensions 2 3 Figure 3 1 Repositioning Input Voltage Selector Switch 3 3 Figure 3 2 Changing Power Cord Plugs 3 3 Figure 3 3 Proper Work Clamp Connection 3 4 Figure 3 4...

Page 8: ...dy 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 a...

Page 9: ... an air supplied helmet 5 98 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 10: ...Examine 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 ...

Page 11: ...d and the work cable Route torch leads as close 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 Co...

Page 12: ...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 13: ...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 14: ...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 15: ...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 16: ...SPECIFICATIONS 2 1 Operator Manual In this section Introduction 2 2 Specifications 2 2 Power Supply 2 2 PAC110 Torch 2 3 S Mark 2 4 IEC Symbols Used 2 4 Section 2 SPECIFICATIONS ...

Page 17: ...ent I2 17 27 amps Full Rated Output 27 amps at 91 VDC at 104 F 40 C Duty Cycle X at 40 C at rated output voltage U2 and at rated output current I2 35 I2 27A U2 91V 60 I2 21A U2 88V 100 I2 17A U2 87V See power supply data tag for more information on duty cycle Ambient Temperature and Duty Cycle Power supplies will operate between 14 and 104 F 10 and 40 C Power supplies operated in an ambient temper...

Page 18: ... System PAC110 Torch Recommended Cutting Capacity 1 4 inch 6 mm 25A 35 duty cycle Maximum Cutting Capacity 3 8 inch 10 mm 25A 35 duty cycle Severance Cutting Capacity 1 2 inch 12 mm 25A 35 duty cycle Gas Flow 270 scfh 4 5 scfm at 60 psi 127 l min at 4 1 bar Weight 3 pounds 1 4 kg Figure 2 2 PAC110 Torch with Dimensions ...

Page 19: ...azard of electrical shock O I Direct Current DC Alternating current AC Plasma cutting torch AC input power connection The terminal for the external protective earthed conductor A chopper based power source Anode work clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle The power is on The power is off Volt amp curve IEC SYMBOLS USED ...

Page 20: ... Upon Receipt 3 2 Claims 3 2 Locating Power Supply 3 2 115 230 Voltage Configurations 3 2 Input Voltage Selector Switch 3 2 Power Cord Plugs 3 2 Grounding 3 4 Work Cable and Clamp 3 4 Plasma Air Supply 3 4 Additional Air Filtration 3 5 Air Hose Connection 3 5 ...

Page 21: ...rvice at 1 800 643 0030 in the U S and Canada or your authorized Hypertherm distributor LOCATING POWER SUPPLY Locate the Powermax350 power supply near the 115V or 230V wall receptacle Allow at least 10 inches 0 25 m of space at the front and back of the power supply for proper ventilation 115 230 VOLTAGE CONFIGURATIONS The 115 230V Powermax350 power supplies are shipped to operate at the following...

Page 22: ...r cord This procedure is necessary if 230V input power is required See the procedure in Fig 3 2 for installing a power cord plug 2 1 3 2 4 5 6 7 1 Input Voltage Selector switch 2 Retaining screw Remove screw and position switch to select required voltage Reinstall retaining screw and tighten to secure switch in place 3 Power Cord plug 115V shown If plug does not match voltage at receptacle or type...

Page 23: ... clamp and the workpiece make good metal to metal contact Attach the work clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields EMF Do not attach the work clamp to the portion of the workpiece to be cut away PLASMA AIR SUPPLY The air supply for the Powermax350 can be supplied as shop compressed air or cylinder compressed air A high pressure regulator o...

Page 24: ... Panel 1 Air fitting Install 1 4 NPT quick disconnect nipple on to air fitting using a liquid pipe sealant CAUTION Never use Teflon tape when installing the nipple or adapters Bits of tape can break off and enter the air line and harm the pressure regulator pressure switch and valve Nipple is found in the consumables box located in the left side of the power supply cover 2 Air hose Use a 3 8 inch ...

Page 25: ...ERATION In this section Controls and Indicators 4 2 Operating Instructions 4 3 Operating Tips 4 4 Changing Consumable Parts 4 4 Cutting 4 5 Piercing 4 6 Operating Data 25A Consumables 4 7 Common Cutting Faults 4 8 Duty Cycle and Overheating 4 8 ...

Page 26: ...s loose Yellow OVER TEMP LED When illuminated indicates that the power supply has overheated AMPS GAS TEST SET Adjustment Knob Adjusts output current between 16 and 25 amps The GAS TEST SET position allows adjustment of the air pressure Pressure Regulator Adjustment Knob Regulates input gas pressure to the power supply Pressure Gauge Indicates gas pressure at the power supply ON I OFF 0 Power Swit...

Page 27: ... the workpiece Do not attach it to the portion that will fall away 7 The Powermax350 is now ready to operate When you are ready to cut place the tip of the torch on the workpiece Press the torch switch to start the arc 8 The arc will transfer from the torch to the workpiece Move the torch in the desired direction at a speed which will ensure good cut quality See Cut Chart later in this section 9 W...

Page 28: ...it is damaged replace it 6 Replace the parts as shown in Fig 4 3 Each part fits in only one direction so you cannot put the parts in backwards Also the torch will not fire if the parts are improperly installed 7 When the nozzle electrode and swirl ring are properly in place replace the retaining cap When the retaining cap is tightened the microswitch will click indicating that the torch is again r...

Page 29: ...ully penetrate the workpiece Hold the torch lightly on the metal or just above the metal Holding the torch firmly to the work piece 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 ...

Page 30: ...er material Make sure that the torch is pointed away from you and the people near you to avoid any danger from sparks and hot metal Fig 4 7 When the pierce is complete bring the torch to a perpendicular position and 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 nozzle ...

Page 31: ...erials on site in order to obtain optimum cut quality Swirl Ring 020239 Extended Electrode 020382 Extended Nozzle 120504 Retaining Cap 020218 Material Thickness Arc Current Approximate Travel Speed ga or in mm A ipm mm min Mild Steel 18 GA 1 3 25 70 1775 12 GA 2 8 25 52 1320 1 8 3 6 25 47 1190 3 16 4 8 25 33 825 1 4 6 0 25 17 430 3 8 9 0 25 9 225 Stainless 18 GA 1 3 25 65 1650 Steel 12 GA 2 8 25 4...

Page 32: ...EATING The duty cycle is the amount of time in minutes that a pilot or plasma arc can remain on within a 10 minute period when operating at 104 F 40 C At the 25 amp setting the arc can remain on 3 5 minutes out of every 10 minutes without causing the temperature sensors to disable the unit At 20 amps the duty cycle is 60 or 6 minutes out of every 10 minutes At 17 amps the duty cycle increases to 1...

Page 33: ...ver Temp 5 3 PAC110 Torch Repair 5 4 Parts and Required Tools 5 4 Remove Torch Main Body 5 4 Install New Torch Main Body 5 4 Basic Troubleshooting 5 6 Technical Questions 5 8 Parts 5 8 Powermax350 Hand Systems 5 8 Consumable Parts 5 8 PAC110 Torch Assembly and 15 Ft 4 5 M Torch Lead 25A 5 9 PAC110 Torch Assembly and 25 Ft 7 6 M Torch Lead 25A 5 9 In this section ...

Page 34: ...vice or main tenance work is complete In other countries follow appropriate national or local safety procedures Under severe conditions routine maintenance should be performed more frequently Before Each Use Check the air pressure Check the torch and consumables Every Week Check the torch cap on sensor system by listening for the micro switch to click when the retaining cap is loosened See Changin...

Page 35: ...ver the torch cap shut down system has been activated turn the power Off O and then On I to reset the system Check the torch cap shutdown system once a week as follows Turn power On I and loosen the torch cap If shutdown system works properly READY LED extinguishes and TORCH CAP LED illumi nates If the shutdown system does not work properly turn power Off O and check for proper air pressure see Se...

Page 36: ...isassemble and repair the torch refer to Figure 5 2 and perform the following procedure 1 Remove the five screws which secure the handle halves together 2 Remove the torch main body and torch switch from the handle halves 3 Disconnect the cinch strap Tyrap 4 Cut the four white wires connecting the torch lead to the plunger Cut the wires at the butt splice 5 Cut the two blue wires connecting the to...

Page 37: ...h lead to the butt splice connecting the black plunger wire to the torch main body using the crimping tool 5 Connect the cinch strap Tyrap as shown 6 Install the torch main body assembly and torch switch into one of the handle halves While position ing the handle halves together be careful not to pinch any wires Be especially careful around the torch switch retainers 7 Replace the five screws to s...

Page 38: ...lation of swirl ring 1 3 Refer to Service Manual IM 292 802920 for more detailed troubleshooting 2 1 Place the Power switch to On I 2 2 Plug in the power cord 2 3 Check line disconnect fuses and replace if needed or reset circuit breakers 2 4 Refer to Service Manual IM 292 802920 for more detailed troubleshooting 3 1 Check that the work clamp is connected 3 2 Clean or replace worn consumables as n...

Page 39: ...troubleshooting 8 1 Check torch retaining cap to ensure it is tight 8 2 Refer to Service Manual IM 292 802920 for more detailed troubleshooting 9 1 Thermostat in power supply is open overheating Allow the fan to run the thermostat closes when the unit has cooled see Section 4 Duty Cycle and Overheating 9 2 Refer to Service Manual IM 292 802920 for more detailed troubleshooting 10 1 Refer to Servic...

Page 40: ...ice Manual IM 292 802920 for wiring diagrams higher level troubleshooting and more parts list information PARTS Powermax350 Hand Systems 070052 115 230 VAC 1 Phase 60 Hz 15 ft 4 5 M 070053 115 230 VAC 1 Phase 60 Hz 25 ft 7 6 M 070055 CE 115 230 VAC 1 Phase 50 Hz 15 ft 4 5 M 070056 CE 115 230 VAC 1 Phase 50 Hz 25 ft 7 6 M Consumable Parts The consumable parts are found in a box located in the left ...

Page 41: ...n 020239 Ring Swirl 020382 Electrode Extended 120504 Nozzle Extended 25A 020218 Cap Retaining 020588 Torch Main Body with Switch PAC110 044016 O Ring BUNA 90 Duro 614X 070 029241 Torch Lead 15 ft 4 5 m 029257 Torch Lead 25 ft 7 6 m See Fig 5 3 for consumable parts Handle 001192 Torch Lead 029241 15 ft 4 5 m 029257 25 ft 7 6 m Torch Pushbutton Switch 005094 Handle 001192 O Ring 044016 Screw 075339 ...

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