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MAXPRO200® - Powermax 105

1. 4 10 9 8 7 6 Item PartNumber Description Quantity 1 428036 Chopper replacement kit 1 2 127014 Coolant reservoir cap 1 3 002546 Coolant reservoir 1 4 006099 Coolant drain valve 1 5 228993 Coolant solenoid valve replacement kit 1 6 428039 Pump motor replacement kit 1 7 015665 Fitting male elbow 3 8 inch NPT x 1 2 inch push in tube 2 8 428043 Pump replacement kit 1 9 015815 Fitting elbow 1 2 inch x 1 2 inch push in tube brass 2 10 074354 Cable holder for 1 2 inch diameter cable 17 11 104407 Bushing dust seal 6 12 074353 Cable holder for 1 4 inch diameter cable 10 13 074355 Cable holder for 3 4 inch diameter cable 10 168 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Power supply 5 2 e e 3 amp n 10 4 9 7 8 7 Item Part Numb
2. LEAN 75 u 17000000 uo ALE E A 3 190 pale A gt sl lt 98 N 59 Ovt 55 2 e 58 155 E gt 25485 gege a 350 553 E oae zm c sz 7 Es 6 2 NJ 83 mE ma sS 2 93 500 lt pza O 25 8 DET I maid 1 j 5 28 23 P E Iz o SN LU OL di eeu 58 mm Is 9 93 2 ouv as G eom 8 3 101 wa og EN m 2 3 N m ad s _ za 25 TI T gr N eee 2 yn af 58 J ae zat DE XC m lt gg e 41 3 LEE 9d 2 n E ag 93 a 29 lt 2 23 23 g 8 F 2 2 B 2323 555 959 UJ gt 2 Fe s 73877 931531 006 4 Lois INSHSHISHSdAH 4 Measure the ohm value between the nozzle and the plate The reading should be lt 4 ohms A measurement gt 4 ohms indicates a faulty connection between the torch and I O board or between the I O bo
3. M 63 Premixed coolant for standard operating temperatures eene nnne 6 Custom Coolant mix for cold operating temperatures below 12 C 10 F 64 Custom Coolant mix for hot operating temperatures above 38 C 100 F eene 65 Water purity requirements eret tette td ce eer P LR RETE Ce ket Pede a Raro nee ERE e Race ds 65 MAXPRO200 Instruction Manual 807700 Revision 1 3 Contents Fill the power supply with coolant I U tete tette te teinte tete 66 Connectithe supply Gases x xe eee u n ln DA 67 Diego 67 No No supply gas connection 2 67 Os Air Supply gashool up s sis diastase cients Saale db cU S nines ae Uude 67 Gas requirements u uuu u i a Dn n e epi n e 71 Setting the supply gas regulators 71 aas regulators este ae eer S AT EM MD M Id 72 S pply gas pl mbing ete betae tein 73 oupply gasheses E 74 DALI see Shad 74 A E E E E A 74 E EE EE EN E EAEE EE EE ON EE 74 Operation ecc anaa 7
4. 31 D 31 National and local environmental regulations tente tente tentent tente tentat te tette tentes te tenta tensa 31 The RoHS directivas o nad adn catia anaes 31 Proper disposal of Hypertherm products I tenete intet tenente tetendit 31 The WV EERE 2 G Sp Sisa ua abu te ic eie icr ciere 31 The REACH regulation re tica cena iva d ses iwa a ide deret Rs dede 32 Proper handling and safe use of chemicals testet te tette tentatio tesa tensa 32 Furmes emissioncand air gaal rra ara EA subinde nie an PLE D E 32 274124 33 sisi Stews M 33 Cones ated dca ate 33 Powet Supply Er Ment et ada tii 33 Ignition Console MEETS 33 33 LAE MUT ME
5. TvIH3S 150 MAXPRO200 Instruction Manual 807700 Revision 1 Pilot arc current levels Plasma gas 50 Amps 130 Amps 200 Amps Air 20 Amps 35 Amps 40 Amps N 35 40 Amps O 20 Amps 35 Amps 40 Amps Transfer current Maintenance Transfer is determined by CS1 PCB3 I O board Transfer occurs when the current on the work lead is gt 7 Amps MAXPRO200 Instruction Manual 807700 Revision 1 151 Maintenance Chopper tests WARNING ELECTRIC SHOCK HAZARD Use extreme care when working near the chopper modules Each large electrolytic capacitor blue cased cylinder stores large amounts of energy in the form of electric voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the chopper and the diode heatsinks Never discharge any capacitor with a screwdriver or other implement explosion property damage and or personal injury will result Automatic chopper and current sensor tests during power up After you turn ON the power to the system and the preflow starts the system will automatically run the following series of tests The system performs a chopper test verifying there is no output current Less than 5 amps is considered no current 1 The main contactor is open IGBTs are off a If there is current on channel A error code 401 is displayed b If there is current on channel
6. Timeline Component Part number Quantity Coolant filter element 027005 1 Coolant solution 70 30 028872 4 5 5 years 3300 arc hours Torch o ring 044026 2 Air filter element 011093 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 Main contactor 200V 240V 003233 Main contactor choose one 1 Main contactor 380V 600V 003249 Torch main body straight torch 420087 Torch main body quick disconnect torch 220921 Torch main body choose one 1 Torch main body 90 Hand torch 420070 6 years 3600 arc hours Torch main body 65 Hand torch 420109 Air filter element 011093 1 Pump replacement kit 428043 1 System Torch leads dependant 1 Fan 450 550 cfm 120 VAC 50 60 Hz 10 027079 1 inches Heat exchanger fan 11 inches 127091 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 6 5 years 3900 arc hours Torch o ring 044026 2 Air filter element 011093 1 MAXPRO200 Instruction Manual 807700 Revision 1 163 Maintenance 164 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Control panel Item Part Number Description Quantity 1 428032 Control panel replacement kit 1 2 108797 Knob soft black no pointer 3 3 007050 Rocker switch bezel 1 4 005678 Rocker switch 1 5 075237 Screw control panel and enclosure panels 10 32 Torx T 25 18 165 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Power s
7. 9 oA Og Rad i a dr attend NN ALLE NL E 9 Electric shoek can kill trt een t been el eire ria db n d e a Posee irn ra 10 Cutting can cause Tire OF explosion xe uei w inb reta Er 11 Eire prevefitioniz ec SING e ere Du E Ed pe hdi ade Ede 11 Explosion srian M 11 Toxic tumes CAUSE mju or ASAI dete AR RN EIES OE EA REE A 12 Grounding sately sits ths p unu aa uma A IM LAT ADEM 13 Static electricity can damage circuit boards 13 Compressed gas equipment safety tette tette PREES tenente tente ttn 14 Gas cylinders can explode if damaged uuu uu p upas ls seen tentent ntnn tnter tettn uuu as u Sasa 14 A plasma arc can cause injury and burns u ceeded 14 Arc rays canburn eyes and skin sede mentiti tete pepe 15 Pacemaker and hearing aid operation asas testet ie teste testet sese 16 Noise damage utet mtt tac e Ht de n eR t B e d ennai de do 16 A plasma arc can damage frozen pipes U entente U tette tete 16
8. number Name 00 Power up 01 Initial checks 02 Gas purge 03 Ready for start 04 Preflow 05 Preflow hold 06 Ignite 07 Pilot arc 08 Rampup 09 Main arc 10 Rampdown 11 Rampdown complete 12 End of cycle 14 Shutdown 17 Standby 120 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Sequence of operation and power supply status Power up status 00 1 Initialization of microprocessor hardware Initialization of power supply gas system and display System will display dots on the current display System will look for shield gas button press to indicate USB host firmware update System will stay in this state until the rocker switch is turned on Initial checks status 01 1 System will turn on the plasma gas channel at 100 flow and will measure the pressure The system will use this value as the inlet pressure If the inlet is above or below the minimum the system will generate error code 63 System will read the torch ID jumpers and verify it s a valid ID If no torch ID is detected the system will generate error code 99 System will perform a chopper test verifying there is no output a Main contactor off open IGBTs off f there is current on channel the system will generate error code 401 If there is current on channel B the system will generate error code 402 If there is current on both channels the system will generate error c
9. MAXPRO200 Instruction Manual 807700 Revision 1 139 Maintenance Coolant flow test The control board receives an electrical signal in Hz from the flow sensor that is converted and shown as flow in gallons per minute Normal flow is 4 5 lpm 1 2 gpm but this will vary depending on lead lengths and whether the power is 50 Hz or 60 Hz PCB4 will allow the system to operate if the coolant flow is 1 9 lpm 0 5 gpm or greater If the system shows a coolant flow error 093 the system will need to be turned OFF and then ON again and the following test needs to be performed to determine if the problem is coolant flow or the flow switch 1 Turn OFF the power and remove the right side panel from the power supply 2 Remove the return hose at the top of the coolant tank Push the connector collar toward the fitting and pull the hose away from the fitting This will release the coolant hose No tools required Put the end of the return hose into a 4 liter 1 gallon container 140 MAXPRO0200 Instruction Manual 807700 Revision 1 Maintenance 3 You will need to enable the flow function before the count reaches 5 in the 3 digit display Turn ON the power and press and release the current knob twice until the flow function is enabled Turn OFF the power after the coolant flows for 30 seconds 4 Measure the amount of coolant i
10. Pd arg A 4 3 3V 1 nO 2VAOCL 120VAC OUT 044 IIIIGIIIIIIIIIIII III FIRMWARE LABEL l TP20 24V m SONOS I I IIIIIIIIIIIIIIIIIIIIIII Hs TCHVLV EldL 1241 TP13 TP21 TP11 ASL Sdl gg 15V TPS HLD OG H MOTN PWRGND 026 5181 45V EB E 141 o 24 15 Je Bu START luvis TIDO TID2 TID3 06 01 02 m 03 D4 FLAG 061 2 Lf J17 H SHVLV PLVLV TP9 TP12 64 91f J16 1 J21 145 146 Maintenance Gas leak tests Note See Diagnostic functions on page 128 for details about getting to the gas test functions Function Description 001 Flow gas at set pressure Plasma and shield gases flow at the set value Plasma gas leak check The plasma channel is pressurized and the pressure trapped The 3 digit display shows the actual pressure The system remains in this state until you select another function or return to cutting The pressure in the plasma channel should remain stab
11. Typical gouge profile for 200A air Metal removal rate on mild steel 18 7 Kg hr 41 2 Ibs hr Speed 1270 mm min 50 ipm Stand off 12 7 mm 0 5 inch Angle 35 O gt lt yO 4 10 7 mm 0 42 inches 5 4 4 mm 0 18 inches Typical gouge profile for 200A O Metal removal rate on mild steel 20 5 Kg hr 45 Ibs hr Speed 1270 mm min 50 ipm Stand off 12 7 mm 0 5 inch Angle 35 lt 2 6 10 4 mm 0 41 inches 7 5 4 mm 0 21 inches MAXPRO200 Instruction Manual 807700 Revision 1 85 Operation Varying the gouge profile You can vary the gouge profile and the metal removal rate by varying the speed of the torch over the workpiece varying the distance between the torch and the workpiece varying the angle of the torch to the workpiece and varying the current output of the power supply The following actions have the stated effects on the gouge profile Increasing the speed of the torch will decrease width and decrease depth Decreasing the speed of the torch will increase width and increase depth Increasing the standoff of the torch will increase width and decrease depth Decreasing the standoff of the torch will decrease width and increase depth Increasing the angle of the torch more vertical will decrease width and increase depth Decreasing the angle of the torch less vertical will increase width and decrease depth Increasing t
12. e bead eda eran 44 Gro nding practices s iecit rawa rita n die cric d no non ie ce pica 44 Placement of the power SUPPLY u u a inuns hab reor nan resta ep beo dett ean beni amende 48 Bie certos eieice T 49 Work lead Connections 52 Torch connections nette derent foe Wa ie A A k 5 Connect the torch to the quick disconnect receptacle 54 Torch mounting and alignment inari rtt td diene SE rd i Sd 55 Mounting 2 54 tese edo 55 Torch alignrient cree avd ont cem edt tt 55 ONC interface cable 56 Notes to CNC interface cable run list I tenente tentent tenente tente teneret tenente 56 Remote ON OFF switch provided by customer Conci bug 58 Powerireq lrement u uy 60 Generali sr cere E I Lc E dr eeu nn 60 line disconnect 61 Main power Cable nn er teca reo n a a 61 Connectthe power rp a e eie bag S p rte Rma RR 62 Torch Coolant requirements
13. nter tenente tenente entente nente tenente tente nennen 121 PCB block diagrari tette ra tentia be ici eh i n a d bn ib si 126 14 COGS MOT 127 Diagnostic fin ClONS EE 128 Troubleshooting table rennen tet D n t t nda ta t Pura d 129 HOT 137 Power meas re Menti HH 138 MAXPRO200 Instruction Manual 807700 Revision 1 5 Contents Power supply coolant system servicing 139 Draining he coolant System 139 Goolant flow test ioi eoe dot 140 Coolant system filter replacement 142 Air filter element tc ood n edidit e e e n EAE ce ec in a us 143 Control board eei tectae le eta te oa e taie 144 Control board LED list sed lh dee e s du s d oie ei ides 144 Control board test points rei En ANE NL NANI 144 M L M sha 147 Sar ette aaa 148 Operations RI 148 Start circuit functional SCHEMALIC aite tene is 148 otart circuit troubleshooting uec tete 149 Filet amp are current levels edd OR IU eU Dd de HEC 151 Transfer
14. 151 Chopper tests cast temperet A eben erbe turtle 152 Automatic chopper and current sensor tests during 152 Using a meter to measure open circuit voltage 153 Phase OSS COTS CHOON e 154 iborehilead 16st 3 35 Mrs en rd o T ost 155 Preventive MaINtONanGe 156 VEO 7 5 rS 156 Preventive maintenance protocol 4444 tette a r a napaka a 156 m M M 156 157 Toreh man DOY eS 157 Gas NAWS a A i dte emi mien A OOOO 157 able connections 2 9 itae u tete stab R A ROE RETEA E at ied 158 lghitionenelosure E ta 158 usu au 158 a tA k ONS 158 Preventive Maintenance Master Schedule 159 Daily 159 a p CEP 159 Semi annuallyzi s u 159 DUBII Hp 159 Preventive Maintenance
15. A fault was detected on channel A of the chopper Turn OFF the line power to the system Check the wiring between the control board and the chopper for damaged wires and proper connections and then turn ON the line power again so the automatic diagnostic checks will run lf the error changes to a 409 error replace the chopper assembly 132 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Number Name Description Corrective action 108 Transfer at power up The system has detected current on the work lead during power up 1 Verify that the chopper PCB is functioning properly by checking the LEDs on the board against the LED list in the Maintenance section See Start circuit troubleshooting on page 149 2 Replace the chopper PCB if connections are correct and not damaged 3 Verify that the main contactor CON1 is not welded closed or closing at power up 109 Coolant Flow At power up Coolant flow measured during power up and before pump motor has been turned on 1 Verify that the shield cap is properly installed A loose shield cap can allow shield gas to get into the coolant and cause a coolant flow error 2 Verify that the torch lead connections are good Turn off the power to the system wait 30 seconds and turn the power back on Sometimes if you turn the power off and then on too quickly it may cause a 109 error 4 Disconnect the transfer sensor
16. CNC interface cable Part Number Length Part Number Length 223327 1 3 m 5 feet 223330 15 m 50 feet 223328 3 0 m 10 feet 223331 23 m 75 feet 223329 7 5 m 25 feet 223332 30 m 100 feet Power supply end CNC end Wire Pin Input Input color number Output Signal name Function Output Notes Orange 1 Input Start The CNC initiates preflow and if the hold input is not active Output White 2 Input Start continues with the plasma arc The system will stay in preflow if the Output 1 hold input remains active Brown 3 Input CNC delays plasma arc initiation This signal is normally used Output ME 1 White 4 input Hold in combination with the start signal to synchronize multiple torches Output Black 5 Output Motion Notifies the CNC that an arc transfer has occurred and to begin Input White 6 Output Motion machine motion once the CNC s pierce delay has timed out Input 2 Red 7 Output Error Notifies the CNC that an error has occurred Input White 8 Output Error Input Notes to CNC interface cable run list Inputs are optically isolated They require 24 VDC at 12 5 mA or dry contact closure at 8 mA Outputs are optically isolated open collector transistors The maximum rating is 24 VDC at 10 mA Although the power supply has an output capability it is normally used solely as an input There is no 24 VDC power avallable
17. Safety critical components are replaced with unauthorized spare parts Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification or otherwise CE marking constitutes a 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 MAXPRO200 Instruction Manual 807700 Revision 1 Product Stewardship 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 Marking Certificates of compliance for Hypertherm products are available from the Downloads Library on the Hypertherm web site at https www hypertherm com Differences in national standards Nations may apply different performance safety or other standards National differences in standards include but are not limited to Voltages Plug and cord ratings Language requirements Electromagnetic compatibility requirements These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product For example the CSA vers
18. 95 Machine torch i uv yu n ND dU NA IA DEI AUI IUE 95 E 95 Optimizing eut quality bete s etse 96 TPS tortable and torch iisdem hates Rana aie ead oes 96 SQtUP tips 96 Maximize the life of consumable parts I n n aa 96 Additional factors of Cut Quality rece du 97 eun 97 DES 98 Straightness of the Cut surface eee Ec nii Asia 98 How to increase cutting speed 1 ete tet tete tt tat t tac Da n ra en ada n Ea trato 98 Estimated kerf width compensation eese nennen tenente 99 Mg PEE 99 Irc Q 100 ticharts s sess eiim c AL m Da A EEA E rasa Ld tet et bie trn etie 101 Maintenance 119 119 Preventive Maintenance ayasa u 119 Power SUpply Slat s bin repre enden 120 Sequence of operation and power supply status
19. Hypertherm b Use the 1 4 inch NPT Female port from which the air fitting was removed to connect a user supplied supply gas hose 3 Setthe gas pressure regulators See Setting the supply gas regulators on page 71 O Air Supply gas hook up 1 Disconnect the air supply from the system 2 Remove the plasma supply tube from filter regulator output port MAXPRO200 Instruction Manual 807700 Revision 1 67 Installation Use the supplied plug to block the open plasma outlet port of the filter regulator S P 2 7 7 7 xr H 4 Connect only filtered and regulated oxygen to the plasma gas Inlet See Gas regulators on page 72 for a suitable oxygen regulator Note An oxygen fitting kit 428054 with the parts described below is available from Hypertherm There are several options for connecting the oxygen supply gas line Remove the 015811 fitting and put an 015009 fitting user must order the part See the note above Use the correct Hypertherm supply gas tubing 046231 to connect to the fitting 015811
20. Transformer air core Transformer coil Triac VAC source MAXPRO200 Instruction Manual 807700 Revision 1 185 Wiring Diagrams 186 MAXPRO200 Instruction Manual 807700 Revision 1 Air Air Air Filter Regulator Pressure gage Shield Gas amp Pilot Arc Plasma Gas Blue Hose Black Hose 21 46 71 96 Hand Mech Torch MAXPRO 200 Gas Schematic N2 N2 N2 Filter Regulator Pressure gage Shield Plasma Power Supply board Shield Gas amp Pilot Arc Plasma Gas Blue Hose Black Hose 21 46 71 96 Hand Mech Torch O2 AIR Air 02 Filter Regulator Pressure gage Plugged Shield Power Supply board Shield Gas amp Pilot Arc Plasma Gas Blue Hose Black Hose 21 46 71 96 4 Hand Mech Torch 187 Torch Lead Assembly Plasma Gas Lead Plasma Gas Lead lenoid V 5 Gas Solenoid Valve Enable Cooling Supply Lead Plasma Solenoid Cooling Return Lead Negative Lead P Unit 1 Start Triager Pilot Arc Lead Power Supply Lead Length ID Unit M Torch Lifter 3 Phase LU Optional Unit Power w Ground um Torch Workpiece Work Lead CNC CUSTOMER SUPPLIED ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 1 OF 9 AN 188 009045 FILTER SHEET BUS VOLTAGE BUS VOLTAGE 129854 PWM CHP A 01 GND CHOPPER TEMP GND D 5V PWM CHP B D2
21. 1 Control transformers Part number Description Part number Description 229535 200 volt 50 60 Hz 229538 415 volt 50 60 Hz 229536 220 volt 50 60 Hz 229539 440 volt 50 60 Hz 229537 240 volt 60 Hz 229488 480 volt 60 Hz 229514 380 volt 50 Hz 229540 600 volt 50 60 Hz 229515 400 volt 50 Hz Item Part Number gt Description Quantity 1 See table above Control transformer 1 2 027079 Fan 450 550 cfm 120 50 60 Hz 1 3 101205 Ignition enclosure panel ignition 1 4 428044 Inlet gas plug replacement kit 1 5 015812 Adaptor 1 4 inch NPT o ring x 5 16 inch 1 6 010875 Label Danger voltage 1 Not shown 428054 Kit MAXPRO200 O S A Oxygen quick connect kit 1 Not shown 015015 Adapter 1 4 inch 6 Male 90 degree 1 Not shown 015817 Adapter 3 8 inch FNPT x 1 2 inch push in tube 1 MAXPRO200 Instruction Manual 807700 Revision 1 171 Parts List Ignition enclosure 2 ES To e Qe 5 Y Q 3 x e 3 E 2 p S e m LT 4 Number Description Quantity 1 428040 PCB replacement 1 2 428041 panel replacement kit includes PCB 1 3 229487 Ignition transformer 1 4 109636 EMI
22. 2 Advance to state 12 End of Cycle End of cycle status 12 1 Turn on plasma and shield gases for postflow 2 System will verify coolant flow is above the minimum error code 93 3 System will verify the plasma start signal is off 4 Once the plasma start signal is off the system will advance to state 3 Ready for start Shutdown status 14 1 System will turn off all power supply coolant and gas outputs Standby status 17 1 the rocker switch is turned off the system will enter the standby state 2 When the rocker switch is turned on the system will advance to state O Power up MAXPRO200 Instruction Manual 807700 Revision 1 125 Maintenance 2 O I s un p1eoq 1 99 ime jueuno Jamod g V JeddoujS 4eddouj e qeu3 e qeu3 8 INMd sng V D 19JsueJ lt e qeo jonuo3 jeuondo p1eoq 928J19 UI EUlSP d ujBue pee Ajuo uo101 puer youms YOJOL e qeo 1 llonuoo 10sues lqe1 105 5 PCB block diagram 0200 Instruction Manual 807700 Revision 1 126 Error codes Maintenance When the fault indicator is illuminated the error code number can be seen in the three digit display
23. 2 The cutting table is used for the common or star EMI ground point and should have threaded studs welded to the table with a copper bus bar mounted on them A separate bus bar should be mounted on the gantry as close to each motor as possible If there are motors at each end of the gantry run a separate EMI ground cable from the far motor to the gantry bus bar The gantry bus bar should have a separate heavy EMI ground cable 21 2 mm 4 AWG 047031 to the table bus bar The EMI ground cables for the torch lifter and the RHF console must each run separately to the table ground bus 44 MAXPRO200 Instruction Manual 807700 Revision 1 Installation A ground rod that meets all applicable local and national electrical codes must be installed within 6 m 20 ft of the cutting table This is a PE ground and should be connected to the cutting table ground bus bar using 16 mm 6 AWG green and yellow grounding cable 047121 or equivalent 4 For the most effective shielding use the Hypertherm CNC interface cables for I O signals serial communication signals between plasma systems in multi drop connections and for interconnections between all parts of the Hypertherm system 5 All hardware used in the ground system must be brass or copper While you can use steel studs welded to the cutting table for mounting the ground bus no other aluminum or steel hardware can be used in the ground system AC power PE and service grounds must be conne
24. 202 15 Ecological information ceret ce count ata ink 202 16 Other informiatlOn zu cca ute he dire ae wana qct E 202 8 MAXPRO200 Instruction Manual 807700 Revision 1 Safety RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine understand the potential for personal injury and follow the related instructions to avoid the hazard FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety labels on your machine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the controls properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols A signal word DANGER or WARNING is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific hazards DANGER safety messages precede related instructions in the manual that will result in serious injury or death if not followed cor
25. 223331 223332 Work leads Part Number 223335 223336 223337 223338 Work clamp Part Number 008539 Hand torch leads Part Number 229498 229499 229500 229501 Inline valve kit Length 7 5 m 25 feet 15 m 50 feet 23 m 75 feet 30 m 100 feet Length 1 3 m 5 feet 3 0 m 10 feet 7 5 m 25 feet 15 m 50 feet 23 m 75 feet 30 m 100 feet Length 7 5 m 25 feet 15 m 50 feet 23 m 75 feet 30 m 100 feet Description Giround clamp Length 7 5 m 25 feet 15 m 50 feet 23 m 75 feet 30 m 100 feet Part Number Description 428055 Replacement for the valve located in the torch lead Hand torch heat shield 127389 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List 175 Parts List 90 degree hand torch Item Part Number Description Quantity 1 420108 90 degree hand torch assembly 1 228980 90 degree hand torch assembly with 7 5 m 25 feet lead 1 228981 90 degree hand torch assembly with 15 m 50 feet lead 1 228982 90 degree hand torch assembly with 23 m 75 feet lead 1 228983 90 degree hand torch assembly with 30 m 100 feet lead 1 2 228985 Handle replacement kit 1 001905 90 degree torch handle left and right sides 1 002244 Safety trigger 1 027254 Safety trigger spring 1 075841 Pan head screws 6 210185 Hand torch label 1 210209 Hypertherm IEC label 1 3 420070 Torch main body 1 4 044026 O ring 1 239 inch x 0 070 inch 2 17
26. 52 54 55 56 48 50 54 58 3 4 164 0 19 60 0 38 200 1 2 7 8 169 0 19 50 0 38 200 1 4 1 173 0 25 35 0 45 180 1 7 1 1 4 176 0 25 25 0 45 180 2 3 1 1 2 179 0 25 20 1 3 4 190 0 25 12 Edge start 2 200 0 25 8 with IHS tab without IHS tab 106 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Mild steel Flow rates Ipm scfh Plasma Air Shield Plasma Air Shield 200 A Cutting 32 67 123 260 D yp 220832 220936 220935 220831 220834 220937 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow d pun Pierce Height B 7 6 15 3 22 9 30 5 m 76m 15 3 22 9 30 5 m mm Volts mm mm min mm Factor Seconds Lead Lead Lead Lead Lead Lead Lead Leaq 6 0 146 1 5 6210 3 0 200 0 3 8 0 150 3 4 4850 5 1 150 0 4 10 0 156 4 6 3735 6 9 150 0 4 12 0 154 3 8 3415 9 5 250 0 6 15 0 153 3 1 2845 7 8 250 0 7 68 69 70 71 48 50 54 58 20 0 154 3 0 1920 75 250 0 8 25 0 154 3 2 1430 8 0 250 1 0 32 0 161 3 1 805 7 8 250 1 3 38 0 168 4 4 570 44 0 175 4 4
27. Failure to do so could result in a cracked torch head hoses or other damage to the torch coolant system due to freezing Use the chart below to determine what percentage of propylene glycol to use in the mixture Mix 10096 propylene glycol 028873 with the premixed Hypertherm coolant 028872 to increase the percentage of glycol in the premixed Hypertherm coolant The 100 glycol solution can also be mixed with purified water see the chart below for water purity requirements to achieve the required protection from freezing Note The maximum percentage of propylene glycol should never exceed 50 Freezing Point of Propylene Glycol Solution C F 1 T CR WEN Hypertherm pre mix F 12 10 lt 18 0 G 5 29 20 Maximum glycol percentage 3 MN TT 51 60 57 70 EST 0 10 20 30 40 50 60 of Propylene Glycol 64 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Custom Coolant mix for hot operating temperatures above 38 C 100 F Treated water with no propylene glycol can only be used as coolant when operating temperatures are never below 0 C 32 F For operations in very warm temperatures treated water will provide the best cooling properties Treated water refers to a mixture of purified water that meets the specifications below and 1 part benzotriazole BZT to 300 parts of water BZT 128020 acts as a corrosion inhibitor for the copper based coolant
28. There are three general types of error codes Self clearing An overtemperature error for example will clear when the power supply cools off Low priority The user must select the fault icon and press the current selection knob to see the error code This type of error can be cleared with the start signal High priority The system will automatically select the fault icon and show the error code This type of error requires the power to the system to be turned off and then on again after the cause of the error has been corrected 3 digit display icons Name Description The remote icon illuminates when there is serial communication with the power supply You can still cycle through the functions but cut parameters can only be changed through the CNC CD gug 1 Remote 2 Amps Increase or decrease the amperage by selecting the amps icon and turning the knob The current increases or decreases in 1 amp increments when you turn the knob slowly You can jump from one process amperage to another when you turn the knob quickly 2 3 Fault The fault icon illuminates when an error occurs If the error code number is 60 or less press the current selection knob to navigate to the illuminated fault icon When the fault icon is selected the error code appears in the 3 digit display If the error code is 60 or greater the system automatically selects the faul
29. Wiring diagram symbols i Battery T Cap polarized ae Cap not polarized Ground clamp Ground chassis Ground earth Receptacle Relay coil Relay normally closed E 777 m Cap feed through 5 IGBT Relay normally open s Circuit breaker Inductor Relay solid state AC T Coax shield T LED Relay solid state DC Current sensor Relay solid state dry e Current sensor Lj MOV Resistor DC supply lt SCR KP Diode gt Socket Shield WA Door interlock Plug Shunt N PNP transistor Spark gap T Feedthrough LC Vy VV Potentiometer NS Switch flow Filter AC Push button normally closed Switch level normally closed o w O Fuse Push button normally open ak dcm 184 MAXPRO200 Instruction Manual 807700 Revision 1 Switch pressure normally open Switch 1 pole 1 throw Switch 1 pole 2 throw Switch 1 pole 1 throw center off Switch temperature normally closed Switch temperature normally open Terminal block Time delay closed NC off Torch symbols Electrode J LJ W gt 5 O Wiring Diagrams Time delay open NO off AF Valve solenoid Time delay open NC on Voltage source Time delay closed NO off gt Zener diode Transformer
30. ata 184 MAXPRO200 Instruction Manual 807700 Revision 1 7 Contents Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture 197 1 Identification of the substance mixture and of the company undertaking seen 197 2 AZArdS IGS utei m 198 Composition information on ingredients 198 4 Fitst id measures ode etia ee nd date rb apas 198 5 Firesfighitirig measures ain acetic viter cr rene Pha 198 6 Accidental release measures 2 U tad i ten IH a deb ek Ha f cR e ae 199 Z Handing and storage tete 199 8 Exposure controls personal protection U I tenente entente tnnt inte tein inte toten inte uuu 199 9 Physical and chemical properties U U tete tinus iato toes tatto to tanta 200 TO Stability and reactivity s oa oid e ER d 200 LOX COlOGICAl INTORMALIOM EDS 201 12 Ecological informatiori cost cont ita tec tacta ta c teta ten A ENEAN 201 19 7Disposal considerations enin ac derer ie dabis eni e Ee ted deter D 201 1 4 Transport inf ormati ni
31. lt 015009 7777 68 MAXPRO200 Instruction Manual 807700 Revision 1 Installation b Usea suitable O fitting to connect to the 8 mm 5 16 inch tubing that you removed from the plasma gas Inlet c Remove the plasma gas tubing and 8 mm 5 16 inch fitting 015811 and connect to the 1 4 inch NPT female threads 015811 477 MAXPRO200 Instruction Manual 807700 Revision 1 Installation d Remove the bushing and fitting to connect to 1 4 inch G female threads 015810 and amp 051811 5 Reconnect the air supply 6 Setthe gas pressure regulators See Setting the supply gas regulators on page 71 70 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Gas requirements The system is configured for air air cutting when it is shipped Connect an air supply to the filter regulator that is mounted
32. on the rear panel of the power supply If cutting with or N2 N you will have to make changes to the gas connections See Connect the supply gases on page 67 CAUTION Gas supply pressures not within the specifications in Section 2 can cause poor cut quality poor consumable life and operational problems If the purity level of the gas is too low or if there are leaks in the supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Parts life can shorten Setting the supply gas regulators 1 Turn OFF the power to the system Set all the supply gas regulator pressures to 6 2 bar 90 psi 2 Turn ON the power to the system 3 Afterthe purge cycle is complete press the current selection knob to get to the test mode When the test mode icon is illuminated turn the knob to get to test 005 Flow gas at full pressure Set all supply regulators to a system inlet pressure of 6 2 bar 90 psi 4 Press and release the current selection knob until the amps icon is illuminated MAXPRO200 Instruction Manual 807700 Revision 1 71 Installation Gas regulators Note A separate gas regulator is needed only when cutting with oxygen Use a high quality 1 stage gas regulator to maintain consistent gas supply pressure if using liquid cryogenic or bulk storage Use a high quality 2 stage gas regulator to maintain consistent gas supply pressure from high press
33. yourself from work and ground Disconnect power before servicing Do not touch live parts Plasma fumes can be hazardous Do not inhale fumes Use forced ventilation or local exhaust to remove the fumes Do not operate in closed spaces Remove fumes with ventilation Arc rays can burn eyes and injure skin Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away Do not remove destroy or cover this label Replace if it is missing damaged or worn 21 Safety 22 0200 Instruction Manual 807700 Revision 1 Introduction Hypertherm s CE marked equipment is built in compliance with standard EN60974 10 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN60974 10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity In such cases it may be necessary to use other measures to further reduce interference This cutting equipment is designed for use only in an industrial environment Installation and use The user is responsible
34. 0 5 15 0 162 3 6 1120 71 200 0 8 20 0 166 3 9 470 8 7 220 1 4 English Material Arc Cut Cutting i Pierce Plasma Cutflow Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 25ft SOft 75ft 100ft 25 508 75ft 100 ft in Volts in Dm in Factor Seconds Lead Lead Lead Lead Lead Lead Lead Lead 3 16 153 0 12 125 10 24 200 0 2 1 4 154 0 12 115 10 24 200 0 2 3 8 158 0 13 75 0 26 200 0 3 68 69 70 71 36 39 42 44 1 2 160 0 13 55 0 26 200 0 5 5 8 163 0 14 40 0 28 200 0 8 3 4 165 0 15 25 0 33 220 1 3 with IHS tab without IHS tab MAXPRO200 Instruction Manual 807700 Revision 1 115 Operation Aluminum Air Plasma Air Shield 200 A Cutting 420045 Flow rates Ipm scfh Air Plasma Air Shield 32 68 123 260 220488 220937 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow B oid adios osos beds 520 Pierce Height D 7 6 15 3 229m 30 5m 76m 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Leaq Lead Lead mm
35. 067 Magnetics over temp Main transformer has over heated 1 Verify that the magnetics fan is operating properly Spinning fan blades should be difficult to see 2 Blow dust out of the system especially from fans and inductors 3 If voltage is low or near O VDC inspect wiring between inductor A s temperature sensor and J1 12 pins 4 and 5 on the control board Look for shorts between wires or to ground 4 If wiring is good the inductor has overheated Allow the power supply to idle with the fans running for a minimum of 30 minutes to cool the inductors 068 Inductor A over temp Inductor has over heated MAXPRO200 Instruction Manual 807700 Revision 1 131 Maintenance Number Description Corrective action 069 Inductor B over temp Inductor has over heated 1 Verify that the magnetics fan is operating properly Spinning fan blades should be difficult to see Blow dust out of the system especially from fans and inductors If voltage is low or near VDC inspect wiring between inductor B s temperature sensor and J1 12 pins 7 and 8 on the control board Look for shorts between wires or to ground If wiring is good the inductor has overheated Allow the power supply to idle with the fans running for a minimum of 30 minutes to cool the inductors 071 Coolant over temp Torch coolant has overheated Verify that the heat exchanger fan is spinning Blow dus
36. 1 across each of R34 R35 and R36 The work lead should not have any cuts or breaks Verify a resistance of 10 or less The work lead connection to the cutting table should be clean and have good contact to the table Verify 014 is illuminated If it is not illuminated the board may need to replaced or the board not be receiving power Fire the torch in the air and verify that is illuminated If it is not illuminated but a pilot arc is established the pilot arc IGBT 07 may need to be replaced 5 Place a 10 AWG 6 mm jumper in parallel across the work lead WORK H8 wire labeled J2 9 and J7 Nozzle wire labeled J2 7 Perform a test cut The nozzle will wear out after just a few starts If the arc transfers check R34 R35 R36 27 the chopper and the wiring between them replace parts as necessary Chopper PCB MAXPRO200 Instruction Manual 807700 Revision 1 149 Maintenance LED Description D1 Chopper A PWM D2 Chopper B PWM Pilot arc enable D6 4 chopper circuit power D10 Gate drive optocoupler 5V power indicator s J7 H9 NOZZLE D14 Pilot arc circuit power indicator D20 Bus voltage 5V circuit power indicator D22 Chopper 15V power indicator t Descri
37. 125 1135 3 16 1 4 5 16 3 8 1 2 5 8 3 4 7 8 1 1 1 4 1 1 2 1 3 4 2 50A Air Air 0 061 0 066 0 071 0 066 0 061 0 060 0 059 N A 0 063 0 068 130A Air Air 130A 200A Air Air 200A Thickness inches Aluminum 018 020 024 030 036 048 060 075 105 125 135 3 16 1 4 5 16 3 8 1 2 5 8 3 4 7 8 1 1 1 4 1 1 2 1 3 4 2 50A Air Air 130A Air Air 130A 200A Air Air 200A Operation Cut charts The following cut charts for the MAXPRO200 show the consumable parts cutting speeds and the gas and torch settings required for each process allowing for differences in the lead length While you can use these parameters for cutting with both mechanized and handheld torches the consumable part numbers listed with each cut chart are specific to mechanized torches Refer to Hand held cutting and gouging consumable selection on page 87 for the consumables to use for handheld torches for each process The cut chart values in this document are recommended to provide high quality cuts with minimal dross Because of differences between installations and material composition adjustments may be required to obtain desired results MAXPRO200 Instruction Manual 807700 Revision 1 101 Operation Mild steel Air Plasma Air Shield 50 A Cutting lt 220936 220935 220532 220890
38. 174 Quick disconnect torch u u sna dud caecus 174 Cables e M 175 Machine aoo 175 cables iini ciii dimi e E P d do dr E CH HR P n ERR 175 Work leads MEE REED IEEE EIL E M 175 Work Clamp Re EE 175 torch e 175 Inline valve asta u Haec uude N E p META 175 Harid torch heat shield 127389 ioci bn pie o 175 90 degree hand torchi s ic tct re ttc iced tem reci ede cem ta re E rec a 176 65 degree LI DA TL IUE 177 Consumable pans kits cde Rt d td edunt tut Neb ea utei mter eet 178 Mechanized torch consumable kit 428013 178 Hand torch consumable kit 428014 n a 179 pct epp 180 ONY OOM cid 180 sasakuna eL EM A 180 ton 180 Recommended Spare parts it tnter rien itid dr dr rbd de 181 Wiring Di gra MS Ju u 183 WIRING SynIDOIS
39. 395 Edge start 50 0 180 4 4 270 English Plasma Cutflow Shield Cutflow 5 Pierce Height Dor 2bft 75ft 100ft 25ft 75ft 1008 Lead Lead Lead Lead Lead Lead Lead Leaq TE ini Factor 20 Seconds 1 4 143 0 08 235 0 15 200 0 3 3 8 157 0 19 150 0 28 150 0 3 1 2 153 0 14 130 0 28 200 0 3 5 8 153 0 12 105 0 28 250 0 5 3 4 154 0 12 80 0 28 250 0 6 68 69 70 71 48 50 54 58 7 8 154 0 13 65 0 31 250 0 7 1 154 0 13 55 0 31 250 0 8 1 1 4 161 0 13 32 0 35 280 1 5 1 1 2 168 0 18 22 1 3 4 175 0 18 15 Edge start 2 181 0 18 10 with IHS tab without IHS tab MAXPRO200 Instruction Manual 807700 Revision 1 107 Operation lt gt 220532 Stainless steel Air Plasma Air Shield 220936 220935 50 A Cutting 220890 Flow rates Ipm scfh Air Plasma Air Shield 12 25 103 218 220529 ayy 220528 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow e s ini 2 Pierce Height Dolor 7 6 15 3 22 9 30 5 m 76m
40. B expected value on channel B 2 Disconnect any exterior equipment from the I O Board Example Arc Voltage connection 4 that the 10 Oh ist the I i Current too high on Current exceeded the maximum the 10 Ohmifesistor the UO board not damaged 419 Current sensor A and expected value on channel A and 2 Disconnect any exterior equipment from the I O Current sensor B channel B Board Example Arc Voltage connection 136 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Initial checks Before trouble shooting do a visual check and verify that proper voltages are present at the power source transformers and power distribution board DANGER ELECTRIC SHOCK HAZARD Always use caution when servicing a power supply when plugged in and the covers are removed Dangerous voltages exist within the power supply which could cause injury or death 1 Disconnect line power by turning OFF the main disconnect switch 2 Remove the power supply s top panel and 2 side panels 3 Inspect interior of power supply for discoloration on PC boards or other apparent damage If a component or module is obviously defective replace it before doing any testing Refer to the Parts List section to identify parts and part numbers 4 fno damage is apparent connect power to the power supply and turn ON the main disconnect switch 5 Measure the voltage between the L1 L2 and L3 terminals of TB1 located on th
41. Conditions to avoid None anticipated Incompatible materials Keep away from oxidizing agents Hazardous decomposition product s Carbon monoxide Carbon dioxide Nitrogen oxides 200 MAXPRO200 Instruction Manual 807700 Revision 1 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture 11 Toxicological information 11 1 1 Substances Acute toxicity Ingestion Inhalation Skin Contact Eye Contact Hazard label s Serious eye damage irritation Respiratory or skin sensitization Mutagenicity Carcinogenicity Reproductive toxicity STOT single exposure STOT repeated exposure Aspiration hazard Low oral toxicity but ingestion may cause irritation of the gastrointestinal tract Unlikely to be hazardous by inhalation Mild irritant to rabbit skin Mild irritant to the eye None Mild irritant to the eye Mild irritant to rabbit skin Not known IARC NTP OSHA ACGIH do not list this product or any components thereof as known or suspected carcinogen Not known Not known Not known Not known 12 Ecological information Toxicity Persistence and degradability Bioaccumulative potential Mobility in soil Results of PBT and vPvB assessment Other adverse effects Do not let this chemical product enter the environment Biodegradable None anticipated The product is predicted to have moderate mobility in soil None assigned None anticipated 13 Disposal considerations Waste treatment methods D
42. Dry dust collechion 1nformation rtu eati usa niani duis dir tesi sese 17 18 oymbolsand marks ed ANAMA a aa Aa ones WS 19 Additional safety information kuk 20 EI rg 20 Electromagnetic Compatibility ener rennen enr u uuu uu nara tn ama u 23 ntrod 6tiorba CT 23 lnst ll tion and USS ZR E 23 ASSOSSMEONU OF ANCA 23 Methods of FEC UGINGSMISSIONS UE RE Edere EA PAATENEN FEA 23 EIER Ice M 23 MAXPRO200 Instruction Manual 807700 Revision 1 1 Contents Maintenance of cutting equipment I U U teet into tuni 24 Cutting Cables 24 Equipotential bending iti et io lih neto 24 Earthing of the Workplece 24 oereeriing andsshielding suy m susu susya S EIU DE 24 Warranty 25 hwradeoc M 25 General
43. Fill the power supply with coolant on page 66 Qr guo Ur NE 8 E zm MW Cain I NN VILI Xd 142 MAXPRO0200 Instruction Manual 807700 Revision 1 Maintenance Air filter element replacement 1 Disconnect the electrical power and the gas supply and remove the filter bowl and the old filter element a Pull down and hold the black release tab b Rotate the filter bowl in either direction until it releases c Pullthe filter bowl down to remove it The bowl has an o ring around the top Do not discard the o ring If the o ring needs to be replaced use part number 011105 2 Turn the plastic disk under the filter element counter clockwise about 1 4 turn and remove the old filter element Install the new filter element 011093 3 Re install the filter bowl a Hold down the black tab and slide the filter bowl over the new filter element b Rotate the filter bowl until it locks in place MAXPRO200 Instruction Manual 807700 Revision 1 143 Maintenance Control board Control board LED list LED Description LED Description D1 Torch ID 0 D46 High frequency
44. GND GND TEMP ADC 63 63 OPTIONAL ied ARCEN VOLTAGE WIRES NEED BE CONNECTED IF PLASMA INTERFACE BOARD IS INSTALLED CHASSIS WIRE RUNS ARE TO A TERMINAL BLOCK NEAR GND PLASMA INTERFACE BOARD MOUNTING LOCATION SS R CURRENT A CEH ARC VOLTAGE O O N E o CHOPPER CURRENT BOARD INDUCTOR 1 141216 TEMP P 18V 5V 014 18V 06 15V D22 D 5V 010 A 5V 020 mm 009224 CS1 1KV PA LEAD TO TORCH INPUT POWER FROM FACILITY J7 1112 13 JNEGATIVE J lt RED BLK 20 cs FR 2 INDUCTOR 2 lose PTS PETERE 3 C4 SHEET CHOPPER Rs 3 A4 CURRENT B 10R J3 10 CHOPPER CURRENT B 23 6 SHOWN WIRED FOR 480V SEE PAGES 6 AND 7 FOR 2 9 WORK OTHER CONFIGURATIONS H8 J POSITIVE R34 R35 R36 WORK J2 2 1R 1R 1R Shown for 480V COLLECTOR PILOT ARC 1 7 CONTROLLER CONTROL 127 TRANSFORMER NOZZLE 12 YEL 24VAC RED 120VAC ORN 240VAC CONTROL XFORMER ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 2 OF 9 189 ETO CONTROL 2 4 TRANSFORMER 120VAC F2 120VAC D 240VAC ORN 240VAC F1 OPTIONAL Ji 8 J8 CUSTOMER BLK REMOTE 24 POWER SWITCH POWER ON STANDBY a 120VAC SWITCHED g 240VAC SWITCHED POWER SUPPLY CONTROL BOARD 141201 026 4 15V D31 AF 240V FUSED AC INPUT 033 3 3V D37
45. Lead Lead Lead Lead Lead Lead 5 0 156 3 2 4460 6 4 200 0 4 6 0 159 3 2 3980 6 4 200 0 4 10 0 160 3 2 2900 6 4 200 0 5 12 0 162 3 2 2260 6 4 200 0 8 69 70 71 72 42 45 48 51 15 0 165 3 4 1760 7 9 230 0 9 20 0 172 4 2 1190 10 1 240 1 1 25 0 185 6 4 790 11 4 180 2 0 32 0 191 6 4 520 Edge start 38 0 197 6 4 310 English Material Arc Cut Cutting Plasma Shield Thickness Voltage Height Speed Pierce Height Delay 25ft 75ft 100ft 25ft 75ft 100 ft in Volt in Second Lead Lead Lead Lead Lead Lead Lead Lead Sm P anciens 3 16 159 0 13 180 10 25 200 0 4 1 4 159 0 13 150 10 25 200 0 4 3 8 160 0 13 120 10 25 200 0 5 1 2 163 0 13 80 0 25 200 0 8 5 8 166 0 14 65 0 32 230 0 9 69 70 71 72 42 45 48 51 3 4 170 0 16 50 0 38 240 1 0 7 8 178 0 19 40 0 38 200 1 5 1 186 0 25 30 0 45 180 2 0 1 1 4 191 0 25 21 Edge start 1 1 2 197 0 25 12 with IHS tab without IHS tab 112 MAXPRO200 Instruction Manual 807700 Revision 1 Aluminum Air Plasma Air Shield 50 A Cutting Operation Flow rates Ipm scfh Air Plasma Air Shield 12 25 104 218 220532 220936 220935 220890 220529 7 220528 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these c
46. Protocol Checklist 160 Year 1 preventive maintenance PM kits cssssessssssssscssesssessscsssssssssssssssesssessessnssseesssesessesssessscsnssssesuseseessesseessesneesnssnsessesseesseass 161 Maintenance kits parts Ist terti d Perte dani ra c ee Fiir dat derer eara 161 Service parts replacement schedule 161 6 MAXPRO200 Instruction Manual 807700 Revision 1 Contents Parts HL rem 165 Gontrol panel sued sua taU tta escas 165 meis M 166 e Mose o cC 172 Height control conriection s eee te 173 Sensor THC connection kit 428023 sees nnne tente tentent tete treten 173 Sensor PHC connection kit 428022 iarain ia ANNA NR ARTER RAA ANNAA 173 Wire groups and harnesses E nad R EO 173 USB cables for software updates det aee de ndn ndn n dra d ded de 173 Cable for USB Update 223291 oiii ce ite ted a abd decided fei i e D cd ecol 173 Cable for USB update 2232739 5 eese ER HR S Dei eder Er cR 173 Power supply gas hose kit 228862 u kaa e kaa au aska Sawka awa Wasa 173 Machirie torches usu eoo ree ene obe oe ime On bc dam tn e bnc o d ad e Pe ad et indes 174 TORCH EE IE E EOD
47. System will execute the ignition sequence by turning off the torch valve then turning on the High Frequency The system will turn on the torch valve again while continuing to activate the High Frequency 2 The system will monitor for pilot arc current If pilot arc current is not detected the ignition sequence will be repeated up to 5 times after that the system will have error code 20 Pilot arc fault and advance to state 11 Rampdown Complete 3 System will check for an over current condition Chopper A over current the system will generate error code 134 Chopper B over current the system will generate error code 138 4 f chopper current is detected during the sequence the system will advance to state 7 Pilot Arc Pilot arc status 07 1 System will display actual gas pressures on the 2 digit pressure displays 2 System will verify the gas pressures are within tolerance Low plasma pressure the system will generate error code 44 High plasma pressure the system will generate error code 45 Low shield pressure the system will generate error code 53 High shield pressure the system will generate error code 54 3 System will check for over current Chopper A over current the system will generate error code 134 Chopper B over current the system will generate error code 138 4 System will check for minimum coolant flow If it is below minimum the system will generate error code 93 5 System will check for minimum ch
48. Upon receipt Verify that all system components on your order have been received Contact your supplier if any items are missing nspect the system components for any physical damage that have occurred during shipping there is evidence of damage refer to Claims All communications regarding claims must include the model number and serial number located on the rear of the power supply 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 authorized Hypertherm distributor Claims for defective or missing merchandise If any of the merchandise is defective or missing contact your supplier If you need additional assistance call Customer Service listed in the front of this manual or your authorized Hypertherm distributor Installation requirements installation and service of the electrical and plumbing systems must conform to national and local electrical and plumbing codes This work should be performed only by qualified licensed personnel Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual or your authorized Hypertherm distributor Noise levels Acceptable noise levels as defined by national and local
49. aluminum Worn or damaged consumables may produce intermittent dross Straightness of the cut surface A typical plasma cut surface is slightly concave The cut surface may become more concave or convex Correct torch height is required to keep the cut surface acceptably close to straight voltage to increase the torch to work distance and straighten the cut surface A convex cut surface occurs when the cut height is too great or the cutting current is too high First reduce the arc voltage then reduce the cutting current If there is overlap between different cutting currents for that thickness try the consumables designed for the lower current A strongly concave cut surface occurs when the torch to work distance is too low Increase the arc How to increase cutting speed To increase cutting speed you can decrease the torch to work distance However decreasing this distance will increase the negative cut angle For mechanized applications the torch must not touch the workpiece while piercing or cutting For hand held applications the shield can be touching the workpiece to provide stability during cutting 98 0200 Instruction Manual 807700 Revision 1 00 4408 002044 66 Estimated kerf width compensation The kerf widths in the following charts are for reference Differences between installations and material composition may cause actual results to vary from
50. at the J6 CNC connector The wire clips on the center panel should be used to help route the CNC cable from the rear panel opening of the power supply to J6 on the control board Open the clips by depressing the release tab and add the CNC cable to the wires that are already present in the clip See the figure on the next page oF N 56 MAXPRO200 Instruction Manual 807700 Revision 1 Installation CNC cable routing and connection to control board from the To J6 on the control board m MAXPRO200 Instruction Manual 807700 Revision 1 57 Installation Remote ON OFF switch provided by customer WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring the removal of the plasma system cover must be performed by a qualified technician See Safety on page 9 of your instruction manual for more safety precautions 1 Remove the 4 screws that secure the control panel to the power supply and locate terminal block J1 8 on the power supply control board 2 Remove the jumper wire between terminal 1 and terminal 2 Use a sturdy tool to depress the corresponding orange release buttons on the spring clamp connector 1234567 58 MAXPRO200 Instruction Manual 807700 Revision 1 Installation 3 Connect the switch to terminals 1 and 2 as shown below Use a sturdy tool to dep
51. cleaning 8 Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab pipe cleaner or clean cloth Do not use alcohol Damage to the threads usually results from not cleaning the torch and retaining cap threads properly so that dirt and particulates accumulate in the threads 9 Inspect the torch insulator for cracks Replace the torch if you find cracks 10 Inspect all o rings on the torch body and consumables Make sure that the correct amount of lubricant a thin film is applied to these o rings Too much lubricant may obstruct gas flows 11 Check that the retaining or shield cap is tightened securely to the torch main 12 Inspect all hose fittings at the rear of the torch for wear Damage to the fitting threads may indicate that overtightening has occurred 13 Check that all connections between the torch and torch leads are tight but do not overtighten See torque specs in the nstallation section of this manual When removing consumables always place them on a clean dry oil free surface since dirty consumables may cause the torch to malfunction Gas flows 14 Perform the appropriate gas flow tests described under Diagnostic functions on page 128 MAXPRO200 Instruction Manual 807700 Revision 1 157 Maintenance 15 If the gas line pressures hold steady perform a system gas leak test as specified in this manual 16 Check for hose restrictions as follows a Check
52. codes may be exceeded by this plasma system Always wear proper ear protection when cutting or gouging Any noise measurements taken are dependant on the specific environment in which the system is used See also Noise can damage hearing in the Safety section of this manual Specific information by product can be found in the Hypertherm downloads library at https www hypertherm com Xnet library DocumentLibrary jsp Select the product you are looking for from the Product Type drop down menu choose Regulatory from the Category drop down menu and choose Acoustical Noise Data Sheets from the Sub Category drop down menu Press Submit MAXPRO200 Instruction Manual 807700 Revision 1 41 Installation Placement of system components Place all system components in position prior to making electrical gas and interface connections Use the diagram in this section for component placement guidelines Ground all system components to earth See Recommended grounding and shielding practices on page 44 for details To prevent leaks in the system tighten all gas connections as shown below A Torque specifications Ibf in Ibf ft Gas or water hose size kgf cm ZEN Up to 10 mm 3 8 in 8 9 9 8 75 85 6 25 7 12 mm 1 2 in 41 5 55 360 480 30 40 42 MAXPRO200 Instruction Manual 807700 Revision 1 Installation System components Torch Cable and lead e Torch
53. de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Utiliser exclusivement les torches indiqu es dans le manual Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev C 0200 Instruction Manual 807700 Revision 1 WARNING LABELS This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on the label MAXPRO200 Instruction Manual 807700 Revision 1 1 1 1 2 1 3 2 1 2 2 3 1 3 2 3 3 4 1 4 2 4 3 5 1 Safety Cutting sparks can cause explosion or fire Do not cut near flammables Have a fire extinguisher nearby and ready to use Do not use a drum or other closed container as a cutting table Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered Turn off power before disassembling torch Do not grip the workpiece near the cutting path Wear complete body protection Hazardous voltage Risk of electric shock or burn Wear insulating gloves Replace gloves when wet or damaged Protect from shock by insulating
54. detected for Current on channel A did not return to Verify that the surge circuit on the I O board is 12 longer than exbected on 0 as expected functioning Current sensor P g Current detected for Current on channel B did not return to Verify that the surge circuit on the I O board is 419 longer than expectedion as expected functioning properl Current sensor B P MP Current sensor A and Current from output was detected 414 Current sensor B signals on channel B and output from channel Verify that the current sensor wiring is not crossed crossed B was detected on channel A Current detected on 415 Current sensor Biwhen Current fom output A Was detected Verify that the current sensor wiring is not crossed MAXPRO200 Instruction Manual 807700 Revision 1 135 Maintenance Number Description Corrective action Current detected on 416 ferent sensor A when Current rom output B was detected Verify that the current sensor wiring is not crossed expected on Current on channel A sensor B 1 Verify that the 10 Ohm resistor on the I O board is 417 Current too high on Current exceeded the maximum not damaged Current sensor A expected value on channel A 2 Disconnect any exterior equipment from the I O Board Example Arc Voltage connection 1 Verify that the 10 Ohm resistor on the I O board is 418 Current too high on Current exceeded the maximum not damaged Current sensor
55. every version of a product 68 A S mark The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60674 1 CSA mark Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety The products were evaluated tested and certified by CSA International Alternatively the product may have a mark by one of the other Nationally Recognized Testing Laboratories NRTL accredited in both the United States and Canada such as Underwriters Laboratories Incorporated UL or TUV CE mark 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 filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking GOST TR mark CE versions of Hypertherm products that include a GOST TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation c Tick mark CE versions of Hypertherm products with a c Tick mark comply with the EMC regulations required for sale in Australia and New Zealand CC
56. filter 1 5 008482 Power cord strain relief 380V 400V 415V 440V 480V and 600V power supplies 1 008052 Power cord strain relief 200 208V 220V and 240V power supplies 1 172 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Height control connection kits Sensor THC connection kit 428023 The kit contains a PCB 141201 and a wire harness 229554 A CNC interface cable is not supplied The desired length should be ordered separately Sensor PHC connection kit 428022 The kit contains a PHC plasma interface assembly 228256 with a 1 3 m 5 feet interface cable attached A CNC interface cable is not supplied The desired length should be ordered separately Wire groups and harnesses Part Number Description 229437 Main wire harness all power supplies 229438 Primary power wire group for 380V 400V 415V 440V 480V and 600V power supplies 229439 EMI filter wire group for 400V and 415V power supplies 229558 Contactor wire adaptors 229561 Primary power wire group for 200 208V 220V and 240V power supplies USB cables for software updates Cable for USB update 223291 Note This cable allows the system software to be upgraded using a USB memory stick xo MD 3 Me Cable for USB update 223273 Note This cable allows the system software to be upgraded using a laptop ele 39 LER vA Power
57. for installing and using the plasma equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of the work piece In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Assessment of area Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account MAXPRO200 Instruction Manual 807700 Revision 1 Electromagnetic Compatibility EMC Other supply cables control cables signaling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equip d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hearing aids f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used in th
58. parts can cause a fatal shock or severe burn Operating the plasma system completes an electrical circuit between the torch and the workpiece The workpiece and anything touching the workpiece are part of the electrical circuit Never touch the torch body workpiece or the water in a water table when the plasma system is operating Electric shock prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and boots and keep your body 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 the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground ELECTRIC SHOCK CAN KILL 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 a
59. persists after mechanical causes have been eliminated see Tips for table and torch check the cut height especially if cut angles are all positive or all negative A positive cut angle results when more material is removed from the top of the cut than from the bottom Anegative cut angle results when more material is removed from the bottom of the cut Cause Solution Negative angle The torch is too low Increase arc voltage to raise the torch The torch is too high Decrease arc voltage to lower the torch MAXPRO200 Instruction Manual 807700 Revision 1 97 Operation Dross Low speed dross forms when the torch s cutting speed is too slow and the arc shoots ahead It forms as a heavy bubbly deposit at the bottom of the cut and can be removed easily Increase the speed to reduce the dross High speed dross forms when the cutting speed is too fast and the arc lags behind It forms as a thin linear bead of solid metal attached very closely to the cut It is welded to the bottom of the cut and is difficult to remove To reduce high speed dross Decrease the cutting speed Decrease arc voltage to decrease the torch to work distance Notes Dross is more likely to form on warm or hot metal than on cool metal The first cut in a series of cuts will likely produce the least dross As the workpiece heats up more dross may form during subsequent cuts Dross is more likely to form on mild steel than on stainless steel or
60. precautions should be adopted during the actual installation and operation Procedures for periodic inspection and testing Where required by local national regulations IEC 60974 4 specifies test procedures for periodic inspection and after repair or maintenance to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974 1 Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non operating tests The tests are performed with the power and ground connections removed Hypertherm also removes some protective devices that would cause false test results Where required by local national regulations a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC60974 4 The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed Qualification of test personnel Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair preferably someone also familiar with welding cutting and allied processes The safety risks to personnel and equipment when unqualified personnel are performing these tests may be much greater than the benefit of periodic inspection and testing 28 Hypertherm recommends that only visual inspection be performed unless the electrical
61. replacement parts The kit should be kept in stock and be used as part of your routine maintenance schedule The straight torch and the hand torches only have two replaceable o rings 92 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Torch connections Quick disconnect torch Torch main body Quick disconnect receptacle Shield gas Pilot arc Coolant return Plasma gas N Coolant supply Straight torch tp 5 Plasma gas Coolant supply also contains the negative lead Shield gas also contains the pilot arc lead O N Coolant return MAXPRO200 Instruction Manual 807700 Revision 1 93 Operation Replace the torch water tube DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE Always disconnect power to the power supply before inspecting or changing torch consumable parts Use gloves when removing consumables The torch might be hot Note The water tube may seem loose when correctly inserted but any side to side looseness will disappear after the electrode is installed 1 Turn OFF all power to the system 2 Remove consumables from torch See nstall and inspect consumables on page 90 3 Remove the old water tube 4 Apply a thin film of silicone lubricant on the o ring and install new water tube The o ring should look shiny but there should not be any excess or built up lubricant 5 Replace consuma
62. sr eani c b LU dei 25 ciues DERE 26 Limitation of AA E rn dde a D ek 26 Natioral and COGS m 26 BEER 26 e N 26 EE gene 26 Product Stewardship Lu UI vadam cimo kw riu wo rir E iniaa 27 IPIYOd Cti rr P 27 National and local safety regulations uy py Su E aqa te ene intente tette tette tentat 27 Certification test oes EEG E iE pito ertet task ae ee tan 27 Differences in national staridards uiri rat iboart ia iea navei danadana aiik jaaiet 27 Safe installation and use of shape cutting equipment 28 Procedures for periodic inspection and testing essent n nanas 28 Qualification of test personnel ieiunio aves rode dett ede de de de bre dead deg De dr d d dec 28 Residual current devices RODS uyu sya k au n tenente tentent te tentent tette tette tte tette tete teta so sete testa 28 Fligherzlevel SyStembs sabe de De 29 Environmental Stewardship
63. system contained in the plasma system Water purity requirements It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or cooling system Always use water that meets the minimum and maximum specifications in the table below when using a custom coolant mix Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will alter the water flow and produce an unstable arc Water that does not meet the maximum purity specifications below can also cause problems Deionized water that is too pure will cause leaching problems with the coolant system plumbing Use water purified by any method deionization reverse osmosis sand filters water softeners etc as long as the water purity meets the specifications in the table below Contact a water specialist for advice in choosing a water filtration system Water purity measurement method Water purity Conductivity Resistivity Dissolved solids Grains per gallon uS cm mO cm ppm of NaCl gpg of CaCO2 at 25 C 77 F at 25 C 77 F Pure water for reference 0 055 18 3 0 0 only Maximum purity 0 5 2 0 206 0 010 Minimum purity 18 0 054 8 5 0 43 Maximum potable water 1000 0 001 495 25 for reference only MAXPRO200 Instruction Manual 807700 Revision 1 65 Installation Fill the power supply with coolant The system will take 14 2
64. those shown in the tables Metric Thickness mm Mild steel 50A Air Air 50A Air 130A Air Air 130A Air 200A Air Air 200A Air Stainless steel 50A Air Air 130A Air Air 130A No 200A Air Air 200A No Aluminum Air Air 130A Air Air 130A No No 200A Air Air 200A uonei do 001 004408 uononasu 0020 44 English Thickness inches Mild steel 0 018 0 020 0 024 0 105 0 125 0 135 3 16 1 4 5 16 3 8 1 2 5 8 3 4 7 8 1 1 1 4 1 1 2 1 3 4 2 Air Air 0 069 0 056 0 058 0 063 Air 0 057 0 063 0 059 130A Air Air 0 085 0 090 0 095 130A O Air 0 092 0 093 0 095 200A Air Air 0 111 0 114 0 118 0 116 0 126 0 135 0 147 0 158 0 165 0 172 0 200 0 227 200A Air 0 109 0 123 0 119 0 125 0 132 0 145 0 157 0 180 0 203 0 229 0 255 Stainless Thickness inches steel 018 020 024 030 036 048 060 075 105
65. to the filter regulator WARNING CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen enriched atmosphere that it creates As a precaution Hypertherm recommends that an exhaust ventilation system be installed when cutting with oxygen Flashback arrestors are required unless not available for specific gases or required pressures to prevent fire from propagating back to supply gas MAXPRO200 Instruction Manual 807700 Revision 1 73 Installation Supply gas hoses Air Caution Never use teflon tape O Part number Length Part number Length 024671 8 m 10 ft 024740 25 m 82 ft 024658 4 5 m 15 ft 024744 85 m 115 ft 024659 75 m 25 ft 024678 45 m 150 ft 024765 10 m 35 ft 024680 60 m 200 ft 024660 15 m 50 ft 024767 75 m 250 ft 024766 20 m 65 ft G Oxygen Part number Length Part number Length 024607 3 m 10 ft 024738 25 m 82 ft 024204 4 5 m 15 ft 024450 35 m 115 ft 024205 75 m 25 ft 024159 45 m 150 ft 024760 10 m 35 ft 024333 60 m 200 ft 024155 15 m 50 ft 024762 75 m 250 ft 024761 20 m 65 ft Q Nitrogen d H Part number Length Part number Length 024210 3 m 10 ft 024739 25 m 82 ft 024203 4 5 m 15 ft 024451 35 m 115 ft 024134 75 m 25 ft 024120 45 m 150 ft 024211 10 m 35 ft 024124 60 m 200 ft 024112 15 m 50 ft 0
66. 0 1 29 20 34 30 Temperature 40 40 46 50 51 60 57 70 0 10 20 30 40 50 60 of Propylene Glycol MAXPRO200 Instruction Manual 807700 Revision 1 203 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture 204 MAXPRO200 Instruction Manual 807700 Revision 1 Revision Changes MAXPRO 200 Revision Changes Changed page Description of changes for revision 1 date of revision March 2013 Cover and Title Page Revision number and dates changed Font size changed for the Product Stewardship and Environmental Stewardship information to match font size 9 used for and Warranty This added two pages to the Product Stewardship section 121 through 125 Headers updated to match the Power supply status table on page 118 Updated the description for error code 51 from The pilot arc temperature has exceeded it s maximum rating 130 to Maximum pilot arc duration exceeded Changed corrective action 1 from let the system cool off to Allow the power supply to idle with the fans running for 10 seconds Updated the description for error code 67 to say Main transformer has over heated Changed corrective 131 action 2 and 4 to say main transformer instead of inductors Changed corrective action 3 for error code 69 to say inductor B s instead of the transformer s Changed corrective action 1 for error code 93 to say level instead of height Added corrective actio
67. 0 200 0 5 English Plasma Cutflow Shield Cutflow 2 Pierce Height Dd 2bft 75ft 100ft 25ft 75ft 1008 Lead Lead Lead Lead Lead Lead Lead Leaq vole n Pm Factor Seconds 0 018 98 0 06 300 0 12 200 0 0 0 024 98 0 06 290 10 12 200 0 0 0 030 98 0 06 280 10 12 200 0 0 0 036 89 0 06 270 10 12 200 0 1 0 048 94 0 06 260 10 12 200 0 1 68 68 69 69 25 27 29 31 0 060 99 0 06 240 10 12 200 0 1 0 075 99 0 06 220 0 12 200 0 1 0 105 99 0 07 160 0 14 200 0 2 0 135 99 0 07 130 0 14 200 0 3 3 16 103 0 09 85 0 15 150 0 4 1 4 103 0 10 65 0 15 150 0 5 with IHS tab without IHS tab MAXPRO200 Instruction Manual 807700 Revision 1 103 Operation Mild steel Flow rates Ipm scfh Air Plasma Air Shield Air Plasma Air Shield 130A Cutting 33 70 68 145 220536 220936 220935 220892 220488 220487 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow B oid adios osos beds 520 Pierce Height D 7 6 15 3m 229m 30 5 m 76m 15 3 22 9 30 5
68. 0 Instruction Manual 807700 Revision 1 Installation Torch lead connections 1 Insert the end of the torch lead through the opening of the ignition enclosure as shown below Secure the collar on the torch lead to the ignition enclosure by aligning the tabs on the collar with the corresponding openings in the ignition enclosure rotate the collar until it stops and verify that the collar will not detach when released 2 Connect the CPC connector to the CPC receptacle MAXPRO200 Instruction Manual 807700 Revision 1 49 Installation Note The plasma gas and coolant return hose connectors mentioned below are push to connect fittings To make a connection push the hose fitting into the appropriate connector until it stops 12 mm 0 472 in Ello Connector collar lt disconnect a fitting push the connector collar and hose toward the fitting hold the collar place and pull the hose away from the fitting E ee 3 Connect the coolant return hose red 50 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Note The shield gas pilot arc and coolant supply negative lead hose connectors mention
69. 00 POWER SUPPLY 013384 SHEET 5 OF 9 192 D WIRED FOR 440V 50 60HZ 3 INPUT POWER FROM FACILITY C WIRED FOR 220V 50 60HZ B L1 L2 L3 INPUT POWER FROM FACILITY A WIRED FOR 600V 60HZ PEL1 12 13 INPUT POWER FROM FACILITY WIRED FOR 380V 50 60HZ TAI T 1A L1 L2 L3 jg INPUT POWER 54 FROM FACILITY oj iH ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 6 OF 9 193 Air N2 SHIELD PLASMA 21 46 71 96 TORCH VALVE Plasma ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 7 OF 9 194 7 Power supply CHECK VALVE FLOW SENSOR RESERVOIR FINE FILTER p INTERNAL BYPASS 1 SHUT OFF VALVE COLD PLATE 1 LLL 25 50 75 100 pm I D POWER LEAD q B TORCH ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 8 OF 9 195 POWER SUPPLY CONTROL SENSOR THC 141171 PLASMA INTERFACE I O 141201 SHEET GAS CONSOLE j CNC INTERFACE PLASMA INTRFC START RELAY J 12 1 IN START 229554 D6 mu CNC HOLD NEUT 5 SENSOR PHC PLASMA INTERFACE I O 12V FIELD HOLD XFER 1 CNC HOLD MOTION 49 012 CNC MOTION CNC ERROR 49 014 ERROR O OO N CNC HOLD OUT 0
70. 0096 33 kW 40 C 104 F Ambient temperature Duty cycle Power supplies will operate between 10 C 40 C 10 C and 40 C 14 and 104 Power factor cosq 0 98 33 kW output Cooling Forced air Class F Insulation Class H Power supply Regulatory Voltage Phase 10 part numbers U Hz approval U 1 x 1 73 078610 200 208 3 50 108 104 CSA 374 078611 220 3 50 60 98 CSA 37 4 078612 240 3 60 90 CSA 37 4 078613 380 3 50 57 CCC 37 4 078614 400 3 50 60 54 CE GOST R 37 4 078615 415 3 50 52 CE GOST R 37 4 078616 440 3 50 60 49 CSA 37 4 078609 480 3 60 45 CSA 37 4 078617 600 3 60 36 CSA 37 4 63 5 mm 2 5 inches 688 mm 27 1 inches 133 mm 5 25 inches 998 mm 39 3 inches Ol 927 mm 40 1 inches 5 7 kg 740 Ib 36 MAXPRO200 Instruction Manual 807700 Revision 1 Specifications Mechanized torches Straight torch 428024 The outside diameter of the torch mounting sleeve is 50 8 mm 2 0 inches The minimum bend radius for the torch lead is 152 4 mm 6 0 inches k 397 15 mm 15 64 inches 279 40 mm 11 00 inches 11775 mm 4 64 inches 12 70 mm 0 50 inches 44 20 mm 1 74 inches O N 46 degrees 7 44 20 mm 1 74 inches MAXPRO200 Instruction Manual 807700
71. 1 DRY DUST COLLECTION INFORMATION 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 worst case Kst value see annex F that could be generated from dust so that the explosion vent size and type can be designed NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems but it does apply these new requirements to all dry dust collection systems Note 2 Users of Hypertherm manuals should consult and comply with all applicable federal state and local laws and regulations Hypertherm does not by the publication of any Hypertherm manual intend to urge action that is not in compliance with all applicable regulations and standards and this manual may never be construed as doing so 17 Safety LASER RADIATION Exposure to the laser output can result in serious eye injury Avoid direct eye exposure LASER RADIATION DO NOT STARE INTO BEAM CLASS 2 LASER PRODUCT For your convenience and safety on Hypertherm products that use a laser one of the following laser radiation labels has been applied on the product near where the laser beam exits the enclosure The maximum output mV wavelength emitted nM and if appropriate the pulse durat
72. 15 HOLD OUT ARC VOLTAGE INPUT ELECTRODE NEG EMI GROUND ELECTRODE WORK A YEL BLK YEL BLK CONNECTIONS SHOWN FOR SENSOR OR SENSOR PHC THC Ni ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 9 OF 9 196 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture 1 Identification of the substance mixture and of the company undertaking Product identifier Torch coolant 3096 PG mixture GHS product identifier Not applicable Chemical name Not applicable Trade name Torch coolant 3096 PG mixture CAS No Not applicable EINECS No Not applicable REACH registration no Not available Relevant identified uses of the substance or mixture and uses advised against Identified use s Industrial use only Uses advised against Not available Details of the supplier of the safety data sheet Company Identification Hypertherm Telephone 1 603 643 5638 USA 31 0 165 596 907 Europe E Mail competent person technical service Hypertherm com Address P O Box 5010 Hanover NH 03755 USA USA Vaartveld 9 4704 SE Roosendaal Nederlands Europe Emergency telephone number 800 255 3924 USA 1 813 248 0585 International MAXPRO200 Instruction Manual 807700 Revision 1 197 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture C Classification GHS Classification Signal word s According to regulation EC No 1272 2008 CLP According to Directi
73. 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Leaq Lead Lead mm Volts mm mm Factor Seconds 0 5 101 1 5 8000 3 0 200 0 0 0 8 102 1 6 7750 3 2 200 0 0 1 0 102 1 8 7115 3 6 200 0 1 1 2 103 1 8 6350 3 6 200 0 1 62 63 63 63 39 42 45 47 1 5 106 1 8 5335 3 6 200 0 1 2 0 108 2 0 4200 4 0 200 0 1 2 5 111 2 0 3300 4 0 200 0 2 3 0 112 2 0 2800 4 0 200 0 3 4 0 116 2 2 2300 4 4 200 0 4 6 0 123 2 5 1400 5 0 200 0 5 English Plasma Cutflow Shield Cutflow Hachi Sposi Pierce Height Bie 2bft 5Oft 75ft 100ft 258 75ft 1008 2 4 Lead Lead Lead Lead Lead Lead Lead Lead m Tom 0 018 101 0 06 300 0 12 200 0 0 0 024 101 0 06 275 10 12 200 0 0 0 030 102 0 06 265 10 12 200 0 0 0 036 102 0 06 250 0 12 200 0 1 0 048 103 0 07 225 10 14 200 0 1 62 6 6 6 9 42 45 47 0 060 106 0 07 190 10 14 200 0 1 0 075 107 0 07 165 10 14 200 0 1 0 105 112 0 08 125 10 16 200 0 2 0 135 113 0 08 85 0 16 200 0 3 3 16 119 0 09 55 0 18 200 0 4 1 4 124 0 10 45 0 20 200 0 5 with IHS tab without IHS tab 108 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Stainless steel Flow rates Ipm scfh Air Plasma Air Shield Air Plasma Air Shield 130A Cutting 33 70 69 145 A Y 220536 220936 220935 220892 220488 220487 Note Gas pre
74. 16 126 0 09 75 0 18 200 0 4 1 4 131 0 10 50 0 20 200 0 5 with IHS tab without IHS tab 0200 Instruction Manual 807700 Revision 1 113 Operation Aluminum Air Plasma Air Shield 130 A Cutting 220536 220936 220935 220892 Flow rates Ipm scfh Air Plasma Air Shield 33 70 69 1 45 220488 220487 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 7 6 15 3m 229m 30 5 m 76m 15 3 22 9 30 5 min Volt mm mm min mm Factor Second Lead Lead Lead Lead Lead Lead Lead Lead s 6 0 156 2 8 2370 5 6 200 0 2 10 0 161 3 0 1470 6 0 200 0 3 12 0 163 3 0 1230 6 0 200 0 5 68 69 70 71 22 24 26 28 15 0 165 3 2 1050 6 4 200 0 8 20 0 169 3 6 725 7 9 220 1 3 25 0 175 4 0 525 Edge start English Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 25ft 75ft 100ft 25ft 5Oft 75ft 100 ft 9 Le
75. 2 220892 Nozzle 130A Air No 2 220893 Nozzle 130A Oo 2 220935 Shield cap Oo Air No clockwise 1 220936 Shield cap Oo Air No clockwise with IHS tab 1 220937 Electrode 200 Oo Air 6 420044 Nozzle 200A Air No 6 420045 Shield 200A Air No 2 428054 Kit MAXPRO200 S A Oxygen quick connect kit 1 881430 MAXPRO200 machine torch brochure 1 178 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Hand torch consumable kit 428014 Part number Description Quantity 027055 Silicone lubricant 1 4 ounce tube 1 044026 O ring 1 239 x 0 070 2 104119 Consumable tool 1 220488 Swirl ring 130A Oo Air and 200 A Air 2 220521 Water tube 1 220831 Nozzle 200A 2 220834 Swirl ring 200A 1 220935 Shield Oo9 Air No clockwise 2 220937 Electrode 200A Oo Air 8 420044 Nozzle 200A Air No 4 420058 Shield 200A Air No 2 420059 Shield 200A 1 420066 Nozzle 200A Air Gouging 2 420067 Shield 200A Air Gouging 2 428054 Kit MAXPRO200 O S A Oxygen quick connect kit 1 881440 200 hand torch brochure 1 MAXPRO200 Instruction Manual 807700 Revision 1 179 Parts List Supply gas hoses Oxygen Caution Never use teflon tape on any joint preparation N H Part number 024607 024204 024205 024760 024155 024761 Nitrogen Part number 024210 024203 024134 024211 024112 024763 Air O Part number 024671 024658 0246
76. 20070 90 degree torch main body 1 420087 Straight torch main body 1 420109 65 degree torch main body 1 428034 manifold replacement kit 1 428035 Castor wheel kit 1 428036 Chopper replacement kit 1 428037 Flow meter replacement kit 1 428038 Coolant filter replacement kit 1 428039 Pump motor replacement kit 1 428040 PCB replacement kit 1 428041 panel replacement kit includes PCB 1 428042 Pressure transducer replacement kit 1 428043 Pump replacement kit 1 428044 Inlet gas plug replacement kit 1 428054 Kit MAXPRO200 O S A Oxygen quick connect kit 1 428055 In line valve replacement kit 1 0200 Instruction Manual 807700 Revision 1 181 Parts List 182 MAXPRO200 Instruction Manual 807700 Revision 1 Wiring Diagrams This section contains the wiring diagrams for the system When you trace a signal path or reference the Parts List or Troubleshooting sections the following conventions will help you understand the organization of the wiring diagrams Sheet numbers are located in the lower right hand corner of each page References to other pages use the following connection symbol Sheet 4 D3 e Sheet number Coordinates Reference block Use the sheet number to find the reference sheet Line up the coordinates A D on the Y axis and numbers 1 4 on the X axis of each sheet to find the reference blocks similar to a road map MAXPRO200 Instruction Manual 807700 Revision 1 183 Wiring Diagrams
77. 22 Serial communications RX TP6 PWM channel A 5V TP23 CNC start TP7 PWM channel B 5V TP24 CNC start TP8 Pilot arc enable 5V TP25 Serial communications TX TP9 Shield valve output 24V TP26 15VAC power output to chopper TP10 Plasma valve enable 5V TP27 Inductor 2 temp input analog 3 3V TP11 Shield valve enable 5V TP28 Inductor 1 temp input analog 3 3V TP12 Plasma valve output 24V TP29 Main transformer temp input analog 3 3V TP13 Plasma valve enable TP30 Multiplexed transformer and inductor temps input TP14 Digital logic ground TP31 24V same connection as TP20 TP15 Power ground TP32 Spare input not used analog 3 3V TP16 Analog signal ground TP33 Plasma pressure input analog 5V TP17 Pump motor enable 5V TP34 Shield pressure input analog 5V 144 MAXPRO200 Instruction Manual 807700 Revision 1 Iro De 141169 REV C L PART NUMBER m TESTED LABEL 240VAC IN SERIAL NUMBER CM LABEL omoooo 120VACIN 1 moooooo MO 0000 2 7141 Y ZEN Pad PUMP TP17 mu m 240VAC OUT 1no 042 0600000000008 056 IIIIIOIIIIIIIS TP29 TP28 6cdl 8241 6191 5VUN FIRMWARE EB LABEL
78. 24764 75 m 250 ft 024763 20 m 65 ft 74 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Daily start up Before turning on the power to the system make sure that the cutting environment and clothing worn by users in that environment meet all the safety requirements outlined in Safety on page 9 DANGER ELECTRIC SHOCK CAN KILL Before operating this system you must read the safety section thoroughly Turn OFF the power supply s main disconnect switch before proceeding with the following steps 1 Turn OFF the main disconnect switch to the power supply 2 Remove the consumables from the torch and check for worn or damaged parts Always place the consumables on a clean dry oil free surface after removing Dirty consumables can cause the torch to malfunction and can shorten the life of the coolant pump See Install and inspect consumables on page 90 for details Refer to Cut charts to choose the correct consumables for your cutting needs 3 Replace consumable parts See nstall and inspect consumables on page 90 for details 4 Make sure that the torch is perpendicular to the workpiece lt gt 1 Shield 4 ring 2 Nozzle retaining cap 5 Electrode 3 Nozzle 6 Torch main body quick disconnect torch shown MAXPRO200 Instruction Manual 807700 Revision 1 75 Operation Controls and indicators Control panel descriptions 1 Power switch 3
79. 45 47 0 060 110 0 07 290 0 14 200 0 1 0 075 110 0 07 275 10 14 200 0 1 0 105 111 0 08 180 0 16 200 0 2 0 135 111 0 08 110 0 16 200 0 3 3 16 116 0 09 75 0 18 200 0 4 1 4 118 0 10 60 0 20 200 0 5 with IHS tab without IHS tab 102 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Mild steel Flow rates Ipm scfh Plasma Air Shield Plasma Air Shield 0 220532 220936 220935 220891 220529 220528 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead length Metric Plasma Cutflow Shield Cutflow i os Bod Eu Pierce Height 7 6 15 3 229 30 5 76m 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm min mm Factor Seconds 0 5 98 1 5 7550 3 0 200 0 0 0 8 96 1 5 7050 3 0 200 0 0 1 0 90 1 5 6775 3 0 200 0 1 1 2 94 1 5 6600 3 6 200 0 1 68 68 69 69 25 97 29 31 1 5 99 1 5 6150 3 6 200 0 1 2 0 99 1 5 5400 3 6 200 0 1 2 5 99 1 8 4300 4 0 200 0 2 3 0 99 1 8 3650 4 0 200 0 3 4 0 101 2 0 2800 4 6 200 0 4 6 0 103 2 5 1750 5
80. 5 Dally startz p E EN IN 75 Controls and indicators eec ise dita bai iic c na a a tibus t sn den chc ta n I 76 Fower s pply oae retener eerta eni zune lem iini ertet 77 Crac 77 S igit display functions 78 c ttingi process oed M 79 Handheld Cutting 80 SPECIICATIONS 80 Consumable selection and gas settings 80 StartIng 8 M 80 81 E ER 82 Specificatioris ttc edente tee n e edi d ee eee E ed t Pede cde 82 Qouging safety urus 82 a0uge a WOIkplece 82 e ere legea a aa a 83 SUPA IE OU IIS saus asua aaa aa aaa saiwa 83 SIdesgo giig MM EE 84 Gouge profiles and metal removal rates I I I I U Q a 85 Varying the gouge profile uu 86 parameters dn ie 86 Meclianized cornsuma
81. 50 Diagnostic mode is active the system will perform the function for the mode that is selected a Test gas the plasma and shield gases flow at a set value b Revision the display will show the software revision MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance c Plasma leak check the plasma channel will be pressurized then the pressure trapped The display on the power supply control panel will show actual pressures The system will remain in this state until commanded to another test The pressure in the plasma channel is expected to remain within 2 psi for a period of 5 minutes The shield gas channel is expected to drop to near O psi d Test gas full pressure plasma and shield gases flow at full pressure Low pressure errors will be typical in this mode as the system is attempting to achieve the maximum flow possible e Torch ID the display on the power supply control panel will show the torch ID f In line valve test the plasma channel will briefly pressurize then the system will close the Burkert valve in the power supply and open the in line torch valve The plasma pressure is expected to drop to near psi less than 5 psi in less than seconds 5 plasma start signal is received and there are no temperature errors the system will advance to state 4 Preflow Preflow status 04 1 System will turn on plasma and shield gases 2 System will verify gas pressures are above the minimum an
82. 59 024765 024660 024766 180 Length Part number Length 3 m 10 ft 024738 25 m 82 ft 4 5 m 15 ft 024450 35 m 115 ft 75 m 25 ft 024159 45 m 150 ft 10 m 35 ft 024333 60 m 200 ft 15 m 50 ft 024762 75 m 250 ft 20 m 65 ft Length Part number Length 3 m 10 ft 024739 25 m 82 ft 4 5 m 15 ft 024451 35 m 115 ft 75 m 25 ft 024120 45 m 150 ft 10 m 35 ft 024124 60 m 200 ft 15 m 50 ft 024764 75 m 250 ft 20 m 65 ft Length Part number Length 8 m 10 ft 024740 25 m 82 ft 4 5 m 15 ft 024744 85 m 115 ft 7 5 m 25 ft 024678 45 m 150 ft 10 m 35 ft 024680 60 m 200 ft 15 m 50 ft 024767 75 m 250 ft 20 m 65 ft MAXPRO200 Instruction Manual 807700 Revision 1 Recommended spare parts Parts List Part number Description Quantity 003233 Contactor 200 208V 220V and 240V power supplies 1 003249 Contactor 380V 400V 415V 440V 480V and 600V power supplies 1 011093 Air filter element 1 027005 Coolant filter element 1 027055 Silicone lubricant 1 4 ounce tube 1 027079 Fan 450 550 cfm 120 VAC 50 60 Hz 1 028872 Coolant solution 70 30 PG 1 gallon 4 127091 Heat exchanger fan 1 141171 Control Board 1 220921 Quick disconnect torch main body 1 220942 Torch Mounting sleeve 1 3 4 inch 1 220943 Torch Mounting sleeve 2 inch 1 420033 Quick disconnect torch receptacle 1 4
83. 6 200 0 8 5 8 159 0 14 40 Edge start 3 4 165 0 15 25 with IHS tab without IHS tab 110 0200 Instruction Manual 807700 Revision 1 420045 Stainless steel Air Plasma Air Shield 220936 220935 200 A Cutting 420044 Operation Flow rates Ipm scfh Air Plasma Air Shield 32 68 123 260 220488 yy 220937 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow 1 Teen 22 Pierce Height Dr 7 6 15 3 229 30 5 76m 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm min mm Factor Seconds 4 0 148 2 7 5695 5 4 200 0 4 6 0 150 3 0 3105 6 0 200 0 4 10 0 150 3 2 2485 6 4 200 0 5 12 0 152 3 2 2245 6 4 200 0 8 52 54 55 56 48 50 54 58 15 0 157 3 8 1700 7 6 200 0 8 20 0 164 4 9 1155 9 8 200 1 0 25 0 168 5 6 670 11 8 210 1 6 32 0 174 5 6 515 38 0 180 5 6 310 Edge start 50 0 188 5 6 203 English Plasma Cutflow Shield Cutflow e Voas odi a
84. 6 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List 65 degree hand torch Part Number Description Quantity 1 420107 65 degree hand torch assembly 1 228976 65 degree hand torch assembly with 7 5 m 25 feet lead 1 228977 65 degree hand torch assembly with 15 m 50 feet lead 1 228978 65 degree hand torch assembly with 23 m 75 feet lead 1 228979 65 degree hand torch assembly with 30 m 100 feet lead 1 2 228986 Handle replacement kit 1 001906 65 degree torch handle left and right sides 1 002244 Safety trigger 1 027254 Safety trigger spring 1 075841 Pan head screws 6 210184 Hand torch label 1 210209 Hypertherm IEC label 1 3 420109 Torch main body 1 4 044026 O ring 1 239 inch x 0 070 inch 2 MAXPRO200 Instruction Manual 807700 Revision 1 177 Parts List Consumable parts kits Mechanized torch consumable kit 428013 Part number Description Quantity 020415 Electrode 200A and 130A 2 027055 Silicone lubricant 1 4 ounce tube 1 044026 O ring 1 239 x 0 070 2 104119 Consumable tool 1 220487 Electrode 130 A Oo Air 4 220488 Swirl ring 130 A Oo Air and 200 A Air 2 220491 Shield 130 A Oo 1 220521 Water tube 1 220528 Electrode 50 A Oo Air 4 220529 Swirl ring 50 A Oo Air and 130A or 200A 1 220532 Shield 50A Oo Air 1 220536 Shield 130A Air No 1 220831 Nozzle 200A 2 220832 Shield 200A 1 220834 Swirl ring 200A 1 220890 Nozzle 50A Air 2 220891 Nozzle 50A
85. AWG 21 2 mm 4 AWG 480 VAC 3 45 amps 70 amps 21 2 mm 4 AWG 13 3 mm 6 AWG 600 VAC 3 36 amps 50 amps 13 3 mm 6 AWG 8 3 mm 8 AWG Note Wire AWG recommendations came from Table 310 16 of the National Electric Code Handbook USA 60 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Line disconnect switch The line disconnect switch serves as the supply voltage disconnecting isolating device Install this switch near the power supply for easy access by the operator Installation must be performed by a licensed electrician and according to applicable national and local codes The switch should Isolate the electrical equipment and disconnect all live conductors from the supply voltage when in the OFF position Have OFF and ON position clearly marked with OFF and I ON Have an external operating handle capable of being locked in the OFF position Contain a power operated mechanism that serves as an emergency stop Have slow blow fuses installed for the proper breaking capacity see table on previous page Main power cable Wire sizes vary based on the temperature rating of the cable insulation and the distance of the unit from the main box Use a 4 conductor Type SO input power cable with a conductor temperature rating of 60 C 140 or 90 C 194 Installation must be performed by a licensed electrician MAXPRO200 Instructio
86. B error code 402 is displayed c If there is current on both channels error code 400 is displayed 2 The main contactor is closed IGBTs are off a If there is current on channel A error code 406 is displayed b If there is current on channel B error code 407 is displayed c lf there is current on both channels error code 408 is displayed If the coolant flow is above the minimum level the system will do a high power test on the chopper Note the system is live at this time The system is applying power to the torch even though no arc will be present at the torch The system performs a chopper LEM Test The test checks for current between 10 60 amps Less than 5 amps is considered no current 3 The main contactor is closed IGBTs are on a If there is no current on channel A error code 409 is displayed b If there is no current on channel B error code 410 is displayed c If there is no current both channels error code 408 is displayed 4 The main contactor is closed IGBTs are on a If channel A current does not go to 0 error code 411 is displayed b If channel B current does not go to 0 error code 412 is displayed c the current on both channels does not go to 0 error code 413 is displayed 5 The main contactor is closed IGBTs are on a Channel A current detected on channel B input error code 415 is displayed b Channel B current detected on channel input error code 416 is displayed c Channel A current dete
87. C mark The China Compulsory Certification CCC mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China UkrSEPRO mark The CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine MAXPRO200 Instruction Manual 807700 Revision 1 19 Safety 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 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 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 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Oylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada NFPA Standard 51B Cutting and Welding Processes National Fire Protection Associati
88. DE IF DAMAGED cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accordance with applicable national and local codes Never use a oylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for 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 Instant on torches Plasma arc comes on immediately when the torch Switch is activated A PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc will cut quickly through gloves and skin Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others 14 0200 Instruction Manual 807700 Revision 1 Safety Z RAYS CAN BURN EYES AND SKIN Eye protection Plasma arc rays produce intense Cuffless trousers to prevent entry of sparks and slag visible and invisible ultraviolet and infrared rays that Remove any combustibles such as a butane lighter can burn eyes and skin or matches from your pockets before cutting Use eye protection in accordance with applicable national and local codes Cutting area Prepare the cutting area to r
89. E d 33 2 MAXPRO200 Instruction Manual 807700 Revision 1 Contents Gooling system d LE dtes 35 System gas requirements cette a 35 Power supply 36 MeGhan ized tren ess 37 Straight torch 14 28094 seas nie Societies Se ae acaba E RIS 37 Quick disconnect torch 428027 428028 I U a 38 TOC ES 39 90 4 420108 4 39 GD degree hand torch 2420107 uu tmt dins tern i ic ia tr d nna Dark aha td 40 Installation 41 16 112 uW a W A uW a 41 Claim vite wot iat E E E iw sitesi 41 Installation requirements 4 iir pr are Dan 41 INGISS 1SVEIS cet DERE 41 Placement Of SyStemCOMPONESNtS dtt te eee tei debe reca 42 Recommended grounding and shielding practices sesenta theta tentes intente testante 44 5 wawawa W p au A La u uu aa 44 Types OF grounding nne cec e SS Sata
90. Flow rates Ipm scfh Air Plasma Air Shield 12 25 103 218 220529 220528 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow we beds Eu Pierce Height Dir 7 6 15 3 229 30 5 76m 15 3 22 9 30 5 m Lead Lead Lead Cead ead Lead mm Volts mm mm min mm Factor Seconds 0 5 112 1 5 9400 3 0 200 0 0 0 8 111 1 5 8510 3 0 200 0 0 1 0 111 1 5 8050 3 0 200 0 1 1 2 110 1 8 7625 3 6 200 0 1 62 63 63 63 39 42 45 47 1 5 110 1 8 7370 3 6 200 0 1 2 0 110 1 8 6735 3 6 200 0 1 2 5 111 2 0 5080 4 0 200 0 2 3 0 111 2 0 3760 4 0 200 0 3 4 0 113 2 3 2415 4 6 200 0 4 6 0 118 2 5 1600 5 0 200 0 5 English Plasma Cutflow Shield Cutflow 5 2 Pierce Height Putin 25ft 75ft 100ft 25ft 75ft 100 ft Lead Lead Lead Lead Lead Lead Lead Lead Vale 0 018 112 0 06 375 10 12 200 0 0 0 024 112 0 06 350 10 12 200 0 0 0 030 111 0 06 340 10 12 200 0 0 0 036 111 0 06 325 0 12 200 0 1 0 048 110 0 07 300 10 14 200 0 1 62 63 63 63 39 42
91. Instruction Manual S gt 2 5 es e ER S Register your new Hypertherm system Register your product online www hypertherm com registration for easier technical and warranty support You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation For your records Serial number Purchase date Distributor Maintenance notes 200 Sensor Sensor PHC and Hypertherm are trademarks of Hypertherm Inc and may be registered in the United States and other countries 2013 Hypertherm Inc MAXPRO0200 Instruction Manual 807700 Revision 1 English March 2013 Hypertherm Inc Hanover NH 03755 USA Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service technical service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email 866 643 7711 Tel Return Materials Authorization 877 371 2876 Fax Return Materials Authorization return materials hypertherm com RMA email Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm 5 Pte 82 Gentin
92. Ji 501 S62 R2 HV XFRMR 1 y Y x e PILOT ARC V 2 R1 Le T T m J7 CIRCUIT ll E WORK pos 9 CA 1 le z 28 R 8 ve 59 5 e MAXPRO200 Instruction Manual 807700 Revision 1 153 Maintenance Phase loss detection 1 Turn OFF all power to the system and remove the cover from the contactor CON1 2 Inspect the condition of the 3 contacts for excessive wear If one or more of the contacts are worn excessively replace CON1 and restart the system OK Excessive wear 154 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Torch lead test 1 Turn OFF all power to the system 2 Locate the chopper board 3 Install a temporary jumper wire between J7 H9 NOZZLE and the work lead connection J9 H8 WORK on the chopper board
93. Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm min mm Factor Seconds 3 0 149 3 0 5350 6 0 200 0 1 4 0 147 3 0 4630 6 0 200 0 2 6 0 142 2 4 3865 7 2 300 0 3 10 0 152 4 1 2445 8 2 200 0 5 68 69 70 71 22 24 26 28 12 0 154 4 1 2045 8 2 200 0 5 15 0 155 4 4 1445 8 8 200 0 8 20 0 158 4 6 815 9 6 210 1 2 25 0 166 4 6 415 Edge start 32 0 178 5 1 250 English Plasma Cutflow Shield Cutflow 2 TA Hes reed Pierce Height Dis 25ft 5 75ft 100ft 25ft 5Oft 75ft 100 ft Lead Lead Lead Lead Lead Lead Lead Lead volts 0 135 149 0 12 220 024 200 0 1 3 16 145 0 12 160 0 24 200 0 2 1 4 141 0 10 150 10 28 300 0 3 3 8 151 0 16 100 0 32 200 0 5 68 69 70 71 29 24 26 28 1 2 154 0 16 75 0 32 200 0 5 5 8 155 0 18 50 1036 200 0 8 3 4 156 0 18 35 0 38 210 1 2 1 167 0 18 15 Edge start 1 1 4 178 0 20 10 with IHS tab without IHS tab 104 MAXPRO200 Instruction Manual 807700 Revision 1 Operation Mild steel Flow rates Ipm scfh Plasma Air Shield Plasma Air Shield 130A Cutting 20 42 86 183 yp 220491 220936 220935 220893 220488 220487 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc vo
94. Pierce Height Dolor 2bft 75ft 100ft 258 75ft 1008 Lead Lead Lead Lead Lead Lead Lead Lead Vols Seconda 3 16 149 0 11 240 10 22 200 0 4 1 4 150 0 12 210 10 24 200 0 4 3 8 150 0 13 170 10 25 200 0 5 1 2 153 0 13 120 0 25 200 0 8 5 8 159 0 16 85 0 32 200 0 8 52 54 55 56 48 50 54 58 3 4 163 0 19 60 0 38 200 1 0 7 8 166 0 21 50 0 42 200 1 4 1 168 0 22 40 0 45 210 1 6 1 1 4 174 0 22 20 1 1 2 180 0 22 12 Edge start 2 188 0 22 8 with IHS tab without IHS tab 0200 Instruction Manual 807700 Revision 1 111 Operation Stainless steel Flow rates Ipm scfh Plasma No Shield Plasma N Shield 200 A Cutting 37 79 107 225 65 420045 220936 220935 420044 220529 020415 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 7 6 15 3 22 9 30 5 m 76m 15 3m 22 9 30 5 m min Volt mm mm min mm Factor 90 Second Lead Lead
95. Revision 1 37 Specifications Quick disconnect torch 428027 or 428028 torch mounting sleeve for the quick disconnect torch is available with an outside diameter of 50 8 mm 2 0 inches or 44 45 mm 1 75 inches The minimum bend radius for the torch lead is 152 4 mm 6 0 inches 3 pe gt 435 33 mm 17 14 inches 279 40 mm 11 00 inches 76 98 mm 3 03 inches 78 95 mm 3 11 inches 12 70 mm 0 50 inches of Oo N 44 20 1 74 7 46 degrees 8 5715 9 25 9 44 20 mm 1 74 inches 38 0200 Instruction Manual 807700 Revision 1 Specifications Hand torches 90 degree hand torch 420108 The minimum bend radius for the torch lead is 152 4 mm 6 0 inches 0 91 kg 2 0 Ib gt 310 40 mm 12 22 inches 90 degrees 44 20 mm 1 74 inches 305 05 mm 12 01 inches A N 149 10 mm 5 87 inches MAXPRO200 Instruction Manual 807700 Revision 1 39 Specifications 65 degree hand torch 420107 The minimum bend radius for the torch lead is 152 4 mm 6 0 inches gt 290 58 mm 11 44 inches 65 degrees 44 20 mm 1 74 inches 285 24 mm 11 23 inches oy 238 51 mm 9 39 inches 40 MAXPRO200 Instruction Manual 807700 Revision 1 Installation
96. SDIO D3 SDIO CMD 3 3V JTAG MICRO SDIO CK USB MICRO SD spio po SDIO D1 IN START POWER SUPPLY CONTROL SDIO CD 8 141171 CNC HOLD sd MOTION CNC INTERFACE USB VBUS 012 USB DM ERROR 014 USB OTG ERROR USB GND JTMS SWDIO HIER SEE PAGE 9 FOR CONNECTION TO SENSOR PHC FOR CONNECTIONS TO A CNC PLEASE REFERANCE THEIR MANUAL CNC HOLD OUT CNC HOLD OUT D15 OnNouhWOND Ty MANUAL SHEET TORCH 4 START CNC START IN START IN START 24 poses s RS422 RX INTERFACE TORCHIDO RS422 TORCHIDi D2 RS422 Rns42 GND TORCHID2 TORCHIDS 04 016 CAN RX RS422 RX 017 CAN TX 1 2 3 4 5 6 7 8 9 OMANOaRWN CAN 24V SHEET VALVE 3 B1 FILTER ELEC SCH MAXPRO200 POWER SUPPLY 013384 MECHANIZED TORCH PIN 1 SHORTED TO PIN 2 MANUAL TORCH START SWITCH ACROSS PIN 1 AND PIN 3 SHEET 4 OF 9 IN START IN START START 191 WIRED FOR 480V 60HZ WIRED FOR 240V 60HZ WIRED FOR 200V 50 60HZ L1 1213 PE L1 1213 PE L1 L2 L3 INPUT POWER offs INPUT POWER 4 INPUT POWER FROM FACILITY FROM FACILITY P FAC WIRED FOR 400V 50 60HZ WIRED FOR 415V 50 60HZ PEL1 L2 L3 1 12 13 INPUT POWER INPUT POWER FROM FACILITY eire FROM FACILITY ELEC SCH MAXPRO2
97. The coolant cools the chopper torch lead and torch The cooling system also contains flow and temperature sensors that verify the cooling system is working properly System gas requirements Gas quality and pressure requirements Gases Quality Pressure 10 Flow rate O oxygen 99 5 pure liquid gas recommended 621 kPa 6 2 bar 90 psi 3400 120 scfh Clean dry and oil free N nitrogen 99 9 pure liquid gas recommended 621 kPa 6 2 bar 90 psi 11330 I h 400 scfh Clean dry and oil free Air Clean dry and oil free ISO 8573 1 class 1 4 2 621 kPa 6 2 bar 90 psi 11330 400 scfh Gases by process Mild steel Stainless steel Aluminum Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas HJ HJ HJ 1 1 1 I I I 1 I I I 1 1 1 1 1 1 t 4 t 2 4 4 t 2 4 4 t 2 7 N 7 N 7 1 1 1 1 1 1 1 Y Y Y Y Y Y Y Y Y Cutting 50 A Air or Air Air Air Air Air Cutting 130 A Air or Air Air Air Air Air Cutting 130 A No No No No Cutting 200 A Air or Air Air Air Air Air MAXPRO200 Instruction Manual 807700 Revision 1 35 Specifications Power supply Maximum Open Circuit Voltage 00 360 VDC Maximum output current 15 200 Amps Output voltage 50 165 VDC Duty cycle rating X 1
98. Volts mm mm Factor Seconds 4 0 150 2 2 6215 4 4 200 0 5 6 0 156 3 0 5195 6 0 200 0 5 10 0 156 3 3 3930 6 6 200 0 5 12 0 159 3 7 3370 7 4 200 0 5 52 54 55 56 48 50 54 58 15 0 163 4 0 2625 8 0 200 0 8 20 0 169 4 9 1625 9 8 200 1 0 25 0 177 5 6 1050 11 4 210 1 4 32 0 187 5 6 515 11 4 210 1 7 38 0 195 5 6 310 Edge start English Plasma Cutflow Shield Cutflow 2 TA Hes reed Pierce Height Dies 25ft 5Oft 75ft 100ft 25ft 75ft 100 ft Lead Lead Lead Lead Lead Lead Lead Lead volts n pm in Factor Seconds 3 16 150 0 10 230 0 20 200 0 5 1 4 158 0 13 200 0 25 200 0 5 3 8 155 0 13 160 0 25 200 0 5 1 2 160 0 15 125 10 30 200 0 5 52 54 55 56 48 54 58 5 8 164 0 16 95 0 32 200 0 8 3 4 168 0 19 70 0 38 200 1 0 7 8 173 0 21 50 0 42 200 1 2 1 178 0 22 40 0 45 210 1 4 1 1 4 187 0 22 20 0 45 210 1 7 1 1 2 195 0 22 12 Edge start with IHS tab without IHS tab 116 MAXPRO200 Instruction Manual 807700 Revision 1 6 420045 Aluminum N Plasma Shield 200 A Cutting Operation Flow rates Ipm scfh Plasma Shield 37 79 107 225 220529 2 020415 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc
99. ad Lead Lead Lead Lead Lead Lead Lead Volts Lidl inc Factor Seconds 1 4 156 0 11 90 0 22 200 0 2 3 8 160 0 12 60 0 24 200 0 3 1 2 164 0 12 45 0 24 200 0 5 68 69 70 71 22 24 26 28 5 8 166 0 13 40 0 26 200 0 8 3 4 168 0 14 30 0 31 220 1 3 1 176 0 16 20 Edge start with IHS tab without IHS tab 114 0200 Instruction Manual 807700 Revision 1 Operation Aluminum Flow rates Ipm scfh Plasma No Shield Plasma N Shield 130A Cutting 32 68 104 218 yp 220536 220936 220935 220892 220529 020415 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 7 6 15 3m 229m 30 5 m 76m 15 3 22 9 30 5 m mn Volt mm Ent Lead Lead Lead Lead Lead Lead Lead Lead Is du iris 5 0 153 3 0 3140 6 1 200 0 2 6 0 154 3 0 2980 6 1 200 0 2 10 0 158 3 3 1830 6 6 200 0 3 68 69 70 71 36 39 42 44 12 0 160 3 3 1510 6 6 200
100. alian standard AS NZS 3760 When you test the insulation of plasma cutting equipment to AS NZS 3760 measure the insulation resistance according to Appendix B of the standard at 250 VDC with the power switch in the ON position to verify proper testing and to avoid the false failure of the leakage current test False failures are possible because the metal oxide varistors MOVs and electromagnetic compatibility EMC filters used to reduce emissions and protect the equipment from power surges may conduct up to 10 milliamperes leakage current to earth under normal conditions If you have any questions regarding the application or interpretation of any IEC standards described here you are required to consult with an appropriate legal or other advisor familiar with the International Electrotechnical standards and shall not rely on Hypertherm in any respect regarding the interpretation or application of such standards MAXPRO200 Instruction Manual 807700 Revision 1 Product Stewardship 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 higher level system A higher level system with hazardous moving parts may constitute industrial machinery or robotic equipment in which case the OEM or end use customer may be subject to additional regulations and standards than those re
101. all hoses to verify that they have no kinks or sharp bends which can restrict gas flow b Ifthe cutting table uses a power track system to support leads from the power supply to the gas console torch check the position of the leads in the power track to ensure the leads do not twist or kink causing a possible restriction Cable connections 17 All cables should be checked for chafing or unusual wear If the outside insulation has been cut or otherwise damaged replace the cable Ignition enclosure 18 Remove the panel from the ignition enclosure and use compressed air to blow out any accumulation of dust and particulates If moisture is present dry the inside of the enclosure with a cloth and try to identify the source of the moisture 19 Ensure that all wiring connections are secure Verify that the enclosure panel fits properly 20 Inspect the torch leads Ensure that they are fastened tightly to the outside of the ignition console System grounding 21 Verify that all components of the system are individually grounded to a driven earth ground as described in the Installation and Grounding sections of this manual a All metal enclosures such as the power supply ignition console and gas console should be connected individually to a ground point These connections should be made with 10 mm2 8 AWG wire USA or equivalent size wire 22 Check the work lead connection particularly where the work lead connects
102. allation shall take precedence over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices Liability cap In no event shall Hypertherm s liability if any 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 whether in court arbitration regulatory proceeding or otherwise 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 26 Insurance At all times you will have and maintain insurance in such quantities and types and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products Transfer of rights You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Within thirty 30 days before any such transfer occurs you agree to notify in writing Hypertherm which reserves the right of approval Should you fail timely to notify Hypertherm and seek its approval as set forth herein the Warranty set forth h
103. and the Council of the European Union authorized Directive 2002 96 EC or WEEE Waste Electrical and Electronic Equipment As required by the legislation any Hypertherm product covered by the directive and sold in the EU after August 13 2005 is marked with the WEEE symbol This directive encourages and sets specific criteria for the collection handling and recycling of EEE waste Consumer and business to business wastes are treated differently all Hypertherm products are considered business to business Disposal instructions for the CE versions of Powermax plasma systems can be found at www hypertherm com weee 31 Environmental Stewardship The URL is printed on the symbol only warning label for each of these CE version Powermax series units shipped since 2006 The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE The REACH regulation The REACH regulation 1907 2006 in force since June 1 2007 has an impact on chemicals available to the European market The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0 196 by weight of the Substances of Very High Concern SVHC Component manufacturers and other downstream users such as Hypertherm are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency ECHA regist
104. ant filter element 027005 1 Coolant solution 70 30 028872 4 1 5 years 900 arc hours Torch o ring 044026 2 Air filter element 011093 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 Main contactor 200V 240V 003233 Main contactor choose one 1 Main contactor 380V 600V 003249 Torch main body straight torch 420087 Torch main body quick disconnect torch 220921 2 years 1200 arc hours Torch main body choose y a 1 Torch main body 90 Hand torch 420070 Torch main body 65 Hand torch 420109 Air filter element 011093 1 Pump replacement kit 428043 1 System Torch leads dependant 1 MAXPRO200 Instruction Manual 807700 Revision 1 161 Maintenance Timeline Component Part number Quantity Coolant filter element 027005 1 Coolant solution 70 30 028872 4 2 5 years 1500 arc hours Torch o ring 044026 2 Air filter element 011093 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 Main contactor 200V 240V 003233 Main contactor choose one 1 Main contactor 380V 600V 003249 Torch main body straight torch 420087 Torch main body quick disconnect torch 220921 years 1800 arc hours Torch main body choose one y 9 1 Torch main body 90 Hand torch 420070 Torch main body 65 Hand torch 420109 Air filter ele
105. ap The high voltage high frequency signal is coupled to the pilot arc lead Torch The maximum production cutting capacity is the maximum thickness that can be cut with a 100 duty cycle The maximum production cutting capacity of the MAXPRO200 torch is 32 mm 1 1 4 inches for mild steel using the 200 amp O Air process 22 mm 7 8 inch for stainless steel and 19 mm 5 8 inch for aluminum using the 200 amp Air Air process Maximum pierce capacity is 32 mm 1 25 inches for mild steel 25 mm 1 inch for stainless steel and 32 mm 1 25 inch for aluminum The maximum severance capacity is the maximum thickness that can be severed without regard for speed and cut quality This thickness should only be cut occasionally and cannot be cut with a 10096 duty cycle The maximum severance capacity of the MAXPRO200 torch is 75 mm 3 inches for mild steel 63 mm 2 1 2 inches for stainless steel and 75 mm 3 inches for aluminum Gas system The gas system manages the pressure and timing of the gas supplied to the torch It consists of a regulator proportional valves pressure transducers and an inline valve located in the torch lead MAXPRO200 Instruction Manual 807700 Revision 1 33 Specifications MAXPRO200 Instruction Manual 807700 Revision 1 34 Specifications Cooling system The cooling system uses a liquid to air cooled heat exchanger and a pump to reduce the temperature of the coolant
106. ard and the power supply 5 Verify that the pilot arc wire on the torch lead is not damaged If it is damaged replace the lead If it is not damaged replace the torch head MAXPRO200 Instruction Manual 807700 Revision 1 155 Maintenance Preventive maintenance Introduction Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system Reduced parts life increases operating costs in two ways the operator must use more electrodes and nozzles to cut the same amount of metal and the work of cutting must stop more often to change consumables Proper maintenance often eliminates the problems that shorten the life of consumable parts Since labor and overhead can account for 80 of the cost of cutting improved productivity can reduce cutting costs dramatically Preventive maintenance protocol If inspection suggests that a component is worn and might require replacement and you would like confirmation of your decision please contact Hypertherm s Technical Service The power supply DANGER ELECTRIC SHOCK CAN KILL Turn off all electrical power before removing the power supply cover and set the line disconnect switch to OFF In the U S use a lock out and tag out procedure until the service or maintenance is complete In other countries follow appropriate local or national safety procedures 1 Turn OFF the power supply and remove all side panels Use compressed air to bl
107. bleS s i rac eit itt tienes a rr 86 held torch Consumables 2 iiie tmt tct netten tetti n deett ded te e rtr da a Perte darte Da Fo Ra PELA E na 86 Hand held cutting and gouging Consumable selection seen a 87 87 Stainless ste6 88 4 MAXPRO200 Instruction Manual 807700 Revision 1 Contents a eate e uei e eee tesi E 89 Install and inspect consumables 90 Install corisumables on Hd t 90 Inspect consultmables sns ren enr teen emer este aaa 91 Foei maintenanCe 92 Routine aene o n ni Dd a ad bo e T E Ba Rr P a i Pad eL dal ta a Rn d 92 Quick disconnect maintenance HR EA OER A te tente tenente ente 92 Maintenance KIb 54i edo RU nia EQ I EMI 92 Toreh uyu 93 Quick disconnecttorch s s u u asa Gate A Goth ttn 93 StraigHbterehsssocsustasc i sm Elec incl te niall EIL E 93 Replace the torch water tube rte tttm 94 COMMON cutting faults A
108. bles See Install and inspect consumables on page 90 94 0200 Instruction Manual 807700 Revision 1 Operation Common cutting faults Machine torch Torch pilot arc will initiate but will not transfer Causes can be Work cable connection on the cutting table is not making good contact Malfunction in the system See the Troubleshooting table on page 129 in the Maintenance section of this manual Torch to work distance is too high The workpiece is not totally penetrated and there is excessive sparking on top of the workpiece Causes can be Current is set too low check cut chart information Cut speed or cut height is too high check cut chart information Torch parts are worn or incorrect see Install and inspect consumables on page 90 Metal being cut is too thick Dross forms on the bottom of the cut Causes can be Cutting speed is not correct check cut chart information Arc current is set too low check cut chart information Torch parts are worn or incorrect see Install and inspect consumables on page 90 Cut angle is not square Causes can be Wrong direction of machine travel High quality side is on the right with respect to the forward motion of the torch Torch to work distance is not correct check cut chart information Cutting speed is not correct check cut chart information Arc current is not correct check cut chart information Damaged or worn con
109. blinking red dot appears in the bottom right corner of each display when the parameters have been changed from the default setting You can return to the default setting by pressing and releasing the knob until you return to the original selection Push and release the plasma gas knob to cycle through the plasma gas selections The pressure will automatically be set when you choose a gas Turning the knob increases or decreases the pressure A blinking red dot appears in the bottom right corner of each display when the parameters have been changed from the default setting You can return to the default setting by pressing and releasing the knob until you return to the original gas selection The shield gas pressure is set automatically when you choose a plasma gas Turning the knob increases or decreases the pressure A blinking red dot appears in the bottom right corner of each display when the parameters have been changed from the default setting You can return to the default setting by pressing and releasing the knob until you return to the original gas selection Note The example shown below is the 50 amp mild steel air air process See the cut chart for details 2 N 50 lt 2 MAXPRO200 Instruction Manual 807700 Revision 1 79 Operation CAUTION SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch sparks and hot metal will spray
110. cle or the straight torch main body to the torch leads and secure using the push to connect fittings Connect to torch lead MAXPR0200 Instruction Manual 807700 Revision 1 53 Installation Connect the torch to the quick disconnect receptacle Align the torch body to the quick disconnect receptacle and connect them by screwing completely together Apply a thin film of silicone lubricant to each o ring The o rings should look shiny but there should not be any excess or built up lubricant 2 5 certain that there is no space between the torch body and the o ring on the quick disconnect m X 54 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Torch mounting and alignment Mounting the torch 1 Torch sleeve Mounting bracket Quick disconnect receptacle 1 Install the torch with torch leads attached in the torch mounting bracket 2 Position the torch below the mounting bracket so that the bracket is around the lower portion of the torch sleeve but not touching the torch quick disconnect 3 Tighten the securing screws Note The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch Torch alignment To align the torch at right angles to the workpiece use a square as shown above MAXPRO200 Instruction Manual 807700 Revision 1 55 Installation
111. crap cutting etc 1 Verify that the correct consumable parts are installed and in good condition 2 Verify proper cutflow gas settings 3 Verify the pierce height setting 4 Verify pierce delay time 026 Lost transfer Last the transfer signal after transfer 5 Verify that the arc did not loose contact with the completed plate while cutting hole cutting scrap cutting etc 6 Inspect the work lead for damage or loose connections 7 Try connecting the work lead directly to the plate 1 Verify phase to phase voltage to power supply 2 Disconnect power to power supply remove cover on contactor and inspect contacts for excessive Phase imbalance to chopper after wear 927 Lost phase contactor engaged or while cutting 3 Inspect power cord contactor and input to chopper for loose connections 4 Perform phase loss test See Phase loss detection on page 154 MAXPRO200 Instruction Manual 807700 Revision 1 129 Maintenance Number Name Description Corrective action 032 Hold timeout Hold signal was active for longer than 60 seconds 1 Check the interface cable for damage The hold wires may be short circuiting inside 2 The CNC is maintaining this input it could be waiting for an IHS complete input from another torch 3 If the CNC interface cable is good and it is a 1 torch system change the control board 044 Low plasma gas pressure Plasma gas pressure is l
112. cted on channel B input and Channel B current detected on channel A input error code 414 is displayed 152 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance 6 The main contactor is closed IGBTs are on a Channel A current higher than expected error code 417 is displayed b Channel B current higher than expected error code 418 is displayed Current on both channels is higher than expected error code 419 is displayed If the chopper test is successful and there are no other severe errors the system will advance to state 3 Ready for start otherwise the system will go to state 14 Shutdown Using a meter to measure open circuit voltage OCV The is 360VDC with no load on the system and can only be measured when the contactor is closed The on the chopper bridges are 127 VAC on 1A 1B 1C amp 2A 2B 2C 1 15 best to use clip on test leads to keep your hands and the meter outside the power supply Connect the meter to 19 WORK and J7 NEGATIVE on the I O board 2 Turn ON the power to the system The automatic chopper test will begin when the purge cycle starts You will hear the main contactor close and O to 5 seconds later the meter should show 360 VDC This is the OCV for chopper channel A The voltage will start to decrease then spike back up to 360 VDC again The second reading represents the OCV for chopper channel B S e HV XFRMR 2 e e 33 U ee J2 e
113. cted to all equipment according to local and national codes 7 Fora system with a remote high frequency console RHF the positive negative and pilot arc leads should be bundled together for as long a distance as possible The torch lead work lead and the pilot arc nozzle leads may be run parallel to other wires or cables only if they are separated by at least 150 mm 6 inches If possible run power and signal cables in separate cable tracks 8 Fora system with an RHF console the ignition console should be mounted as closely as possible to the torch and must have a separate ground cable that connects directly to the cutting table ground bus bar 9 Each Hypertherm component as well as any other or motor drive cabinet or enclosure must have a separate ground cable to the common star ground on the table This includes the ignition console whether if it is bolted to the plasma system or to the cutting table 10 The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch It must be electrically insulated from any metal and from any contact with the floor or building The torch lead can be run in a plastic cable tray or track or covered with a plastic or leather sheath 11 The torch holder and the torch breakaway mechanism the part mounted to lifter not the part mounted to the torch must be connected to the stationary part of the lifter with copper braid at least 12 7
114. curit peut entrainer la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un f t ou un autre contenant ferm comme table de coupage 2 l arc plasma peut blesser et br ler loigner la buse de soi Il s allume instantan ment quand on l amorce 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 3 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 3 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger les oreilles contre le bruit Utiliser un masque de soudeur avec un filtre
115. d 190 Current Sensor B Fault A fault was detected on channel B of the chopper 1 Turn OFF the power to the system Check the wiring between the control board and the chopper for damaged wires and proper connections and then turn ON the power again so the automatic diagnostic checks will run 2 If the error changes to a 410 error replace the chopper assembly MAXPRO200 Instruction Manual 807700 Revision 1 133 Maintenance Number Description Corrective action 1 Verify that the red and black wires on chopper J2 8 The temperature reading was are plugged into the control board at J1 22 Temp sensor unplugged RUNS 300 Chopper unexpectedly low possibly indicating 2 Verify the cold plate temperature sensor wires are the sensor is unplugged plugged into the chopper at J2 9 10K ohm nominal 301 Temp sensor unplugged E Verify the electrical connection back the control Transformer p y 9 board at J1 12 pins 1 2 10K ohm nominal the sensor is unplugged 302 Temp sensor unplugged Vien pM x Verify the electrical connection back to the control Inductor 1 p A y 9 board at J1 12 pins 4 5 10K ohm nominal the sensor is unplugged 303 Temp sensor unplugged ee Verify the electrical connection back to the control Inductor 2 p de mp y 9 board at J1 12 pins 7 8 10K ohm nominal the sensor is unplugged 304 Temp sensor
116. d below the maximum values Low plasma pressure the system will generate error code 44 High plasma pressure the system will generate error code 45 Low shield pressure the system will generate error code 53 High shield pressure the system will generate error code 54 3 System will charge the surge injection circuit 4 System will check for an over current condition Chopper A over current the system will generate error code 134 Chopper over current the system will generate error code 138 5 After 1 second the system will advance to state 5 Preflow hold Preflow hold status 05 1 System will continue running the plasma and shield gas until the hold signal is removed 2 System will verify the gas pressures are within tolerance Low plasma pressure the system will generate error code 44 High plasma pressure the system will generate error code 45 Low shield pressure the system will generate error code 53 High shield pressure the system will generate error code 54 3 System will check for an over current condition Chopper A over current the system will generate error code 134 Chopper over current the system will generate error code 138 4 If the hold signal is active for more than 60 seconds the system will generate error code 32 5 When the hold signal is removed the system will advance to state 6 Ignite MAXPRO200 Instruction Manual 807700 Revision 1 123 Maintenance Ignite status 06 1
117. ders and hoses that contain methane or hydrogen or before letting it touch combustible materials mixtures Keep flames and sparks away from the torch Never cut containers with potentially flammable when using methane or argon hydrogen plasma materials inside they must be emptied and properly cleaned first WARNING Explosion Hazard Ventilate potentially flammable atmospheres before Underwater Cutting with Fuel Gases cutting When cutting with oxygen as the plasma gas an Do not cut aluminum underwater or with water exhaust ventilation system is required touching the underside of the aluminum Cutting aluminum underwater with the water Explosion prevention touching the underside of the aluminum can result in Do not use the plasma system if explosive dust or an explosive condition that can detonate during vapors may be present plasma cutting operations Do not cut pressurized cylinders pipes or any closed container WARNING Hydrogen Detonation with Do not cut containers that have held combustible Aluminum Cutting materials Do not cut under water with fuel gases containing hydrogen Cutting under water with fuel gases containing hydrogen can result in an explosive condition that can detonate during plasma cutting operations MAXPRO200 Instruction Manual 807700 Revision 1 11 Safety The plasma arc by itself is the heat source used for cutting Accordingly although the pla
118. dheld torches for cutting mild steel stainless steel and aluminum You can use the cutting parameters detailed under Cut charts on page 101 with the MAXPRO200 handheld torches as long as you use the following consumables for each process Note consumable part numbers listed above each cut chart are specific to mechanized torches Mild steel 50A hy Air Plasma V Q Jy Air Shield 420063 220528 Plasma W Air Shield 420063 220528 130A Air Plasma yp Air Shield 220487 130A Plasma Air Shield 220487 200A SS Air Plasma 695 77 Air Shield 420058 220937 200A a Plasma 4 65 y Air Shield 2 420059 22083 220937 200 A Gouging W Air Plasma 9 J GD Air Shield lt 420067 420066 220937 200 A Gouging 0 NNN Plasma J Air Shield 420067 220935 420066 220834 220937 MAXPRO200 Instruction Manual 807700 Revision 1 87 220528 220487 020415 220937 020415 220937 MAXPRO0200 Instruction Manual 807700 Revision 1 MAXPRO200 Instruction Manual 807700 Revisi evision Operation Install and inspect consumables Always disconnect power to the power supply before inspecting or changing torch consumable parts Use gloves when removing consumables The torch might be hot Install consumables Check the consumable parts daily for wear before cutting See nspect consumables on page 91 Before removing consumables bring the torch to the edge of the cuttin
119. digit display area Current selection knob 2 digit plasma display area Plasma gas knob OI GO N 2 digit shield display area Shield gas knob 76 0200 Instruction Manual 807700 Revision 1 Operation Power supply operation General system runs a number of tests automatically when the system is turned ON See Automatic chopper and current sensor tests during power up on page 152 There is power to the control board and other non high power components when the main disconnect Switch is on even if the switch on the Power Supply is off The switch is illuminated to indicate that there is power to the system Non high power components include the low power control circuitry in the chopper but not the high power IGBTs which are switched by the contactor 3 digit display counts from 1 to 6 to indicate the 6 second purge that occurs when you turn ON the power supply you will only actually see 1 thru 5 If the system is powered up with the start signal on the 3 digit display will continue to count up When you turn ON the power to the system the displays shows the last process used The user can lock out all inputs current plasma gas and shield gas to the system by pressing and holding both the amps and shield gas control knobs until LOC appears in the 3 digit display The same process unlocks the system and ULC appears in the 3 digit display The user can still c
120. e environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of reducing emissions Mains supply Cutting equipment must be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply 23 Electromagnetic Compatibility 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 cutting power source enclosure Maintenance of cutting equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation The cutting equipment should not be modified in any way except as set forth in and in accordance with the manufacturer s written instructions For examp
121. e design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of cutting or gouging Size air volume ventilation and filtration of the work area Personal protective equipment Number of welding and cutting systems in operation Other site processes that may produce fumes If the workplace must conform to national or local regulations only monitoring or testing done at the site can determine whether the site is above or below allowable levels To reduce the risk of exposure to fumes Remove all coatings and solvents from the metal before cutting Use local exhaust ventilation to remove fumes from the air Do not inhale fumes Wear an air supplied respirator when cutting any metal coated with containing or suspected to contain toxic elements Assure that those using welding or cutting equipment as well as air supplied respiration devices are qualified and trained in the proper use of such equipment Never cut containers with potentially toxic materials inside Empty and properly clean the container first Monitor or test the air quality at the site as needed Consult with a local expert to implement a site plan to ensure safe air quality 12 MAXPRO200 Instruction Manual 807700 Revision 1 Safety GROUNDING SAFETY Work cable Attach the work cable securely to the Input power workpiece or the wor
122. e left side of the power supply See figure on next page Also refer to the wiring diagram in Section 7 if required The voltage between any 2 of the 3 terminals should be equal to the supply voltage If there is a problem at this point disconnect main power and check all connections the power cable and fuses at the line disconnect switch Repair or replace any defective component MAXPRO200 Instruction Manual 807700 Revision 1 137 Maintenance Power measurement DANGER ELECTRIC SHOCK HAZARD There is line voltage at the contactor when the main disconnect switch is on Use extreme care when measuring primary power in these areas Voltages present at the terminal block and contactors can cause injury or death Check the lines in the following order L1toL2 L1toL3 L2toL3 Check each line to ground If one line is 1096 or higher than the other two put that leg on L1 138 MAXPRO0200 Instruction Manual 807700 Revision 1 Maintenance Power supply coolant system servicing Draining the coolant system 1 Turn OFF the power and remove the right side panel from the power supply 9 E E A 2 Locate the coolant drain valve and use a 20 liter 5 gallon container to catch the coolant Coolant will flow as Soon as the drain is opened Close the drain valve when the coolant stops flowing Always dispose of coolant according to local and national codes
123. ed below are slightly different push to connect fittings Slide the hose fitting over the connector and press until it clicks into place To disconnect a fitting pull the connector collar toward the hose and pull the hose away from the fitting 5 Connect the pilot arc shield gas hose blue ho Q O 9 0 e 2 ti lt gt 6 Connect the negative lead coolant supply hose blue with green tape 5 0 v e P tes MAXPRO200 Instruction Manual 807700 Revision 1 51 Installation Work lead connections Part number Length 223335 7 5 m 25 ft 223336 15 m 50 ft 223337 23 m 75 feet 223338 30 m 100 feet Remove the first nut and washer from the work lead terminal and use it to secure the work lead to the terminal OQ B 9 w Lower frame of work table typical 52 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Torch connections Note The connections between the straight torch main body and the torch leads are identical to the connections between the quick disconnect receptacle and the torch leads Align the quick disconnect recepta
124. edicted No Effect Concentration References Risk phrases and safety phrases None Preparation is not classified as hazardous in the sense of directive 1999 45 EC and 2006 121 EC Hazard statement s and precautionary None Preparation is not classified as hazardous in the sense of directive 1999 45 statement s EC and 2006 121 EC Training advice None 202 MAXPRO200 Instruction Manual 807700 Revision 1 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture Additional information USA National Fire Protection Association NFPA Rating Flammability 1 Health O Instability Reactivity 0 Information contained in this publication or as otherwise supplied to Users is believed to be accurate and is given in good faith but it is for the Users to satisfy themselves of the suitability of the product for their own particular purpose Hypertherm gives no warranty as to the fitness of the product for any particular purpose and any implied warranty or condition statutory or otherwise is excluded except to the extent that exclusion is prevented by law Hypertherm accepts no liability for loss or damage other than that arising from death or personal injury caused by defective product if proved resulting from reliance on this information Freedom under Patents Copyright and Designs cannot be assumed Note The original safety data sheet was authored in English Freezing Point of Propylene Glycol Solution C F 4 4
125. educe Wear eye protection safety glasses or goggles with reflection and transmission of ultraviolet light side shields and a welding helmet with appropriate lens shading to protect your eyes from the arc s Paint walls and other surfaces with dark colors to ultraviolet and infrared rays reduce reflection Use protective screens or barriers to protect others Skin protection Wear protective clothing to protect from flash and glare against burns caused by ultraviolet light sparks and hot warn others not to watch the arc Use placards or metal signs Gauntlet gloves safety shoes and hat Flame retardant clothing to cover all exposed areas Minimum Suggested shade Arc current protective shade number for OSHA 29CFR Europe amps number comfort 1910 133 a 5 EN168 2002 ANSI Z49 1 2005 ANSI Z49 1 2005 Less than 40 A 5 5 8 9 41 to 60 A 6 6 8 9 61 to 80A 8 8 8 9 81 to 125 8 9 8 9 126 to 150A 8 9 8 10 151 to 175 A 8 9 8 11 176 to 250A 8 9 8 12 251 to 300 8 9 8 13 301 to 400A 9 12 9 13 401 to 800A 10 14 10 N A MAXPRO200 Instruction Manual 807700 Revision 1 15 Safety N Pacemaker and hearing aid operation can be affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations PACEMAKER AND HEARING AID OPERATION To red
126. en established NOTE It is normal to see an 050 error when cutting with the hand torch if the start signal is removed before the pilot arc time 5 seconds has expired 051 Pilot Arc Over temp Maximum pilot arc duration exceeded 1 Allow the power supply to idle with the fans running for 10 seconds 2 Verify that the pierce height is correct 3 Minimize pilot arcing off the plate 053 Low shield gas pressure Shield gas pressure is less than 2596 of the set desired value 1 Verify gas supply pressure and that sufficient gas remains in your supply 2 Perform the Flow gas at set pressure test 001 and verify the gas settings on the front panel with the parameters in the cut charts See Control board on page 144 3 See Setting the supply gas regulators on page 71 130 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Number Description Corrective action 1 Check for a restriction or dross on the shield cap 2 Perform the Flow gas at set pressure test 001 and verify the gas settings on the front panel with the parameters in the cut charts See Control board on page 144 3 Verify that the pressure transducers are providing the system with the proper pressures Shield gas pressure is 25 greater 997 High shield gas pressure than the set desired value 1 Verify that the correct consumables are properly Coolant flow is less than the required in
127. er gt Description Quantity 1 015669 Male connector 3 8 inch NPT x 1 2 inch 7 2 428034 Gas manifold replacement kit 1 3 428042 Pressure transducer replacement kit 2 4 428037 Flow meter replacement kit 1 5 109636 EMI filter 250 VAC 1 amp 1 phase 2 6 229474 Thermistor 3 8 inch diameter copper pipe clip with connector 1 7 015663 Male connector 1 4 inch NPT x 1 2 inch tube 1 8 006075 Check valve 1 9 015664 Male elbow 1 4 inch NPT x 1 2 inch push in tube 1 10 229482 Heat exchanger with fan 1 127091 Heat exchanger fan only 1 MAXPRO200 Instruction Manual 807700 Revision 1 169 Parts List Power supply 4 SS Number Description Quantity 1 209177 EMI filter 400V and 415V power supplies 2 008301 Fuse holder 1 108571 Fuse holder cover 1 110513 Fuse label F1 F2 1 008551 Fuse 7 5 amp 600 volt 380V 400V 415V 440V 480V and 600V power supplies 2 008709 Fuse 20 amp 500 volt 200 208V 220V and 240V power supplies 2 3 027567 Fan guard 1 4 014373 Inductor 2 5 074212 Cable holder self sticking for 1 2 inch diameter cable 5 6 074356 Cable holder for 1 0 inch diameter cable 5 7 108671 Terminal block 14 AWG 2 0 1 8 003249 Contactor 380V 400V 415V 440V 480V and 600V power supplies 1 003233 Contactor 200 208V 220V and 240V power supplies 1 170 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Power supply
128. erein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise MAXPRO200 Instruction Manual 807700 Revision 1 Introduction Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements National and local safety regulations National and Local safety regulations shall take precedence over any instructions provided with the product The product shall be imported installed operated and disposed of in accordance with national and local regulations applicable to the installed site Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or near the data plate Each certification test mark means that the product and its safety critical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory Hypertherm places a certification test mark on its products only after that product is manufactured with safety critical components that have been authorized by the accredited testing laboratory Once the product has left the Hypertherm factory the certification test marks are invalidated if any of the following occurs product is modified in a manner that creates hazard or non conformance with the applicable standards
129. eriod of two 2 years from the date of its delivery to you with the exception of Powermax brand power supplies which shall be within a period of three 3 years from the date of delivery to you and ii with respect to the torch and leads within a period of one 1 year from its date of delivery to you and with respect to torch lifter assemblies within a period of one 1 year from its date of delivery to you and with respect to Automation products one 1 year from its date of delivery to you with the exception of the EDGE Pro CNC and ArcGlide THC which shall be within a period of two 2 years from the date of delivery to you and iii with respect to Hylntensity fiber laser components within a period of two 2 years from the date of its delivery to you with the exception of laser heads and beam delivery cables which shall be within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any product which has been incorrectly installed modified or otherwise damaged MAXPRO200 Instruction Manual 807700 Revision 1 Warranty Hypertherm provides repair replacement or adjustment of the Product as the sole and exclusive remedy
130. ervice personnel performing the troubleshooting testing are high level electronic service technicians who have worked with high voltage electro mechanical systems Knowledge of final isolation troubleshooting techniques is also assumed In addition to being technically qualified maintenance personnel must perform all testing with safety in mind Refer to the Safety section for operating precautions and warning formats CAUTION Use extreme care when working near the chopper modules Each large electrolytic capacitor blue cased cylinder stores large amounts of electrical energy Even if the power is off dangerous voltages may remain at the capacitor terminals on the chopper and the diode heatsinks Never discharge any capacitor with a screwdriver or other implement explosion property damage and or personal injury will result Preventive maintenance For a complete list of preventive maintenance recommendations see the Preventive Maintenance Master Schedule on page 159 Contact the Technical Services department listed at the front of this manual with any questions regarding the maintenance schedule or procedures MAXPRO200 Instruction Manual 807700 Revision 1 119 Maintenance Power supply status The status state of the power supply is shown in the three digit display To view the power supply status navigate to the fault icon and press and hold the current selection knob until the status code appears Status code
131. ess than 2596 3 of the set desired value 1 Inspect gas supply pressure and volume of gas remaining in supply tanks 2 Verify the gas settings on the front panel with the parameters in the cut charts See Setting the supply gas regulators on page 71 4 Perform the Flow gas at set pressure test 001 and verify the gas settings on the front panel with the parameters in the cut charts See Contro board on page 144 045 High plasma gas pressure Plasma gas pressure is greater than 25 of the set desired value 1 Verify gas supply pressure settings 2 Perform the Flow gas at set pressure test 001 and verify the gas settings on the front panel with the parameters in the cut charts See Contro board on page 144 See Setting the supply gas regulators on page 71 4 The In line valve may not be opening Perform the Plasma leak check 003 and the in line valve check 006 See Control board on page 144 050 Start lost Start signal was received and then lost before an arc was established 1 mechanical relay is being used to provide the system with a start signal this relay is either bouncing when activated or the contacts are faulty Replace the relay 2 Inspect the interface cable for damage faulty crimps or poor electrical connections 3 If the interface cable is good and a relay is not driving the start input the CNC is dropping the start signal before a steady state arc has be
132. etc Other None Occupational Exposure Limits LTEL LTEL STEL STEL Substance 8 hr TWA ppm 8hrTWAmg m3 ppm mg m3 mote Propylene Glycol 57 55 6 ne 10 ne ne AIHA WEEL in the USA Benzotriazole 95 14 7 ne ne ne ne None MAXPRO200 Instruction Manual 807700 Revision 1 199 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture 9 Physical and chemical properties Information on basic physical and chemical properties Appearance Liquid Vapor pressure mm Hg Not available Color Pinkish Reddish Vapor density Air 1 Not available Odor Slight Density g ml 1 0 0 1 g ml Odor threshold ppm Not available Solubility water Soluble pH Value 5 5 7 0 Concentrated Solubility other Not established Melting point freezing 0 C 32 F Partition coefficient n octanol Not available point water Boiling point boiling range 100 C gt 212 F Auto ignition temperature C available Flash point gt 95 gt 203 F Decomposition temperature Not available C Evaporation rate Not available Viscosity mPa s Not available Flammability solid gas Non flammable Explosive properties Not explosive Explosive limit ranges Not available Oxidizing properties Not oxidizing Other information None 10 Stability and reactivity Reactivity None Chemical stability Stable under normal conditions Possibility of hazardous reactions None
133. expected The cause can be Moisture in the gas supply Incorrect gas pressure Consumables incorrectly installed Optimizing cut quality The following tips and procedures will help produce square straight smooth and dross free cuts Tips for table and torch Usea square to align the torch at right angles to the workpiece The torch may travel more smoothly if you clean check and tune motion on the rails and drive system of the cutting table Unsteady machine motion can cause a regular wavy pattern on the cut surface torch must not touch the workpiece during cutting Contact can damage the shield and nozzle and affect the cut surface Plasma setup tips Follow carefully each step in the Daily Start up procedure described earlier in this section Purge the gas lines before cutting Maximize the life of consumable parts Hypertherm s LongLife process automatically increases the gas and current flow at the start of each cut and decreases them at the end to minimize erosion of the electrode s center surface The LongLife process also requires that cuts start and stop on the workpiece torch should never fire into the air Starting the cut at the edge of the workpiece is acceptable as long as the arc is not fired in the air To start with a pierce use a pierce height that is 1 5 to 2 times the cut height Refer to the cut chart for your process for more information Each cut s
134. fr 5V 24V 041 120V FUSED AC INPUT 042 240V INPUT DETECTED D44 120V INPUT DETECTED 070 PUMP MOTOR ENABLE D35 35 CHOPPER A OVER CURRENT 01004 CHOPPER B OVER CURRENT 1 22 11 22 415VAC 2 b 051 4 CONTACTOR ENABLE 046 kh HIGH FREQ ENABLE MAGNETICS FANS AC RTN 120VAC FUSED 240VAC RELAY 240VAC SWITCH OUT INDUCTOR 1 SHEET TEMP 2 C2 INDUCTOR 2 SHEET TEMP 2 B2 190 TRANSFORMER TEMPERATURE INDUCTOR 1 TEMPERATURE INDUCTOR 2 TEMPERTURE oo 00 2 0otN LASMA PRESSURE J1 13 J13 RED BLK YLW CHOPPER CURENT A SHEILD 3 PRESSURE 7 LL O N CHOPPER CURENT A CHOPPER CURENT B CHOPPER TEMP BUS CHOPPER CURENT B CHOPPER TEMP COOLANT TEMPERATURE PILOT ARC TEMP COOLANT TEMP WORK LEAD CURRENT CLT 15V COOLANT FLOW pes WL 15V 24 0104 PLASMA VALVE PWM 0105 4g SHIELD VALVE PWM 24V 1 2 3 4 5 6 7 8 9 P 5V D106 46 TORCH VALVE ENABLE 0101 CHOPPER PWM D102 CHOPPER PWM 0103 PILOT ARC ENABLE WORK LEAD CURRENT 065 TCHVLV TCHVLV RED BLK RED BLK RED BLK RED ENABLE TRANSFORMER FAN 1 WHT J17 XCHANGERL 4 BLK COS CAN SHEET GAS CONSOLE 9 C1 PLASMA INTRFC ELEC SCH MAXPRO200 POWER SUPPLY 013384 SHEET 3 OF 9 12345678 9 1011121314151617181920 1234 56 7 8 910 SDIO D2
135. fy that the LED for PWM is not active Current sensor B current 9 PP 2 Verify that there is DC output on the I O board 405 detected on channel and on channel 1 with contactor on and B WHEE neeuentuas from the Torch to Work connections If DC output PWM off P is found replace the chopper Current sensor current During the chopper test current was T Verify thatthe LED Tor PWM isnot active 2 Verify that there is no DC output the I O board 406 with contactor on and detected on channel A when no 1 from the Torch to Work connections If DC output PWM off current was expected is found replace the chopper Current sensor B current During the chopper test current was Verify thatthe 2 Verify that there is no DC output on the I O board 407 with contactor on and detected on channel B when no from the Torch to Work connections If DC output PWM off current was expected is found replace the chopper 134 0200 Instruction Manual 807700 Revision 1 Maintenance expected on Current sensor A on channel B Number Description Corrective action 1 Verify the output voltage from the contactor 2 Verify the DC voltage on both bridges of the Chopper 3 Verify the DC output on the I O board each current on Current 408 Hear and Current No current detected on channel A and chopper test ST m channel B when current was e
136. g Lane Media Centre Annexe Block A01 01 Singapore 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 86 21 60740393 Fax 07 18 12 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 Technical Service 00 800 4973 7843 Tel Technical Service Hypertherm Japan Ltd Level 9 Edobori Center Building 2 1 1 Edobori Nishi ku Osaka 550 0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax Hypertherm Brasil Lida Rua Bras Cubas 231 Jardim Maia Guarulhos SP Brasil CEP 07115 030 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm M xico S A de Avenida Toluca No 444 Anexo 1 Colonia Olivar de los Padres Delegaci n lvaro Obreg n M xico D F C P 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax Hypertherm Korea Branch 3904 Centum Leaders Mark B D 1514 Woo dong Haeundae gu Busan Korea 612 889 82 51 747 0358 Tel 82 51 701 0358 Fax Contents Safe y Cape FERRE 9 Recognize safety information rette tta tnt Rc seas a n RR Ha a Rc seine ra ed nn t a n Ra nenne 9 Follow Safety INStHUCH E
137. g table with the torch lifter raised to its highest point to prevent the consumables from dropping into the water of the water table Do not overtighten parts Only tighten until mating parts are seated Apply a thin film of silicone lubricant on each o ring The o ring Wipe the internal and external surfaces of the should look shiny but there should not be any excess or built up torch with a clean cloth or paper towel lubricant 1 Install the 2 Install the swirl 3 Install the 4 Install the electrode into ring into the nozzle and swirl nozzle retaining shield onto the the torch head nozzle ring into the cap onto the nozzle retaining nozzle retaining torch head cap cap 90 MAXPRO200 Instruction Manual 807700 Revision 1 Inspect consumables Operation Inspect Look for Action Shield General Erosion or missing material Molten material attached Blocked gas holes Center hole Must be round Replace the shield Replace the shield Replace the shield Replace the shield when the center hole is no longer round General Erosion or missing material Cracks Burn marks Replace the nozzle retaining cap Replace the nozzle retaining cap Replace the nozzle retaining cap Nozzle Always replace the nozzle and the electrode as a set General Erosion or missing material Blocked gas holes Center hole Must be round Signs of arcing Replace the nozzle Replace the nozzle Replace the nozz
138. he current of the power supply will increase width and increase depth Decreasing the current of the power supply will decrease width and decrease depth Cutting parameters The cut charts for the MAXPRO200 show the consumable parts cutting speeds and the gas and torch settings required for each process allowing for differences in the lead length These parameters are used for cutting with both mechanized and handheld torches the consumable part numbers listed with each cut chart are specific to mechanized torches Refer to Hand held torch consumables below for the consumables to use with handheld torches The cut chart values in this document are recommended to provide high quality cuts with minimal dross Because of differences between installations and material composition adjustments may be required to obtain desired results Mechanized consumables The consumable part numbers listed above each cut chart are specific to mechanized torches Hand held torch consumables The following sets of consumables are intended to be used with handheld torches for cutting mild steel stainless steel and aluminum Use the cutting parameters detailed in the Cut charts for cutting with the MAXPRO200 handheld torches Use the following consumables for each process 86 0200 Instruction Manual 807700 Revision 1 Operation Hand held cutting and gouging consumable selection The following sets of consumables are intended to be used with han
139. hould end with the arc still attached to the workpiece to avoid arc blow outs ramp down errors When cutting small parts that drop down after being cut from the workpiece check that the arc remains attached to the edge of the workpiece for proper ramp down If arc blow outs occur try one or more of the following Reduce the cutting speed during the final part of the cut Stop the arc before the part is completely cut to allow completion of the cut during the ramp down Program the path of the torch into the scrap area for ramp down 96 0200 Instruction Manual 807700 Revision 1 Operation Notes Program the path of the torch directly from one cut part into the next without stopping and starting the arc However do not allow the path to lead off the workpiece and back on may be difficult to achieve the full benefits of the LongLife process in some conditions Additional factors of cut quality Cut angle A cut part whose 4 sides average less than 4 of cut angle is considered acceptable The squarest cut angle will be on the right side with respect to the forward motion of the torch determine whether a cut angle problem is being caused by the plasma system or the drive system a Makeatest cut and measure the angle of each side b Rotate the torch 90 in its holder and repeat the process c angles are the same in both tests the problem is in the drive system Jfacut angle problem
140. ide A cotton swab be used to access hard to reach internal surfaces 2 Use compressed air to blow away any remaining dirt and debris from internal and external surfaces Apply a thin film of silicone lubricant on each external o ring The o rings should look shiny but there should not be any excess or built up lubricant 4 lf consumables will be reused use a clean cloth to wipe them off and use compressed air to blow them off before they are installed again This is especially critical for the nozzle retaining cap Quick disconnect maintenance The following steps should be completed every 5 10 times consumables are changed 1 Remove the torch from the quick disconnect assembly 2 Use compressed air to blow off all internal surfaces and the external threads 3 Use compressed air to blow off all internal surfaces at the rear of the torch 4 Inspect each of the 4 o rings at the rear of the torch and the on the quick disconnect receptacle for damage Replace any damaged o rings If they are not damaged apply a thin film of silicone lubricant on each o ring The o rings should look shiny but there should not be any excess or built up lubricant Rear view of torch External threads Maintenance kit Even with proper care the o rings at the rear of the torch will need to be replaced periodically Hypertherm provides a quick disconnect torch maintenance kit 228780 with
141. if and only if the warranty set forth herein properly is invoked and applies Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall be returned with Hypertherm s prior authorization which shall not be unreasonably 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 pre paid by the customer Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph and with Hypertherm s prior written consent The warranty set forth above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty Distributors OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm 25 Warranty Patent indemnity Except only in cases of products not manufactu
142. ignition ON HF circuit active D2 Torch ID 1 D51 Contactor output ON contacts closed D3 Torch ID 2 D61 Torch valve driver error ON error 04 Torch ID 3 D62 Torch valve driver OK ON 24V power is OK D6 CNC start signal ON active D64 Not used D9 Hold input ON active 065 3 5A more detected on the D12 Motion output D68 Coolant flow input pulses from flow sensor D14 Error output D70 Pump enable ON pump motor active D15 Hold output D71 Serial communications TX D16 CAN RX D96 USB BUS voltage error flag D17 CAN TX D100 Over current on chopper B ON overcurrent D26 15 15V voltage indicator D101 Chopper A PWM D31 Fused side of 240VAC input power D102 Chopper B PWM 033 3 3V voltage indicator D103 Pilot arc enable D35 Overcurrent on chopper A ON overcurrent D104 Plasma valve PWM D37 5V voltage indicator D105 Shield valve PWM D40 24V voltage indicator D106 Torch valve enable D41 Fused side of 120VAC input power D107 Not used D42 240V input detection ON 240VAC input detected D111 Serial communications RX D44 120V input detection ON 120VAC input detected Control board test points Test Test point Description point Description TP1 15V TP18 5V regulated TP2 Analog 3 3V TP19 5V unregulated should be 7V or higher Signal ground TP20 24V TP4 3 3V TP21 Not used TP5 15V TP
143. igure below By lightly dragging the shield on the workpiece you can maintain a steady cut For straight line cuts use any straight edge as a guide Piercing 1 Start by holding the torch so that the shield is approximately 1 5 mm 1 16 inch away from the workpiece before squeezing the trigger switch This method maximizes the life of the consumables See figures below 2 Hold the torch at about a 45 angle to the workpiece pointing away from yourself then slowly roll it to a vertical 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 Starting the pierce at an angle permits the hot metal to escape to one side rather than splashing back against the shield protecting the operator from the sparks and extending the life of the shield 3 When the pierce is complete proceed with the cut MAXPRO200 Instruction Manual 807700 Revision 1 81 Operation Gouging Specifications Materials Mild steel stainless steel and aluminum Current 200 Amps Plasma gas types Air Oo Shield gas types Air Torch weight without lead See the Specification section Gouging safety When gouging it is absolutely necessary to wear full protection welding helmet with at least a 12 glass Welding gloves and a welding jacket A heat shield 127389 can be purchased for fur
144. ion is also provided LASER RADIATION AVOID EXPOSURE TO DEAM CLASS 3B LASER PRODUCT Additional laser safety instructions Consult with an expert on local laser regulations Laser safety training may be required Do not allow untrained persons to operate the laser Lasers can be dangerous in the hands of untrained users Do not look into the laser aperture or beam at any time Position the laser as instructed to avoid unintentional eye contact Do not use the laser on reflective workpieces Do not use optical tools to view or reflect the laser beam Do not disassemble or remove the laser or aperture cover Modifying the laser or product in any way can increase the risk of laser radiation Use of adjustments or performance of procedures other than those specified in this manual may result in hazardous laser radiation exposure Do not operate in explosive atmospheres such as in the presence of flammable liquids gases or dust Use only laser parts and accessories that are recommended or provided by the manufacturer for your model Repairs and servicing MUST be performed by qualified personnel Do not remove or deface the laser safety label 18 0200 Instruction Manual 807700 Revision 1 Safety SYMBOLS AND MARKS Your Hypertherm product may have one or more of the following markings on or near the data plate Due to differences and conflicts in national regulations not all marks are applied to
145. ions of Hypertherm s products do not comply with European EMC requirements and therefore do not have a CE marking on the data plate Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate These include but are not limited to Australia New Zealand Countries in the European Union Russia is important that the product and its certification test mark be suitable for the end 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 27 Product Stewardship Safe installation and use of shape cutting equipment IEC 60974 9 titled Arc Welding Equipment Installation and use provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations The requirements of national and local regulations shall be taken into consideration during installation including but not limited to grounding or protective earth connections fuses supply disconnecting device and type of supply circuit Read these instructions before installing the equipment The first and most important step is the safety assessment of the installation The safety assessment must be performed by an expert and determines what steps are necessary to create a safe environment and what
146. ir Plasma Air Shield Air Plasma Air Shield amp 420045 220936 220935 420044 220488 220937 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow S aaa os Pierce Height Ba 7 6 15 3 229 30 5 76m 15 3 22 9 30 5 Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm Factor Seconds 6 0 147 1 0 4885 3 0 300 0 3 8 0 148 1 3 4515 3 9 300 0 5 10 0 151 3 0 3556 5 2 200 0 8 12 0 153 3 0 2794 6 0 200 0 9 15 0 158 4 3 2265 8 6 200 1 0 52 54 55 56 48 50 54 58 20 0 165 4 8 1415 9 6 200 1 4 25 0 172 6 4 940 12 8 200 1 7 32 0 176 6 4 630 12 8 200 2 3 38 0 179 6 4 510 44 0 189 6 4 320 Edge start 50 0 199 6 4 215 English Plasma Cutflow Shield Cutflow Pierce Height D 2bft 75ft 100ft 25ft 75ft 1008 2 Lead Lead Lead Lead Lead Lead Lead Lead Sieben 1 4 145 0 04 190 0 12 300 0 3 5 16 148 0 05 180 10 15 300 0 5 3 8 151 0 10 140 0 20 200 0 8 1 2 154 0 13 110 10 25 200 0 9 5 8 159 0 19 85 0 38 200 1 0
147. isposal should be in accordance with local state or national legislation No special measures are required No specific waste water pretreatment required Additional Information None MAXPRO200 Instruction Manual 807700 Revision 1 201 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture 14 Transport information Not classified as dangerous for transport Transport in bulk according to Annex of MARPOL73 78 and the Code 15 Ecological information USA TSCA Toxic Substance Control Act Listed SARA 302 Extremely Hazardous Substances Not applicable SARA 313 Toxic Chemicals Not applicable SARA 311 312 Hazard Categories None CERCLA Comprehensive Environmental Response applicable Compensation and Liability Act CWA Clean Water Act CWA 307 Priority None Pollutants CAA Clean Air Act 1990 CAA 112 Hazardous None Pollutants HAP Proposition 65 California Not applicable State Right to Know Lists CAS No 95 14 7 Listed in MA NJ PA Canada WHMIS Classification Canada Not classified Canada ingredient disclosure list Not applicable Canada DSL NDSL Listed EU EINECS Europe Listed Wassergef hrdungsklasse Germany None 16 Other information The following sections contain revisions or new statements 1 16 Legend LTEL Long Term Exposure Limit STEL Short Term Exposure Limit STOT Specific Target Organ Toxicity DNEL Derived No Effect Level PNEL Pr
148. k table with good metal to metal contact Do not connect it to piece that will fall away when the cut is complete Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply be Work table Connect the work table to an earth sure to connect the power cord ground wire properly ground in accordance with appropriate national and local electrical codes Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Use proper precautions when handling printed circuit boards 29 Store boards in anti static containers Wear a grounded wrist strap when handling PC boards MAXPRO200 Instruction Manual 807700 Revision 1 13 Safety COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and fittings designed for the specific application Maintain all compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national and local codes GAS CYLINDERS CAN EXPLO
149. ld pressure the system will generate error code 54 3 System will check for over current Chopper A over current the system will generate error code 134 Chopper B over current the system will generate error code 138 4 System will check for minimum coolant flow error code 93 5 System will check the bus voltage equivalent to Line voltage Bus voltage high the system will generate error code 5 Bus voltage low the system will generate error code 6 System will check for phase loss error code 27 7 System will check for over temperature conditions Chopper overtemperature the system will generate error code 65 Transformer overtemperature the system will generate error code 67 Inductor 1 overtemperature the system will generate error code 68 Inductor 2 overtemperature the system will generate error code 69 Coolant overtemperature the system will generate error code 71 8 System will check for lost chopper current error code 24 Lost Current Fault 9 System will check for lost transfer error code 26 Lost Transfer Fault 10 If the plasma start signal is removed the system will advance to state 10 Rampdown Rampdown status 10 1 System will shut off the plasma and shield gases 2 System will rampdown the current 3 When the system reaches the final current it will advance to state 11 Rampdown Complete Rampdown complete state 11 1 Ensure all power supply outputs are off except the main contactor
150. le 2 psi for 5 minutes The shield gas channel should drop to near zero psi less than 5 psi 003 Flow gas at full pressure The plasma and shield gases flow at full pressure It is typical to see low pressure errors 004 during this function because the system is attempting to achieve the maximum flow possible Function 4 is used when setting the supply gas regulators In line valve check The plasma channel is pressurized the system closes the Burkert valve and opens the in line 509 torch valve The plasma pressure is expected to drop to near zero psi less than 5 psi less than 30 seconds MAXPRO200 Instruction Manual 807700 Revision 1 147 Maintenance Start circuit Operation The start circuit is a high speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead the start circuit is built into the chopper in the 200 The start circuit performs 2 functions 1 It allows the initial pilot arc current to flow through the pilot arc lead quickly with little impedance 2 After initial pilot arc current is established the start circuit introduces impedance to the pilot arc lead to aid in transferring the arc to the workpiece See schematic below Start circuit functional schematic Plasma power supply 9 Number Description 1 Chopper Choke Power supp
151. le the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Cutting cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components 24 Earthing of the 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 steel work 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 electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting ci
152. le when the center hole is no longer round Replace the nozzle O rings Damage Replace the o ring Lubricant Apply a thin film of silicone lubricant if the o rings are dry General Damage Replace the swirl ring Dirt or debris Blocked gas holes O rings Damage Lubricant Clean and inspect for damage and replace if damaged Replace the swirl ring Replace the o ring Apply a thin film of silicone lubricant if the o rings are dry Electrode Always replace the nozzle and the electrode as a set Emitter Center surface Emitter wear a pit forms as the emitter wears O rings Damage Lubricant In general replace the electrode when the pit depth is 1 mm 0 04 in or greater Replace the o ring Apply a thin film of silicone lubricant if the o rings are dry MAXPRO200 Instruction Manual 807700 Revision 1 91 Operation Torch maintenance Poor cut quality and premature failure may occur if the torch is not maintained properly The torch is manufactured to very tight tolerances to maximize cut quality The torch should not be subjected to hard impacts that can cause critical features to become misaligned The torch should be stored in a clean location when not in use to avoid contamination of critical surfaces and passages Routine maintenance The following steps should be completed each time consumables are changed O rings 2 1 Use a clean cloth to wipe off the torch inside and outs
153. lead e Work lead CNC interface cable Supply gas hoses A Customer supplied power cable e Main power cable MAXPRO200 Instruction Manual 807700 Revision 1 43 Installation Recommended grounding and shielding practices WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring the removal of the plasma system cover must be performed by a qualified technician See the Safety section of your instruction manual for more safety precautions Introduction This section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency interference RFI and electromagnetic interference EMI also called noise It also describes the DC power ground and the service ground The diagram at the end of this section shows these types of grounds in a plasma cutting system Note The grounding practices in this section have been used on many installations with excellent results and Hypertherm recommends that these practices be a routine part of the installation process The actual methods used to implement these practices may vary from system to system but should remain as consistent as possible However due to the variation in equipment and installations these grounding practices may not succeed in every case to eliminate RFI EMI noise issues Types of grounding Service gr
154. lectors and other solid parts of the torch 32 Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product Fumes emission and air quality Note The following information on air quality is intended for general information only and should not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated In the USA the National Institute for Occupational Safety and Health NIOSH Manual of Analytical Methods is a collection of methods for sampling and analyzing contaminants in workplace air Methods published by others such as OSHA MSHA EPA ASTM ISO or commercial suppliers of sampling and analytical equipment may have advantages over NIOSH methods For example ASTM Practice D 4185 is a standard practice for the collection dissolution and determination of trace metals in workplace atmospheres The sensitivity detection limit and optimum working concentrations for 23 metals are listed in ASTM D 4185 An industrial hygienist should be used to determine the optimum sampling protocol considering analytical acc
155. levant to the plasma cutting system as manufactured by Hypertherm It is the responsibility of the end use customer and the OEM to perform a risk assessment for the higher level System and to provide protection against hazardous moving parts Unless the higher level system is certified when the OEM incorporates Hypertherm products into it the installation also may be subject to approval by local authorities Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site When the external interconnecting cables are subject to oil dust water or other contaminants hard usage ratings may be required When external interconnecting cables are subject to continuous movement constant flexing ratings may be required It is the responsibility of the end use customer or the OEM to ensure the cables are suitable for the application Since there are differences in the ratings and costs that can be required by local regulations for higher level systems it is necessary to verify that any external interconnecting cables are suitable for the end use installation site 0200 Instruction Manual 807700 Revision 1 29 Product Stewardship 30 MAXPRO200 Instruction Manual 807700 Revision 1 Introduction The Hypertherm En
156. line voltage fluctuation product inrush characteristics and regulatory requirements The main feed protection device circuit breaker or fuse must be sized to handle all branch feed loads for both inrush and steady state current The power supply must be wired into one of the branch feed circuits The power supply has a steady state current listed in the table below Use a motor start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national codes Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the rated input current FLA for 0 01 seconds and up to 12 times the rated input current FLA for 0 1 seconds Note The table below is for reference only All local and national electrical code must be followed Rated input Recommended Recommended cable size for 15 m 50 feet current Q X kW time delay high maximum length Input voltage Phase output inrush fuse size Rated for 60 C 140 Rated for 90 C 194 200 208 VAC 3 108 104 amps 175 amps N A 67 5 mm 2 0 220 VAC 3 98 amps 150 amps 85 2 mm 3 0 42 4 mm 1 AWG 240 VAC 3 90 amps 150 amps 85 2 mm 3 0 42 4 mm 1 AWG 380 VAC 3 57 amps 90 amps 33 6 mm 2 AWG 21 2 mm 4 AWG 400 VAC 3 54 amps 80 amps 26 7 mm 3 AWG 21 2 mm 4 AWG 415 VAC 3 52 amps 80 amps 26 7 mm 3 AWG 21 2 mm 4 AWG 440 VAC 3 49 amps 80 amps 26 7 mm 3
157. liters to 17 0 liters 3 75 to 4 5 gallons of coolant depending on the length of the torch leads 1 Add coolant to the power supply until the tank is full 2 Turn ON the power supply then press and release the amps selector knob as many times as a needed until the flow symbol is selected The flow rate will be shown in the three digit display There is a 45 second delay before the system will report a low coolant flow error If the flow rate has not reached 1 9 liters per minute Ipm 0 5 gallons per minute gpm the system will turn off the pump 3 Ifthe system displays an error turn OFF the powertothe 4 Add coolant to the power supply until the tank is system and add coolant to the tank until it is full again full and replace the filler cap Repeat steps 2 and 3 until no error is displayed ep 66 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Connect the supply gases Air air cutting Note Verify that the plasma gas line and the shield gas line are properly connected before connecting the air supply hose and supplying pressurized gas to the system Connect the air supply hose to the filter regulator as shown below lt MALIA supply gas connection 1 Disconnect the air supply hose from the filter regulator 2 Remove the Air fitting 015012 1 4 inch NPT X 6 MALE from the filter regulator Install an 015103 adaptor to use the nitrogen supply gas hose offered
158. ltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow 2 5 Pierce Height Dor 7 6 15 3m 229m 30 5 m 76m 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm min mm Factor Seconds 3 0 130 2 6 5900 5 2 200 0 1 4 0 131 2 7 5325 5 4 200 0 2 6 0 134 2 8 3925 5 6 200 0 3 10 0 136 3 0 2680 6 0 200 0 4 12 0 138 3 0 2200 6 0 200 0 5 62 62 64 64 30 32 35 37 15 0 140 3 6 1665 72 200 0 7 20 0 145 3 9 1195 78 200 1 0 25 0 151 4 1 685 32 0 158 4 6 515 Edge start 38 0 163 4 6 310 English Plasma Cutflow Shield Cutflow e Votos Hon n Pierce Height Dolor 25 50 75ft 100ft 25 5 75ft 1008 Lead Lead Lead Lead Lead Lead Lead Lead In Volts in Factor 90 Seconds 0 135 130 0 10 240 0 20 200 0 1 3 16 132 0 11 190 10 22 200 0 2 1 4 134 0 11 150 10 22 200 0 3 3 8 136 0 12 110 0 24 200 0 3 64 64 30 32 a5 37 1 2 138 0 12 80 0 24 200 0 5 5 8 141 0 15 60 0 30 200 0 7 3 4 144 0 15 50 0 30 200 1 0 1 151 0 16 25 1 1 4 158 0 18 20 Edge start 1 1 2 163 0 18 12 with IHS tab without IHS tab MAXPRO200 Instruction Manual 807700 Revision 1 105 Operation Mild steel Flow rates Ipm scfh A
159. ly control board IGBT Power resistors Diode Cutting arc N Pilot arc 148 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Start circuit troubleshooting DANGER ELECTRIC SHOCK CAN KILL Before operating this system you must read the safety section thoroughly Turn OFF the power supply s main disconnect switch before proceeding with the following steps D14 should always be illuminated Note Reference the chopper PCB figure on the next page D3 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece If arc transfer is immediate the LED may not illuminate If there is no arc at the torch or if the arc will not transfer 1 Turn OFF all power to the system 2 Remove the 6 AWG wire labeled R36 from the R36 power resistor terminal PA WORK Not the smaller 140 mm 5 5 inch 10 AWG wire that connects to R34 3 Verify a series resistance of 3 between J2 COLLECTOR wire labeled J2 2 and R36 PA WORK If the resistance value is not correct check the wiring connections between J2 COLLECTOR wire labeled J2 2 and R34 between R34 no label on wire and R35 and between R35 no label on wire and R36 1 R34 02 COLLECTOR R35 R36 PA WORK Note Resistance value may slowly increase to the correct value due to the capacitance in the circuit 4 Verify a resistance of
160. ment 011093 1 Fan 450 550 cfm 120 50 60 Hz 10 027079 4 inches Heat exchanger fan 11 inches 127091 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 3 5 years 2100 arc hours Torch o ring 044026 2 Air filter element 011093 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 Main contactor 200V 240V 003233 Main contactor choose one 1 Main contactor 380V 600V 003249 Torch main body straight torch 420087 Torch main body quick disconnect torch 220921 Torch main body choose one 1 4 years 2400 arc hours Torch main body 90 Hand torch 420070 Torch main body 65 Hand torch 420109 Air filter element 011093 1 Pump replacement kit 428043 1 System Torch leads dependant 1 Pump motor replacement kit 428039 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 4 5 years 2700 arc hours Torch o ring 044026 2 Air filter element 011093 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 Main contactor 200V 240V 003233 Main contactor choose one 1 Main contactor 380V 600V 003249 5 year 3000 arc hours Torch main body straight torch 420087 Torch main body quick disconnect torch 220921 Torch main body choose one 1 Torch main body 90 Hand torch 420070 Torch main body 65 Hand torch 420109 Air filter element 011093 1 162 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance
161. mm 0 5 inches wide A separate cable must run from the lifter to the gantry ground bus bar The valve assembly should also have a separate ground connection to the gantry ground bus bar 12 If the gantry runs on rails that are not welded to the table then each rail must be connected with ground cable from the end of the rail to the table The rail ground cables connect directly to the table and do not need to connect to the table ground bus bar 13 If you are installing a voltage divider board mount it as closely as possible to where the arc voltage is sampled One recommended location is inside the plasma system enclosure If a Hypertherm voltage divider board is used the output signal is isolated from all other circuits The processed signal should be run in twisted shielded cable Belden 1800F or equivalent Use a cable with a braided shield not a foil shield connect the shield to the chassis of the plasma system and leave it unconnected at the other end 14 All other signals analog digital serial and encoder should run in twisted pairs inside a shielded cable Connectors on these cables should have a metal housing The shield not the drain should be connected to the metal housing of the connector at each end of the cable Never run the shield or the drain through the connector on any of the pins MAXPRO200 Instruction Manual 807700 Revision 1 45 Installation The following picture shows an example of a cutting table ground b
162. n 3 The 132 pump motor may have reached its internal thermal trip point Make sure the side panel is installed for proper airflow and that the heat exchanger fan is working properly 133 Added If the wiring is good the IGBT may have failed to corrective action 4 for error codes 134 and 138 139 Corrected 20 liters to 4 liters in step 2 141 Updated the graph to accurately reflect the new flow sensor 150 Corrected overlapping text TP95 and DCKB on the Chopper PCB graphic 160 Corrected the Preventive maintenance protocol checklist to remove HPR references and make it MAXPRO specific Added Annual preventive maintenance kit part numbers parts lists for the kits and the parts replacement 161 through 163 Schedule Changed item 4 description from Replacement filter element to Air filter element Changed item 6 description 197 from Replacement filter element to Coolant filter element 169 Updated the graphic to show the new flow sensor and removed item 5 Adapter 1 2 push in x 1 2 inch push in tube because it is no longer necessary 172 Added includes PCB to the description for item 2 179 Added a recommended spare parts lists MAXPRO200 Instruction Manual 807700 Revision 1 205 Revision Changes 206 MAXPRO200 Instruction Manual 807700 Revision 1
163. n Manual 807700 Revision 1 61 Installation Connect the power WARNING ELECTRIC SHOCK CAN KILL The line disconnect switch must be in the OFF position before making the power cable connections In the U S use a lock out tag out procedure until installation is complete In other countries follow appropriate national and local safety procedures 1 Insert the power cable through the strain relief at the rear of the power supply 2 Connect the ground lead PE to the GROUND connector as shown below 3 Connect the power leads to the contactor terminals as shown below For models with an EMI filter connect the power leads to the EMI filter terminal block Recommended torque on contactor or EMI filter terminals is 7 8 Nm 60 70 in lbs 4 Verify that the line disconnect switch is in the OFF position and remains in the OFF position for the remainder of the installation of the system 5 Connect the power cord leads to the line disconnect switch following national and local electrical codes North American wire colors European wire colors U Black U Black V White V Blue W Red W Brown PE Earth ground Green yellow PE Earth ground Green yellow Ground L1 L2 L3 O N gt 62 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Torch coolant requirements The system is shipped without any coolant in the tank Before filling the coolant s
164. n the container There should be about 2 liters 0 5 gallon If there is less than 1 liter 0 25 gallon there may be a restriction in the coolant system or a problem with the pump or flow sensor 5 Verify the flow sensor output by measuring the flow output in frequency at the control board Measure the Frequency on J21 pin 3 pulse and pin 2 ground Once you have the frequency use the chart below to get the flow sensors measured flow rate If this number differs more than 0 8 lpm 0 2 gpm from your bucket test the flow sensor may need to be replaced Note The 3 digit display shows actual coolant flow You can compare that measurement to the measurement you get in step 5 to troubleshoot for a PCB problem 1 4 1 2 1 a 29 0 8 lt 0 6 3 iL 0 4 0 2 0 0 20 40 60 80 100 120 140 Measured frequency MAXPRO200 Instruction Manual 807700 Revision 1 141 Maintenance CAUTION Coolant will flow from the filter when the housing is removed Drain coolant before replacing the filter Coolant system filter replacement Make sure the coolant has been drained from the system then turn OFF all power to the system Remove the filter housing Make sure the o ring inside the filter housing remains in place Remove and discard the filter element Install the new filter element 027005 Make sure the o ring is properly installed before re installing the housing Refill the power supply with coolant See
165. nd replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard 10 MAXPRO200 Instruction Manual 807700 Revision 1 Safety CUTTING CAN CAUSE FIRE OR EXPLOSION Fire prevention WARNING Be sure the area is safe before doing any cutting Explosion Hazard Keep a fire extinguisher nearby Argon Hydrogen and Methane Remove all flammables within 35 feet 10 m of the Hydrogen and methane are flammable gases cutting area present an explosion hazard Keep flames away from Quench hot metal or allow it to cool before handling cylin
166. ne voltage 15 The normal lower limit for ile fuses on thecontrol board operation is 108 VAC 120 VAC 10 Line voltage is close to or greater than bath S the upper lirit or 198 AC 29 YAG Verify the line voltage at the control transformer and 006 High line voltage 15 The normal upper limit for the fu es one control board operation is 132 VAC 120 VAC 10 1 Verify that the correct consumable parts are installed and in good condition 2 Perform the gas checks See Control board on page 144 020 Nlo gilot are No current detected from chopper at 3 Verify that there is spark across spark gap RP ignition and before 1 sec timeout 4 Inspect CON1 for excessive wear 5 Perform the torch lead test See Torch lead test on page 155 6 Perform the start circuit test See Start circuit troubleshooting on page 149 1 Verify proper transfer pierce height No current detected work lead e or loose 021 No arc transfer 500 msec after pilot arc current was P 9 established connections 4 Perform the torch lead test See Torch lead test on page 155 1 Verify that the correct consumable parts are installed and in good condition 2 Verify proper cutflow gas settings i i i tting 024 Lost current on chopper Lost current from chopper after 3 Verify the pierce height setting transfer 4 Verify the pierce delay time 5 Verify that the arc did not lose contact with the plate while cutting hole cutting s
167. nerate error code 415 Channel B current detected on channel A input the system will generate error code 416 Channel A current detected on channel B input and Channel B current detected on channel A input the system will generate error code 414 d Main contactor closed IGBTs on Channel A current higher than expected the system will generate error code 417 Channel B current higher than expected the system will generate error code 418 Both channels current higher than expected the system will generate error code 419 If the chopper test is successful and there are no other severe errors the system will advance to state 3 Ready for start otherwise the system will go to state 13 Shutdown Ready for start status 03 1 2 3 4 122 System is waiting for a plasma start signal System is monitoring the over current signals and over temperature conditions Chopper temperature in range or the system will generate error code 65 Transformer temperature in range or the system will generate error code 67 Inductor 1 temperature in range or the system will generate error code 68 Inductor 2 temperature in range or the system will generate error code 69 Coolant temperature in range or the system will generate error code 71 Chopper A over current the system will generate error code 134 Chopper B over current the system will generate error code 138 System is monitoring the pilot arc duty cycle to ensure it is less than
168. nless steel Flow rates Ipm scfh Plasma No Shield Plasma Shield 220536 2209 220529 020415 Note Gas pressure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 7 6 15 3m 229m 30 5 m 76m 15 3 22 9 30 5 min Volt mm mm min mm Factor 90 Second Lead Lead Lead Lead Lead Lead Lead Lead oe 5 0 148 3 0 3140 6 1 200 0 3 6 0 151 3 0 2980 6 1 200 0 3 10 0 152 3 3 1830 6 6 200 0 5 68 69 70 71 36 39 42 44 12 0 154 3 3 1510 6 6 200 0 8 15 0 158 3 6 1120 Edge start 20 0 166 3 8 470 English Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 25ft 75ft 100ft 25ft 5Oft 75ft 100 ft Volts in in Factor Seconds Lead Lead Lead Lead Lead Lead Lead Lead P 3 16 149 0 12 125 10 24 200 0 3 1 4 151 0 12 115 10 24 200 0 3 3 8 152 0 18 75 0 26 200 0 5 68 69 70 71 36 39 42 44 1 2 154 0 13 55 0 2
169. ode 400 b Main contactor on closed IGBTs off f there is current on channel A the system will generate error code 406 If there is current on channel B the system will generate error code 407 If there is current on both channels the system will generate error code 408 System will verify that there is a No transfer signal or the system will generate error code 108 b No start signal or the system will generate error code 50 c No coolant flow or the system will generate error code 109 System will verify that a Temperatures are above the minimum Chopper temperature is above minimum or the system will generate error code 300 Transformer temperature is above minimum or the system will generate error code 301 Inductor 1 temperature is above minimum or the system will generate error code 302 Inductor 2 temperature is above minimum or the system will generate error code 303 Coolant temperature is above minimum or the system will generate error code 304 b Temperatures are below the maximum values Chopper temperature is below maximum or the system will generate error code 65 Transformer temperature is below maximum or the system will generate error code 67 Inductor 1 temperature is below maximum or the system will generate error code 68 Inductor 2 temperature is below maximum or the system will generate error code 69 Coolant temperature is below maximum or the system will generate error code 71 After about 1 second the s
170. on 470 Atlantic Avenue Boston MA 02210 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 LeJeune Road P O Box 351040 Miami FL 33135 10 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O 11 Box 351040 Miami FL 33135 WARNING LABELS This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described 20 Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS Z49 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health Standards 29 CFR 1910 http www osha gov OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 AWS Safety and Health Fact Sheets American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 www aws org technical facts Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables 1 2 Have a fire extinguisher nearby and ready to use 1 3 Do not use a drum or other closed containe
171. on the I O board turn off the power to the system and turn it on again to see if that clears the error 134 Chopper A current exceeded maximum 1 Verify that the chopper PCB is functioning properly by checking the LEDs on the board against the LED list in the Maintenance section 2 Turn off the power to the system and then turn it on again to verify that the system passes the initial power up test 3 Verify the current output on J2 1 white to black 4 VDC 100 amps 4 If the wiring is good the IGBT may have failed Replace the chopper assembly 138 Chopper B over current Chopper B current has exceeded maximum 1 Verify that the chopper PCB is functioning properly by checking the LEDs on the board against the LED list in the Maintenance section See Start circuit troubleshooting on page 149 2 Turn off the power to the system and then turn it on again to verify that the system passes the initial power up test 3 Verify the current output on J2 6 white to black 4 VDC 100 amps 4 If the wiring is good the IGBT may have failed Replace the chopper assembly 161 High coolant flow rate Coolant flow rate has exceeded maximum 1 Check to make sure the shield cap is properly installed A loose shield cap can allow shield gas to get into the coolant and cause this error 2 Check to make sure the consumables are installed properly and are not damage
172. opper current If it is below minimum the system will generate error code 24 Lost Current Fault System will check for the arc transfer signal once it is active the system will advance to state 8 Rampup 7 If the transfer signal in not present within 0 5 seconds Mechanized or 5 0 seconds Hand torch the system will have error code 21 Transfer fault and advance to state 11 Rampdown complete Rampup status 08 1 System will ramp up the current based on the process parameters 2 System will verify the gas pressures are within tolerance Low plasma pressure the system will generate error code 44 High plasma pressure the system will generate error code 45 Low shield pressure the system will generate error code 53 High shield pressure the system will generate error code 54 3 System will check for over current Chopper A over current the system will generate error code 134 Chopper B over current the system will generate error code 138 4 Once the ramp up is finished the system will advance to state 9 Main arc Main arc status 09 1 System will display actual current and pressures 2 System will verify the gas pressures are within tolerance Low plasma pressure and the system will generate error code 44 High plasma pressure and the system will generate error code 45 124 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Low shield pressure the system will generate error code 53 High shie
173. other MAXPRO200 Instruction Manual 807700 Revision 1 47 Installation Placement of the power supply WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring the removal of the plasma system cover must be performed by a qualified technician See the Safety section of your instruction manual for more safety precautions The power supply can be moved by using the lifting eye or by forklift but the forks must be long enough to extend the entire length of the base Take care when lifting so that the underside of the power supply is not damaged The forks must also be centered front to back and side to side to prevent tipping while moving Fork lift speeds should be kept to a minimum especially when making a turn or going around a corner Place the power supply in an area that is free of excessive moisture has proper ventilation and is relatively clean Allow 1 m 3 ft of space on all sides of the power supply for ventilation and service Cooling air is drawn in through the side panel and is exhausted through the rear of the unit by a cooling fan Do not place any filter device over the air intake locations which reduces cooling efficiency and VOIDS THE WARRANTY Do not place the power supply on an incline greater than 10 to prevent it from toppling p p 9 ppling ID 48 MAXPRO20
174. ound also called safety ground or potential earth PE ground is the grounding system that applies to the incoming line voltage It prevents a shock hazard to any personnel from any of the equipment or the cutting table It includes the service ground coming into the plasma system and other systems such as the CNC and the motor drives as well as the supplemental ground rod connected to the cutting table In the plasma circuits the ground is carried from the plasma system chassis to the chassis of each separate console through the interconnecting cables DC power ground also called cutting current ground is the grounding system that completes the path of the cutting current from the torch back to the plasma system It requires that the positive lead from the plasma system be firmly connected to the cutting table ground bus with a properly sized cables It also requires that the slats on which the workpiece rests make firm contact with the table and the workpiece RFI and EMI grounding and shielding is the grounding system that limits the amount of electrical noise emitted by the plasma and motor drive systems It also limits the amount of noise that is received by the CNC and other control and measurement circuits The grounding practices described in this section mainly target and EMI grounding and shielding Grounding practices 1 Unless noted use only 16 mm 6 AWG welding cable 047040 for the EMI ground cables shown on the diagram
175. out from the nozzle Point the torch away from yourself and others Always use the proper protective equipment See Safety on page 9 for more information Handheld cutting Specifications Materials Mild steel stainless steel and aluminum Current 50A 130A and 200A Plasma gas types Air Oo Shield gas types Air No Torch weight without lead Specifications on page 33 Consumable selection and gas settings Refer to Cutting parameters on page 86 for consumable and process information Starting a cut 1 Start cutting from the edge of the workpiece see figure below unless you must pierce For the best results the nozzle orifice should overlap the edge of the workpiece about halfway and the torch arc axis should be perpendicular to the cut surface Note When cutting make sure that the sparks are coming out of the bottom of the workpiece If they are spraying on top of the workpiece you are moving the torch too fast or you do not have sufficient power to fully penetrate the workpiece 2 Hold the torch lightly on the metal or just off the metal and drag the torch across the metal The arc transfers once the torch is within 6 mm 1 4 inch of the workpiece 80 MAXPRO200 Instruction Manual 807700 Revision 1 Operation 3 Pullthe torch through the cut Pulling it is easier than pushing it 4 Hold the torch so the arc is vertical and watch the arc as it cuts along the line see f
176. ow out any accumulation of dust and particulates 2 Inspect wiring harnesses and connections for wear damage or loose connections If you see any discoloration that might indicate overheating contact Hypertherm Technical Service 3 Inspect the main contactor for excessive pitting on the contacts characterized by a blackened rough surface on any of the contacts If this condition exists replacement is recommended 156 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Cooling system 4 nspect the coolant circulating system s filter element at the rear of the power supply If the filter is a brownish color replace it Consult the Parts List in this manual for part numbers 5 Perform a coolant flow test as described in this manual then check for coolant leaks Inspect these locations a The back of the power supply b lgnition enclosure c Torch main body Also check the coolant tank for dirt and particulates Verify that proper Hypertherm coolant is being used Proper Hypertherm coolant 028872 is a pink liquid Torch main body 6 Verify that the water tube is straight and has no pitting on the end 7 Inspect the current ring inside the torch main body The current ring should be smooth and not pitted If no pitting is observed clean the current ring with a clean cotton swab and hydrogen peroxide Do not use alcohol Pitting on the current ring generally indicates improper maintenance for example lack of regular
177. pect connection from cutting table to workpiece 4 lead Date MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Year 1 preventive maintenance PM kits Torch configuration Input Voltage Quick disconnect Straight 65 Hand 90 Hand 200V 240V 428051 428052 428053 428082 380V 600V 428083 428084 428085 428086 Maintenance kits parts list Each of the preventive maintenance kits contains the following parts Description Quantity Description Quantity Description Quantity Air filter element 2 Coolant solution 8 Torch main body 1 Torch bullet plug kit Coolant filter element 2 Main contactor 1 Quick disconnect PM kit only 1 Service parts replacement schedule Timeline Component Part number Quantity Coolant filter element 027005 1 Coolant solution 70 30 028872 4 6 months 300 arc hours Torch o ring 044026 2 Air filter element 011093 1 Coolant filter element 027005 1 Coolant solution 70 30 028872 4 Main contactor 200V 240V 003233 Main contactor choose one 1 Main contactor 380V 600V 003249 1 year 600 arc hours Torch main body straight torch 420087 Torch main body quick disconnect torch 220921 Torch main body choose one 1 Torch main body 90 Hand torch 420070 Torch main body 65 Hand torch 420109 Air filter element 011093 1 Cool
178. ption TP88 ground TP89 15V chopper A TP91 GND 9 15V chopper a gt TP91 IGBT chopper B gate drive TP92 15V chopper B TP93 15V chopper B E 5t 15 PWRGND TP94 Gate drive optocoupler 5V 95 Chopper B PWM TP96 Pilot arc circuit ground TP99 15V Chopper unregulated 18V should be 18 5 or higher TP98 ground TP99 15V TP101 Chopper ground TP102 Signal Bus voltage ground TP103 5V TP104 Pilot arc ground TP105 Signal chopper temp ground TP106 Chopper temp 0 5V analog TP107 Pilot arc 18V TP108 Non isolated chopper ground TP109 Non isolated Bus voltage 0 5V analog TP110 18V TP111 Isolated Bus voltage 0 5V analog TP112 Bus voltage 5V TP113 Chopper A PWM TP97 arg T BUS mo TP102 VOLTAGE SIGNAL Ves TP103 TP112 bV TP110 VBUSg wa 101 18V PWRGND B TP97 18VIN 17000000 006 INH3HLHSdAH Pilot arc unregulated 18V should be 18 5 or higher TP115 chopper A gate drive TP114 148 1 0321531
179. r as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous 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 with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away 7 Do not remove destroy or cover this label Replace if it is missing damaged or worn PN 110584 Rev AVERTISSEMENT Le coupage plasma peut tre pr judiciable pour l op rateur 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 s
180. ration number To provide chemical information as required by the REACH regulation Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC Any use of SVHC in amounts exceeding 0 196 w w of the parts has been eliminated The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance The lubricants sealants coolants adhesives solvents coatings and other preparations or mixtures used by Hypertherm in on for or with its shape cutting equipment are used in very small quantities except the coolant and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization SVHCs Proper handling and safe use of chemicals Chemical Regulations in the USA Europe and other locations require that Material Safety Data Sheets MSDS be made available for all chemicals The list of chemicals is provided by Hypertherm The MSDS are for chemicals provided with the product and other chemicals used in or on the product MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https www hypertherm com On the Search screen insert MSDS in the document title and click on Search In the USA OSHA does not require Material Safety Data Sheets for articles such as electrodes swirl rings retaining caps nozzles shields def
181. rcuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease the risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is provided in IEC 60974 9 Arc Welding Equipment Part 9 Installation and Use Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications MAXPRO200 Instruction Manual 807700 Revision 1 Attention Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty and will constitute misuse of the Hypertherm Product You are solely responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment General Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows if Hypertherm is notified of a defect i with respect to the plasma power supply within a p
182. rectly WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions in this manual that may result in minor injury or damage to equipment if not followed correctly ELECTRICAL HAZARDS Only trained and authorized personnel may open this equipment If the equipment is permanently connected turn it off and lock out tag out power before the enclosure is opened f power is supplied to the equipment with a cord unplug the unit before the enclosure is opened Lockable disconnects or lockable plug covers must be provided by others Wait 5 minutes after removal of power before entering the enclosure to allow stored energy to discharge equipment must have power when the enclosure is open for servicing arc flash explosion hazards may exist Follow ALL local requirements NFPA 7 in the USA for safe work practices and for Personal Protective Equipment when servicing energized equipment The enclosure shall be closed and the proper earth ground continuity to the enclosure verified prior to operating the equipment after moving opening or servicing Always follow these instructions for disconnecting power before inspecting or changing torch consumable parts MAXPRO200 Instruction Manual 807700 Revision 1 Safety 3 Touching live electrical
183. red by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will have the right to defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other product not supplied by Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement and in any event no longer than fourteen 14 days after learning of any action or threat of action and Hypertherm s obligation to defend shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim Limitation of liability In no event shall Hypertherm be liable to any person or entity for any incidental consequential direct indirect punitive or exemplary damages including but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranty failure of essential purpose or otherwise and even if advised of the possibility of such damages National and local codes National and local codes governing plumbing and electrical inst
184. ress the corresponding orange release buttons on the spring clamp connector Note Use a switch relay or solid state relay that is compatible with 24 VDC 100 mA Wires should be a twisted pair Note The power switch on the power supply must be in the ON position for the remote switch to function and the remote switch must be in the ON position closed for the power switch on the power supply to function MAXPRO200 Instruction Manual 807700 Revision 1 59 Installation Power requirements General This equipment complies with IEC 61000 3 1 2 provided that the short circuit power Ssc is greater than or equal to 5 61 MVA at the point between the user s supply and the public system It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power Ssc greater than or equal to 5 61 MVA All switches slow blow fuses and power cables are customer supplied and must be chosen as outlined by applicable national and local electrical codes Installation must be performed by a licensed electrician Use a separate primary line disconnect switch for the power supply Recommendations on fuse and circuit breaker sizing are listed below however actual sizes required will vary based on individual site electrical line conditions including but not limited to source impedance line impedance and
185. ressure Plasma and shield gases flow at the set value 002 Display software revision Shows the current software revision of the power supply Plasma gas leak check The plasma channel is pressurized and the pressure trapped The 3 digit display shows the 003 actual pressure The system remains in this state until you select another function or return to cutting The pressure in the plasma channel should remain stable 2 psi for 5 minutes The shield gas channel should drop to near zero psi less than 5 psi Flow gas at full pressure The plasma and shield gases flow at full pressure It is typical to see low pressure errors 004 during this function because the system is attempting to achieve the maximum flow possible Function 4 is used when setting the supply gas regulators 005 Display torch ID The torch ID indicates the lead length that is connected to the system In line valve check The plasma channel is pressurize the system closes the Burkert valve and opens the in line 006 oe torch valve The plasma pressure is expected to drop to near zero psi less than 5 psi in less than 30 seconds 128 MAXPRO200 Instruction Manual 807700 Revision 1 Troubleshooting table Maintenance Number Name Description Corrective action 000 No Error System is ready to run None Line voltage is close to or less than 2 the lowerlimit ot 102 VAC 120 VAG Verify the line voltage at the control transformer and 005 Low li
186. safety tests are specifically required by local national regulations in the country where the equipment is installed Residual current devices RCDs In Australia and some other countries local codes may require the use of a Residual Current Devices RCD when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment RCDs are designed to safely disconnect the mains electrical supply when an imbalance is detected between the supply and return current there is a leakage current to earth RCDs are available with both fixed and adjustable trip currents between 6 to 40 milliamperes and a range of trip times up to 300 milliseconds selected for the equipment installation application and intended use Where RCDs are used the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators To verify that the RCDs continue to function properly over time both the trip current and the trip time should be tested periodically Portable electrical equipment and RCDs used in commercial and industrial areas in Australia and New Zealand are tested to the Austr
187. sary treat symptomatically 5 Fire fighting measures Extinguish preferably with dry chemical foam or water spray None known MAXPRO200 Instruction Manual 807700 Revision 1 Material Safety Data Sheet MSDS Torch Coolant 30 PG Mixture Fire fighting protective equipment A self contained breathing apparatus and suitable protective clothing should be worn in fire conditions 6 Accidental release measures Personal precautions Put on protective clothing Environmental exposure controls Absorb spillages onto sand earth or any suitable adsorbent material Other None 7 Handling and storage Handling Unlikely to cause harmful effects under normal conditions of handling and use Storage Keep container tightly closed and dry Keep away from heat Keep out of the reach of children Keep away from oxidizing agents Storage temperature Ambient Storage life Stable at ambient temperatures Specific use Industrial use only 8 Exposure controls personal protection Respirators Normally no personal respiratory protection is necessary Wear suitable respiratory protective equipment if exposure to levels above the occupational exposure limit is likely A suitable dust mask or dust respirator with filter type A P may be appropriate Eye Protection Safety spectacles Gloves Wearing of chemical protective gloves is not necessary Body protection None Engineering Controls Ensure adequate ventilation to remove vapors fumes dust
188. se compressed air or a vacuum to clean out dust and particulates 2 Inspect wiring harnesses 3 Inspect main contactor Coolant system P NP P NP P NP 4 Inspect filter element 5 Perform coolant flow test Coolant flow checked at gpm l min 6 Use compressed air or a vacuum to clean out the heat exchanger Torch main body NP NP NP NP NP NP 29 v v v NP Gas flows 7 Inspect water tube 8 Inspect current ring 9 Clean threads on torch front end 10 Inspect torch and consumable o rings 11 Verify proper fit of retaining or shield cap 12 Inspect hose fittings 13 Inspect torch to torch lead connections 14 Inspect plumbing from the gas supply NP Oxygen NP B Nitrogen NP NP Inspect supply gas filter NP Inspect hoses for restrictions DD v NP F Perform the plasma gas leak test General comments and recommendations Pressure drops psi bar in 5 minutes Preventive maintenance performed by 160 Cable connections P NP 15 Inspect torch height control cables Ignition enclosure NP 16 Inspect for moisture dust and particulates NP 17 Inspect torch leads Syst ounding NP 18 Inspect for proper system component grounding 19 Ins
189. sma arc has not been identified as a source of toxic fumes the material being cut can be a source of toxic fumes or gases that deplete oxygen Fumes produced vary depending on the metal that is cut Metals that may release toxic fumes include but are not limited to stainless steel carbon steel zinc galvanized and copper In some cases the metal may be coated with a substance that could release toxic fumes Toxic coatings include but are not limited to lead in some paints cadmium in some paints and fillers and beryllium Gases produced by plasma cutting vary based on the material to be cut and the method of cutting but may include ozone oxides of nitrogen hexavalent chromium hydrogen and other substances if such are contained in or released by the material being cut Caution should be taken to minimize exposure to fumes produced by any industrial process Depending upon the chemical composition and concentration of the fumes as well as other factors such as ventilation there may be a risk of physical illness such as birth defects or cancer It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations TOXIC FUMES CAN CAUSE INJURY OR DEATH The air quality level in any relevant workplace depends on site specific variables such as Tabl
190. ssure values are set automatically by the system when the process is chosen The arc voltage settings in these cut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Material Arc Cut Cutting Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 7 6 15 3m 229m 30 5 m 76m 15 3 22 9 30 5 m mn Volt mm Second Lead Lead Lead Lead Lead Lead Lead Lead 6 0 147 3 5 2625 70 200 0 3 10 0 153 4 1 1700 82 200 0 5 68 69 70 71 22 24 26 28 12 0 155 4 1 1380 82 200 0 8 15 0 160 44 900 Edge start 20 0 170 4 6 430 English Material Arc Cut Cutting gt Plasma Shield Cutflow Thickness Voltage Height Speed Pierce Height Delay 25ft 75ft 100ft 25ft 5Oft 75ft 100 ft in Volt in in Second Lead Lead Lead Lead Lead Lead Lead Lead 5 P rudis 1 4 148 0 14 100 0 28 200 0 3 3 8 152 0 16 70 0 32 200 0 5 68 69 70 71 22 24 26 28 1 2 156 0 16 50 0 32 200 0 8 5 8 162 0 18 30 Edge start 3 4 168 0 18 20 with IHS tab without IHS tab MAXPRO200 Instruction Manual 807700 Revision 1 109 Operation Stai
191. stalled 2 3 Ipm 0 6 gpm 2 Perform the coolant flow test procedure See Coolant flow test on page 140 060 Low coolant flow Inlet pressure measured was greater Verify that the input pressures at the regulators are in 965 Inlet Fressure Fault than 135 or less than 40 psi range 1 Verify that the heat exchanger fan is spinning 2 Blow dust out the heat exchanger with compressed air to clean off the fins 3 Verify that the level of coolant is at the proper height 4 Verify that the coolant mixture is correct propylene glycol A mixture with a high percentage of propylene glycol will have a lower cooling capacity 5 Change the consumables Older consumables emit more heat into the cooling loop 6 Verify the pump flow rate If it is less than 2 3 Ipm 0 6 GPM troubleshoot the low flow rate issue 1 Verify that the magnetics fan is operating properly Spinning fan blades should be difficult to see 2 Blow dust out of the system especially from fans and the main transformer 3 If voltage is low or near 0 VDC inspect wiring between the transformer s temperature sensor and J1 12 pins 1 and 2 on the control board Look for shorts between wires or to ground 4 If wiring is good the transformer has overheated Allow the power supply to idle with the fans running for a minimum of 30 minutes to cool the main transformer Chopper over temp at Chopper is indicating an over temp at power up power up 065
192. sumable parts see Install and inspect consumables on page 90 Short consumable life Causes can be Arc current arc voltage travel speed motion delay gas flow rates or initial torch height not set as specified in the Cut charts Attempting to cut highly magnetic metal plate such as armor plate with a high nickel content will shorten consumable life Long consumable life is difficult to achieve when cutting plate that is magnetized or becomes magnetized easily Beginning or ending the cut beyond the plate surface This draws the arc sideways and can damage the nozzle or shield To achieve consumable long life all cuts must begin and end on the plate surface Hand torch The torch does not cut completely through the workpiece The causes can be The cut speed is too fast The consumables are worn The metal being cut is too thick for the selected amperage Gouging consumables are installed instead of drag cutting consumables The work clamp is not attached properly to the workpiece The gas pressure or gas flow rate is too low MAXPRO200 Instruction Manual 807700 Revision 1 95 Operation Cut quality is poor The causes can be The metal being cut is too thick for the amperage The wrong consumables are being used gouging consumables are installed instead of drag cutting consumables for example Moving the torch too quickly or too slowly The arc sputters and consumables life is shorter than
193. supply gas hose kit 228862 The kit contains Part Number Description Length 046077 Tubing 1 4 inch OD blue 1 foot 046078 Tubing 1 4 inch OD black 1 foot 046231 Tubing 5 16 inch OD black 2 feet 173 MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Machine torches Straight torch Item Part Number Description Quantity 1 428024 Machine torch assembly with 2 0 inch mounting sleeve 1 228937 Machine torch assembly with 1 3 4 inch mounting sleeve 1 2 220943 Torch Mounting sleeve 2 inch 1 220942 Torch Mounting sleeve 1 3 4 inch 1 3 420087 Straight torch main body 1 4 044026 O ring 1 239 inch x 0 070 inch 2 5 220521 Water tube 1 Quick disconnect torch qi a a Number Description Quantity 1 428027 Quick disconnect torch assembly with 2 0 inch mounting sleeve 1 428028 Quick disconnect torch assembly with 1 3 4 inch mounting sleeve 1 2 220943 Torch Mounting sleeve 2 inch 1 220942 Torch Mounting sleeve 1 3 4 inch 1 3 420033 Quick disconnect torch receptacle 1 4 220921 Quick disconnect torch main body 1 5 044026 O ring 1 239 inch x 0 070 inch 2 6 220521 Water tube 1 174 MAXPRO200 Instruction Manual 807700 Revision 1 Leads and cables Machine torch leads Part Number 229477 229478 229479 229480 CNC cables Part Number 223327 223328 223329 223330
194. t icon and the error code number flashes in the 3 digit display Press and hold the current selection knob to see the power supply status number for both types of error code 4 Coolant flow When the coolant flow icon is selected the display shows the coolant flow in gallons per minute When you turn ON the power to the system and select the coolant flow icon before the power supply finishes the purge count the flow switch is overridden and coolant will continue to flow for 30 seconds 5 Test When test icon is selected the system is in test mode A number of functions can be accessed by turning the current selection knob See the maintenance section for detailed information 6 Plasma start lamp This white lamp illuminates when the plasma start signal is given and stays illuminated until the start signal is removed 7 Arc transfer lamp This green lamp illuminates when the arc transfers to the workpiece MAXPRO200 Instruction Manual 807700 Revision 1 127 Maintenance Diagnostic functions Press and release the current selection knob until the Test icon in the 3 digit display is selected Turn the current selection knob to access the functions shown in the table below The function activates when the function number appears in the 3 digit display Function Description 000 No function Gases will stop flowing if the system was in another test mode 001 Flow gas at set p
195. t out the heat exchanger with compressed air to clean off the fins Verify that the level of coolant is at the proper height Verify that the coolant mixture is correct 00 propylene glycol A mixture with a high percentage of propylene glycol will have a lower cooling capacity Change the consumables Older consumables emit more heat into the cooling loop Verify the pump Flow rate If it is less than 0 5 troubleshoot the low flow rate issue Replace the coolant temperature sensor if it is open or shorted Replacement part number is 229474 093 No coolant flow Coolant flow was below 1 9 lpm 0 5 gpm while the system was running or the coolant flow was below 1 7 lpm 0 45 gpm while cutting Verify that the level of coolant is at the proper level Verify that the coolant filter is in good condition replace if necessary The pump motor may have reached its internal thermal trip point Make sure the side panel is installed for proper airflow and that the heat exchanger fan is working properly Perform the coolant flow test See Coolant flow test on page 140 See corrective actions for the low coolant flow error 60 097 No Torch Found Torch or torch ID jumper missing or installed incorrectly 1 Verify that the torch connection by the I O panel CPC plug is good Verify the pin out on the torch lead connection 102 Current Sensor A Fault
196. ther protection Gouge a workpiece Note To choose the correct consumables see Hand held cutting and gouging consumable selection on page 87 1 Hold the torch so that the torch tip is within 1 5 mm 1 16 inch from the workpiece before firing the torch 2 Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip and the workpiece Press the trigger to obtain a pilot arc Transfer the arc to the work piece 3 Maintain an approximate 45 angle to the workpiece as you feed into the gouge Push the plasma arc in the direction of the gouge you want to create Keep a small distance between ANN the torch tip and the molten metal to avoid reducing WF consumable life or damaging the torch Note Changing torch s angle changes the dimensions of the gouge Feeding into the gouge 82 0200 Instruction Manual 807700 Revision 1 Operation Gouging techniques Straight gouging Weaving go MAXPRO200 Instruction Manual 807700 Revision 1 83 Operation Side gouging Weaving gouge 84 MAXPRO200 Instruction Manual 807700 Revision 1 Gouge profiles and metal removal rates Operation Operating parameters 1 Speed 635 to 1270 mm minute 25 to 50 ipm 2 Angle 35 to 45 degrees 3 Standoff 12 7 to 19 0 mm 0 5 to 0 75 inches Maximum arc stretch 76 mm 3 inches infrequent use not 100 duty cycle
197. tive except where it is widely recognized that there is no feasible alternative Declarations of RoHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm There is also a RoHS mark on the Powermax CE versions below the MAXPRO200 Instruction Manual 807700 Revision 1 Environmental Stewardship CE Marking on the data plate of CE versions of Powermax series units shipped since 2006 Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements Proper disposal of Hypertherm products Hypertherm plasma cutting systems like all electronic products may contain materials or components such as printed circuit boards that cannot be discarded with ordinary waste It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes the United States check all federal state and local laws European Union check the EU directives national and local laws For more information visit www hypertherm com weee other countries check national and local laws Consult with legal or other compliance experts when appropriate The WEEE directive On January 27 2003 the European Parliament
198. to the cutting table This must be a good clean connection because a poor connection may cause arc transfer problems 23 Complete the Preventive Maintenance worksheet on the next page for future reference 158 MAXPRO200 Instruction Manual 807700 Revision 1 Maintenance Preventive Maintenance Master Schedule Daily Verify proper inlet gas pressure Verify proper gas flow settings Mandatory at every consumable change Inspect torch and replace consumables as needed Weekly Week Jan Feb April May June July Aug Sept Oct Nov Dec 1 2 3 4 5 Clean power supply with dry oil free compressed air or vacuum Verify cooling fans are working properly Clean torch threads and current ring Verify proper coolant level Semi annually Year 1st Service 2nd Service Replace service parts per the Service part Replacement Schedule Annually Year Replace service parts per the Service Part Replacement Schedule MAXPRO200 Instruction Manual 807700 Revision 1 159 Maintenance Preventive Maintenance Protocol Checklist Location Contact Date Hypertherm system System Serial System arc hours if equipped with an hour meter Comments P Performed NP Not present on system Power supply P NP P NP P NP 1 U
199. to the illuminated fault icon When the fault icon is selected the error code appears in the 3 digit display If the error code is 60 or greater the system automatically selects the fault icon and the error code number flashes in the 3 digit display Press and hold the current selection knob to see the power supply status number for both types of error code 4 Coolant flow When the coolant flow icon is selected the display shows the coolant flow in gallons per minute When you turn ON the power to the system and select the coolant flow icon before the power supply finishes the purge count the flow switch is overridden and coolant will continue to flow for 30 seconds 5 Test When test icon is selected the system is in test mode A number of functions can be accessed by turning the current selection knob See the maintenance section for detailed information 6 Plasma start lamp This white lamp illuminates when the plasma start signal is given and stays illuminated until the start signal is removed 7 Arc transfer lamp This green lamp illuminates when the arc transfers to the workpiece MAXPRO200 Instruction Manual 807700 Revision 1 Operation Choosing a cutting process 1 Use the current selection knob to set the amperage Turning the knob slowly increases or decreases the current 1 amp at a time Turning the knob fast lets you jump quickly to the next process current 130A and 200A A
200. uce magnetic field hazards Keep both the work cable and the torch lead to one 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 Cutting with a plasma arc can exceed acceptable noise levels as defined by local codes in many applications Prolonged exposure to excessive noise can damage hearing Always wear proper ear protection when cutting or gouging unless sound pressure level measurements taken at the installed site have verified personal hearing protection is not necessary per relevant international regional and local codes Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation and or locating the workstation away from the plasma arc Implement administrative controls in the workplace to restrict access limit operator exposure time screen off noisy working areas and or take measures to reduce reverberation in working areas by putting up noise absorbers NOISE CAN DAMAGE HEARING Use ear protectors if the noise is disruptive or if there is a risk of hearing damage after all other engineering and administrative controls have been implemented If hearing protection is required wear only approved personal protective devices s
201. uch as ear muffs or ear plugs with a noise reduction rating appropriate for the situation Warn others in the area of possible noise hazards In addition ear protection can prevent hot splatter from entering the ear A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch 16 0200 Instruction Manual 807700 Revision 1 Safety At some sites dry dust can represent a potential explosion hazard The U S National Fire Protection Association s 2007 edition of NFPA standard 68 Explosion Protection by Deflagration Venting provides requirements for the design location installation maintenance and use of devices and systems to vent combustion gases and pressures after any deflagration event Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system Consult your local Authority Having Jurisdiction AHJ to determine whether any edition of NFPA 68 has been adopted by reference in your local building codes Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration AHJ adopted by reference the Kst value deflagration index and other terms MAXPRO200 Instruction Manual 807700 Revision
202. unplugged di ara Verify the electrical connection back to the control Coolant p ep y 9 board at J1 18 pins 6 7 10K ohm nominal the sensor is unplugged 1 Verify that the contactor is not welded shut or Current sensor and During the chopper test current was 2 Verify that there is no DC output on the I O board 400 Current sensor B current detected on channel A and on channel 1 from the Torch to Work connections If DC output with contactor off B when no current was expected is found replace the chopper 3 Verify that the LED for PWM is not active 1 Verify that the contactor is not welded shut or During the ch r test current wa ipid ON Current sensor A current 1119 chopper test 5 Verify that there is no DC output on the board 401 detected on channel A when with contactor off from the Torch to Work connections If DC output current was expected is found replace the chopper 3 Verify that the LED for PWM is not active 1 Verify that the contactor is not welded shut or During the chopper test current was always Current sensor B current 9 PP i 2 Verify that there is no DC output on the I O board 402 detected on channel B when with contactor off from the Torch to Work connections If DC output current was expected is found replace the chopper 3 Verify that the LED for PWM is not active Current sensor A and D ringthe chogper test c rentwas 1 Veri
203. upply 1 Power supplies Part number gt Voltage AC 078610 200 208 volt 078611 220 volt 078612 240 volt 078613 380 volt 078614 400 volt 078615 415 volt 078616 440 volt 078609 480 volt 078617 600 volt Item Part Number Description Quantity 1 See chart above Power supply 2 428033 Lift eye replacement kit 1 3 428031 Top panel replacement kit 1 4 027967 Handle side panels 2 5 428029 Right side panel replacement kit 1 6 101188 Front panel 1 7 428030 Left side not shown panel replacement kit 1 8 428032 Control panel replacement kit 1 1 Not shown 428035 166 Optional caster wheel kit MAXPRO200 Instruction Manual 807700 Revision 1 Power supply o L L lif l lt o 7 Item Part Number Description 1 141171 Control Board 2 110261 Label Warning instant start 3 010298 Label Warnings 4 011114 Air filter regulator 7 125 psi 1 4 inch auto drain with valve 011093 Air filter element 5 228862 Gas hoses kit not all hoses shown above 6 428038 Coolant filter replacement kit 027005 Coolant filter element 7 228861 Coolant hose kit not all hoses shown above 8 109377 Resistor 1 ohm 500 watts MAXPRO200 Instruction Manual 807700 Revision 1 Parts List Quantity 1 rrr 167 Parts List Power supply
204. uracy cost and optimum sample number Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated Where applicable Hypertherm also uses a third party industrial hygienist to obtain air and water permits If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site you should consult a local expert prior to purchasing installing and operating the equipment MAXPRO200 Instruction Manual 807700 Revision 1 Specifications System description General The MAXPRO200 plasma system is designed to cut a wide range of thicknesses of mild steel stainless steel and aluminum Power supply The power supply is a 200 A 165 VDC constant current supply It contains the circuitry to ignite a torch plus a heat exchanger and a pump to cool the chopper and torch The power supply has a discrete machine interface to provide communication with a CNC Ignition console The ignition console is attached to the outside of the rear panel of the power supply enclosure The ignition console uses a spark gap assembly The ignition console converts 120 VAC control voltage from the power supply into high frequency and high voltage pulses 9 10 kV to initiate the pilot arc at the torch electrode nozzle g
205. ure gas cylinders The high quality gas regulators listed below are available from Hypertherm and meet U S Compressed Gas Association CGA specifications In other countries select gas regulators that conform to national or local codes 2 stage regulator 1 stage regulator Part number Description 128544 Kit Oxygen 2 stage regulator 128548 Kit Oxygen 1 stage regulator for use with cryogenic liquid nitrogen or oxygen 022037 2 stage oxygen regulator Kit includes the 2 stage regulator 022037 and the appropriate fittings 72 MAXPRO200 Instruction Manual 807700 Revision 1 Installation Supply gas plumbing Rigid copper plumbing or suitable flexible hose may be used for all gas supplies Do not use steel black iron or aluminum pipe After installation pressurize the entire system and check for leaks Recommended hose diameters are 9 5 mm 3 8 in for lengths lt 23 m 75 ft and 12 5 mm 1 2 in for lengths gt 23 m 75 ft For flexible hose systems use a hose designed for inert gas to carry air or nitrogen See Supply gas hoses on page 74 for part numbers Caution Never use teflon tape Caution When connecting oxygen to the power supply make sure that all hoses hose connections and fittings are acceptable for use with oxygen Installation must be made in accordance with national and local codes Note When cutting with oxygen as the plasma gas air must also be connected
206. us The components shown here may differ from your system Gantry ground bus Ground rod Plasma system lead Remote high frequency RHF console CNC enclosure Torch holder Plasma system chassis NO 0 WN The following picture shows an example of a gantry ground bus It is bolted to the gantry close to the motor All of the individual ground cables from the components mounted on the gantry go to the bus A single heavy cable then goes from the gantry ground bus to the table ground bus 1 Cable to the cutting table ground bus 2 Ground cables from components on the gantry The following diagram shows an example of grounding the components in a plasma cutting system 46 MAXPRO200 Instruction Manual 807700 Revision 1 Installation oree ee OHE Chassis RFI ground AC earth and ground 1 Cutting table 7 RHF console not on all systems Connect to table ground bus bar 2 Gantry 8 9 System specific component such as metering console gas console or selection console 3 Plasma system 10 chassis 4 Table ground bus bar 11 Torch height control module ArcGlide CommandTHC 5 Gantry ground bus bar 12 System specific component such as a cooler or chiller 6 Torch height control lifter ArcGlide Sensor THC Sensor PHC or
207. ut charts were measured with a lead length of 30 5 meters 100 feet Adjustments to arc voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow 2 Ton sec 22 Pierce Height Dl 7 6 15 3 229 30 5 76m 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Leaq Lead Lead mm Volts mm mm Factor Seconds 0 5 112 1 5 8000 3 0 200 0 0 0 8 113 1 6 7750 3 2 200 0 0 1 0 114 1 8 7115 3 6 200 0 1 1 2 114 1 8 6350 3 6 200 0 1 62 63 63 63 39 42 45 47 1 5 115 1 8 5335 3 6 200 0 1 2 0 120 2 0 4200 40 200 0 1 2 5 123 2 0 3300 40 200 0 2 3 0 124 2 0 2800 4 0 200 0 3 4 0 125 2 2 2300 4 4 200 0 4 6 0 130 2 5 1400 5 0 200 0 5 English Plasma Cutflow Shield Cutflow e 4 scan Pierce Height Dolor 2bft 75ft 100ft 258 75ft 1008 Lead Lead Lead Lead Lead Lead Lead Lead Vole B Seconds 0 018 112 0 06 325 10 12 200 0 0 0 020 112 0 06 315 10 12 200 0 0 0 024 112 0 06 305 10 12 200 0 0 0 030 113 0 06 295 10 12 200 0 1 0 036 114 0 07 280 0 14 200 0 1 62 63 63 63 39 42 45 47 0 048 114 0 07 230 10 14 200 0 2 0 060 115 0 07 195 0 14 200 0 2 0 075 120 0 08 160 0 16 200 0 2 0 105 123 0 08 120 10 16 200 0 3 0 125 124 0 08 100 0 16 200 0 3 3
208. ve 67 548 EEC amp Directive 1999 45 EC 2 Hazards identification None None None None Preparation is not classified as hazardous in the sense of directive 1999 45 EC and 2006 121 EC Risk phrases Safety phrases Hazard statement s Precautionary statement s None None None None 3 Composition information on ingredients HAZARDOUS INGREDIENT 1 Propylene Glycol GHS Classification HAZARDOUS INGREDIENT 2 Benzotriazole GHS Classification WARNING W W CAS No EC No EC Classification 30 50 57 55 6 200 338 0 None Not classified None W W CAS No EC No EC Classification lt 1 0 95 14 7 202 394 1 Xn F Acute Tox 4 Oral Dermal Inhalation Eye Irrit 2 Aquatic Chronic H302 312 319 332 412 For full text of R phrases see section 16 For full text of H P phrases see section 16 Non hazardous components are not listed Inhalation Remove patient from exposure Skin contact Eye contact Ingestion Further medical treatment Combustible but not readily ignited Extinguishing media Unsuitable extinguishing media 198 4 First aid measures Unlikely to be hazardous by inhalation unless present as an aerosol Wash skin with water If substance has gotten into the eyes immediately wash out with plenty of water for several minutes Laxative Do not induce vomiting If swallowed seek medical advice immediately and show this container or label Unlikely to be required but if neces
209. vironmental Specification requires RoHS WEEE and REACH substance information to be provided by Hypertherm s suppliers Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user Any materials that are cut by the end user are not provided by Hypertherm with the product The end user is responsible for the materials being cut as well as for safety and air quality in the workplace The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations National and local environmental regulations National and local environmental regulations shall take precedence over any instructions contained in this manual The product shall be imported installed operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site The European Environmental regulations are discussed later in The WEEE Directive The RoHS directive Hypertherm is committed to complying with all applicable laws and regulations including the European Union Restriction of Hazardous Substances RoHS Directive that restricts the use of hazardous materials in electronics products Hypertherm exceeds RoHS Directive compliance obligations on a global basis Hypertherm continues to work toward the reduction of RoHS materials in our products which are subject to the RoHS Direc
210. voltage settings may be needed for shorter lead lengths Metric Plasma Cutflow Shield Cutflow 2 5 Pierce Height Dor 7 6 15 3 229 30 5 76m 15 3 22 9 30 5 m Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm min mm Factor Seconds 5 0 164 3 2 4770 6 4 200 0 5 6 0 165 3 2 4530 6 4 200 0 5 10 0 165 3 2 3930 6 4 200 0 5 12 0 164 3 2 3370 6 4 200 0 5 69 70 71 72 42 45 48 51 15 0 169 4 1 2620 8 1 200 0 8 20 0 179 5 1 1630 10 2 200 1 2 25 0 189 6 4 1050 32 0 198 6 4 500 Edge start 38 0 206 6 4 310 English Plasma Cutflow Shield Cutflow 1 elisa eight 2 Pierce Height Doky 25 ft 75ft 100 ft 25 ft 75 ft 100 ft z Lead Lead Lead Lead Lead Lead Lead Lead 3 16 165 0 13 190 10 25 200 0 5 1 4 165 0 13 175 10 25 200 0 5 3 8 165 0 13 160 0 25 200 0 5 1 2 164 0 13 125 0 25 200 0 5 69 70 71 79 49 45 48 1 5 8 171 0 16 95 0 32 200 0 8 3 4 177 0 19 70 0 38 200 1 0 7 8 183 0 25 50 0 45 180 1 5 1 190 0 25 40 1 1 4 198 0 25 20 Edge start 1 1 2 206 0 25 12 with IHS tab without IHS tab 0200 Instruction Manual 807700 Revision 1 117 Operation 118 0200 Instruction Manual 807700 Revision 1 Maintenance Introduction Hypertherm assumes that the s
211. xpected 4 Verify that the 10 Ohm resistor on the I O board is sensor B during chopper tesi not damaged 5 Disconnect any exterior equipment from the Board Example Arc Voltage connection 6 Replace the chopper 1 Verify the output voltage from the contactor 2 Verify the DC voltage on Chopper i t on the f h With cho DOSE Bot US 3 ad the DC output on the I O board for urrent on Current No current was detected on channel A 409 E 4 Verify that the 10 Ohm resistor on the I O board is sensor A during chopper when current was expected iest not damaged 5 Disconnect any exterior equipment from the I O Board Example Arc Voltage connection 6 Replace the chopper 1 Verify the output voltage from the contactor 2 Verify the DC voltage on Chopper i t on the 1 f h With choppers active no 3 the DC output on the I O board for eac current on Current No current was detected on channel B test 410 4 Verify that the 10 Ohm resistor on the I O board is sensor B during chopper when current was expected es not damaged 5 Disconnect any exterior equipment from the I O Board Example Arc Voltage connection 6 Replace the chopper Current detected for longer than expected on Current on channel A and channel Verify that the surge circuit on the I O board is 411 2n Current sensor and did not return to O as expected functioning properly Current sensor B Current
212. ycle through the functions in the 3 digit display area current fault coolant flow and test three displays show actual values during cutting The user can make changes to the current the plasma gas and the shield gas settings unless the inputs have been locked out or the system is being controlled remotely The displays show the set values when idle blinking red dot appears in the bottom right corner of each display when the parameters have been changed from the default setting MAXPRO200 Instruction Manual 807700 Revision 1 77 Operation 3 digit display functions Turn the current selection knob to increase or decrease the amperage Push and release the current selection knob to move from one function to the next 78 3 digit display icons Name Description 1 Remote The remote icon illuminates when there is serial communication with the power supply You can still cycle through the functions but cut parameters can only be changed through the CNC 2 Amps Increase or decrease the amperage by selecting the amps icon and turning the knob The current increases or decreases in 1 amp increments when you turn the knob slowly You can jump from one process amperage to another when you turn the knob quickly 3 Fault The fault icon illuminates when an error occurs If the error code number is 60 or less press the current selection knob to navigate
213. ystem determine what coolant mix is correct for your operating conditions Observe the warning and cautions below Refer to the Material Safety Data Sheets appendix for data on safety handling and storage of propylene glycol and benzotriazole WARNING COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF SWALLOWED Propylene glycol and benzotriazole are irritating to skin and eyes and harmful or fatal if swallowed Upon contact flush skin or eyes with water If swallowed seek immediate medical attention Never use automotive antifreeze in place of propylene glycol Antifreeze contains corrosion inhibitors that will damage the torch coolant system Always use purified water in the coolant mixture to prevent damage to the pump and corrosion in the torch coolant system Premixed coolant for standard operating temperatures Use Hypertherm premixed coolant 028872 when operating in a temperature range of 12 C to 40 C 10 F to 104 F Refer to the custom coolant mix recommendations if temperatures during operation are ever outside of this range Hypertherm premixed coolant consists of 69 8 water 30 propylene glycol and 0 2 benzotriazole MAXPRO200 Instruction Manual 807700 Revision 1 63 Installation Custom Coolant mix for cold operating temperatures below 12 C 10 F CAUTION For operating temperatures colder than the temperature stated above the percentage of propylene glycol must be increased
214. ystem will advance to state 2 Gas purge if there are no high priority errors See Error codes on page 127 If a high priority error is generated the system will go to state number 13 Shutdown MAXPRO200 Instruction Manual 807700 Revision 1 121 Maintenance Gas purge status 02 1 System turns on the plasma and shield gases System counts the time in seconds and this is displayed on the 3 digit current display System turns on the coolant pump After six seconds the system will verify the coolant flow is greater than the minimum value If the coolant flow is above the minimum the system will do a high power test on the chopper Note the system is live at this time The system is applying power to the torch even though no arc will be present at the torch Chopper LEM Test a Main contactor closed IGBTs on If there is no current on channel the system will generate error code 409 fthere is no current on channel B the system will generate error code 410 If there is no current on both channels the system will generate error code 408 b Main contactor closed IGBTs on f channel A current does not go to 0 the system will generate error code 41 1 f channel B current does not go to O the system will generate error code 412 fthe current on both channels does not go to the system will generate error code 413 c Main contactor closed IGBTs on Channel A current detected on channel B input the system will ge

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MAXPRO200® - Powermax 105