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Operator Manual - Dep SAE Soudage, Automatismes et

1. ee e go Y s LS nijperiner S 7 ES powermax 1100 c j t j LI 5 19 6 3 3 19 6 498 mm d d Hs TE 498 mm C ELE szi Se C 5 S S LL Figure 2 2 Powermax1100 Power Supply Dimensions PAC135 80A TORCHES Maximum 80A Cutting Capacity PAC135T 1 25 mm 50 duty cycle Recommended 80A Cutting Capacity PAC135T 3 4 20 mm 100 duty cycle Maximum 80A Cutting Capacity PAC135M 1 2 12 mm 50 duty cycle Recommended 80A Cutting Capacity PAC135M 3 8 9 5 mm 100 duty cycle Maximum current at 50 duty cycle 80 amps Gas F OW EE 400 scfh 6 7 scfm at 65 psi 189 l min at 4 5 bar Gouging Capability metal removal rate 6 6 pounds 3 0 kg hr Weight PACTS eee 9 3 pounds 4 2 kg with 25 ft 7 6 m lead 17 8 pounds 8 1 kg with 50 ft 15 m lead Weight PAC135M Sess d Ib SUR 9 6 pounds 4 4 kg with 25 ft 7 6 m lead 18 pounds 8 2
2. a olj p E gt Figure 5 2 Air Filter Removal 4 Clean the air filter with either soap and water or with low pressure compressed air 5 Replace the dry filter in the power unit with the wire mesh facing the fan 6 Replace and refasten the power supply cover s screws powermax1100 Operator Manual 5 3 MAINTENANCE PaRTS BASIC TROUBLESHOOTING GAS s TEMP PRESSURE Problem 1 The ON OFF power switch is set to I ON but the fan does not operate and the POWER ON LED is not illuminated 2 The POWER ON LED is illuminated but the GAS PRESSURE LED is not illuminated 3 The POWER ON LED is illuminated and the LINE VOLTAGE LED is illuminated mmm 9 J ON OFF Power Switch Ss LJ Cause Solutio 1 1 The power cord is not plugged into the power receptacle Plug in the power supply 1 2 The disconnect power switch is not set to ON or there is no power available to the disconnect power switch box Turn the power ON at the main power panel or at the disconnect power switch box 2 1 The gas supply is turned OFF or not connected to the power supply Verify that the gas is turned on and connected to the power supply 2 2 Gas pressure is too low Set gas supply pressure to 90 psi 6 2 bar Verify that there are no leaks in the gas supply line 3 1
3. 3 2 Hoisting e RE EE 3 3 Voltage Gonfig ratonS E 3 4 Power Cords 208 240 480V 200 230 400V and 600V Power Supplies 3 5 Power Cords 230 400V CE Power Supplies sss see 3 6 Changing the Strain Relief Sleeve es 3 6 Single Phase and Three Phase Power Configurations 3 7 lie Un 3 7 TREC S nH 3 7 Power Cord PIUGS EE 3 8 Power Requirements EE 3 8 Line Voltage Disconnect BOX E 3 8 Grounding WE e UU En CN 3 8 Work ereis e Te 3 9 Gas Supply Requirements E 3 9 AIP SUD DIY QUAI EE 3 9 Additional Air Filtration sss eee eee eee MORE RARE eaters ate ca ular details 3 10 Nitrogen Supply Quality EE 3 10 Gas leede o S 3 10 Torch Lead Connection EE 3 11 PAC135M ON OFF Pendant Connection 3 11 PAC135M Torch ON OFF Switch Connection Data 3 11 PACTS SIM TORCH Re lu E 3 11 Machine Interface with PAC135M sse 3 12 Lele d PEE RR 3 13 powermax1100 Operator Manual 3 1 SETUP UPON RECEIPT 1 Verifythatallparts anditems on your order have been received Alert your distributor if any parts or items are damaged or missing 2 Inspectthe power supply for any physical damage that may have occurred during shipping If there is evidence of damage refer tothe Claims section below All communications regarding this equipment must include the model number and serial number located on the back of the Powermax1100 3 Before setting up and operatin
4. Weight 208 240 480V and 200 230 400V without power Cord rp Weight 230 400V CE with power cord Weight 600V with power cord powerimaxt100 Operator Manual SPECIFICATIONS 280 320 VDC 30 80 amps 140 VDC 50 1 280A U 140V 100 1 57A U 140V See data tag on power supply for more information on duty cycle Power supplies will operate between 14 and 104 F 10 and 40 C 19 2 kVA U 1 non CE power supplies 13 1 kVA U 1 CE power supplies 208V 92A 240V 80A 480V 40A 16 50 60 Hz 208V 53A 240V 46A 480V 23A 36 50 60 Hz 200V 96A 230V 84A 400V 48A 16 50 60 Hz 200V 56A 230V 49A 400V 28A 36 50 60 Hz 230V 33A 400V 19A CE 36 50 60 Hz 600V 20A 36 60 Hz Air or Nitrogen Clean dry oil free 99 995 pure 90 psi 6 2 bar 400 scfh 6 7 scfm at 90 psi 189 l min at 6 2 bar supplied to power supply pressure regulator 65 psi 4 5 bar flowing 25 1 638 mm 10 4 264 mm without wheels 15 8 401 mm with wheels 19 6 498 mm without wheels 23 7 602 mm with wheels 77 pounds 35 kg without wheels 89 pounds 40 kg with wheels 87 pounds 39 kg without wheels 99 pounds 45 kg with wheels 160 pounds 73 kg with wheels SPECIFICATIONS 10 4 25 1 264 mm 638 mm SESCH A eee
5. B T Gem d y CH UNS 773 Ann 1 Figure 5 5 PAC135M Torch Assembly and Leads powermaxt100 Operator Manual SA MAINTENANCE PARTS Powermax1100 Field Upgrade Kits and Optional Parts Part Number Description 028714 sssssssss On Off Pendant with Lead 25 ft 7 6 m Also comes standard with most machine torch system configurations 128061 On Off Pendant with Lead 50 ft 15 2 m 128002 te E On Off Pendant with Lead 75 ft 23 m 128142 ti Dn tec Kit Wheels Powermax1 100 128149 ciatis Kit Pilot Arc Controller Powermax1 100 128144 iisoesessssrsennensssesns Kit Machine Interface Powermax1100 208 240 480V 128168 egen neret Kit Machine Interface Powermax1100 200 230 400V 1281609 NEEN Kit Machine Interface Powermax1100 230 400V CE EE Kit Work Cable 50 ft 15 2 m Powermax1100 EE Kit Cooling Air Filter Powermax1100 128147 etre Kit 600V Conversion Powermax1 100 TTOYZS9 is orici ies aa cat eee Filter Element Gas Supply Filter ENEE Jumper Powermax1100 Link Box 023206 eege dree Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits 109068 sss Toroid for power cord ground Powermax1 100 CE power supplies only 002282 iacit tenet Strain Relief Sleeve 0 875 002283 sss Strain Relief Sleeve 0 750 002286 n cR etin Strain Relief Sleeve 0 6
6. 3 See the Powermax1100 service manual for wiring diagrams higher level troubleshooting and more parts list information powermax1100 Operator Manual 5 7 MAINTENANCE PARTS PARTS PAC135 Consumable Parts Shielded 80A 40A Machine Shield Retaining Cap Nozzle 120516 120483 80A 120476 80A NS GES EE Electrode Swirl Ring E 120473 120474 120475 120520 40A 120515 40A 1 Hand Shield C Retaining Cap Nozzle nie Extended Deflector Retaining Cap Nozzle Electrode 120519 120483 120518 120517 Gouging Shield Retaining Cap Nozzle Electrode 120510 120483 120509 120473 l Figure 5 3 PAC135 Consumable Parts See page 4 7 for a description of the consumable parts 5 8 powermax1100 Operator Manual MAINTENANCE PARTS Consumable Parts Kits Hand Consumable Parts Kit 128148 Part Number Description 120473 Electrode PAC135 120517 Electrode PAC135 Extended Nozzle PAC135 80A Nozzle PAC135 Gouging 120518 Nozzle PAC135 Extended 120475 Shield PAC135 Hand 120510 Shield PAC135 Gouging Deflector PAC135 O Ring 864 X 070 Lubricant Silicone 1 4 Oz Tube Electrode Wrench PAC135 Nipple 1 8 NPT QDisc Steel Bushing Reducer 1 4 X 1 8 Brass Box Consumable Parts Description Electrode PAC135 Shield PAC135 Machine Nozzle PAC135 80A Nozzle PAC135 40A Cap PAC135 40A O Ring 864 X 070 Lubricant Silicone 1 4 Oz Tube Elec
7. In other countries follow appropriate local or national safety procedures Single Phase Remove the rear panel Fig 3 2 and connect the power cable to contactor as shown in Fig 3 9 Connect the ground wire to the stud marked G i Black Line U Black or Brown Neutral Line V White or Blue White Ground Green or Green Yellow Green Figure 3 9 Single Phase Power Three Phase Remove the rear panel Fig 3 2 and connect the power cable to the contactor as shown in Fig 3 10 Connect the ground wire to the stud marked ei Brown or Black T N Brown Blue or White KS Blue Black or Red WMA Green Yellow or Green SZ CN L Black Figure 3 10 Three Phase Power powermax1100 Operator Manual 3 7 SETUP POWER CORD PLUGS The user must obtain a power cord plug that is certified by national or local electrical codes The plug should be connected to the power cord by a licensed electrician POWER REQUIREMENTS Line Voltage Disconnect Box Use a separate line disconnect box for each power supply This disconnect box allows the operator to turn the power supply off quickly in an emergency situation The switch should be located near the power supply and should be easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses according to the power requirements listed below Input Input Curr
8. Voltage Current 3m 3 7 5m 7 5 15m 15 30m 30 45m 25 25 25 35 35 7 5 178 mm 5 140 mm 10 d Ground KO Figure 3 6 Power Cord Stripping for 208 240 480V and 200 230 400V Power Supplies powermax1100 Operator Manual 3 5 SETUP POWER CORDS 230 400V CE POWER SUPPLIES The 230 400V CE power supply is shipped with a power cord If the three phase power cord length needs to be changed use the table below to choose the proper wire size for the appropriate length Use a 4 conductor HAR type cord Strip the power cord wires as shown in Fig 3 7 Cap or tin conductor leads and use a 10 terminal on the ground wire The cord should be installed only by a licensed electrician Recommended Power Cord Wire Size mm Voltage Current 3 7 5m 7 5 15m 15 30m 30 45m 6 6 230 VAC 33A 400 VAC 19A 4 4 7 5 178 mm 5 140 mm a L1 L2 F L3 10 Ground O Wind the ground wire 8 turns around the toroid Figure 3 7 Power Cord Stripping 230 400V CE Power Supplies CHANGING THE STRAIN RELIEF SLEEVE Depending on the diameter of the power cord you choose the rear panel strain relief sleeve may need to be changed Alternate sleeves are located on the floor of the power supply behind the rear panel To choose the correct
9. Bowl Draining and Filter Element Cleaning eee eee eee eee ee 5 2 Removal Cleaning and Replacement of the Cooling Air Filter 5 3 Basic Troubleshooting caute tid a deo emu a batur ess 5 4 Technical ell EE 5 7 GC 5 8 PACT35 Gons mable Parts T 5 8 Consumable Parts ee Ee 5 9 PACASST Torch nle U Se de E Se eo Read 5 10 PAGTSSM TON Ee EE 5 11 Powermax1100 Field Upgrade Kits and Optional Parts 5 12 Power Supplies 208 240 480V see 5 12 Power Supplies 200 230 400V ee 5 12 Power Supplies 230 400V UE i sese 5 12 powermax1100 Operator Manual 5 1 MAINTENANCE PARTS INTRODUCTION This section contains information for simple maintenance and troubleshooting A brief parts list is also included For higher level troubleshooting see Technical Questions later in this section ROUTINE MAINTENANCE Bowl Draining and Filter Element Cleaning Moisture in the torch can cause the torch to sputter and hiss If moisture is present purge the gas lines If moisture builds up in the bowl of the filter drain the bowl and clean the filter element 1 Shut off the gas supply and disconnect the gas supply hose from the filter assembly before proceeding 2 Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl Gas supply hose connection Filter element Filter Bowl Cap Figure 5 1 Filter Assembly 3 Unscrew the filter
10. Remove the screws that attach Powermax1100 cover to the chassis Remove the cover 3 Pushthecable through the strain relief at the rear of Powermax1 100 Strain Relief arc voltage cable U J tey Figure 3 16 Location of Arc Voltage Cable Strain Relief 4 Route the cable to the machine interface board located on the top of the power supply near the Powermax1 100 control board Connect the arc voltage cable as shown in Fig 3 17 Tighten the strainrelief J lonas ARC VOLTAGE torch height control START Output ull arc voltage XFER 300 VDC maximum Signal not available on rear panel connector ARC J1 VOLTAGE Figure 3 17 Machine Interface Board Connections for Arc Voltage powermax1100 Operator Manual 3 13 Section 4 OPERATION In this section Controls and Indicators see 4 2 Operating INSMACHONS T 4 3 Pilot Arc Eer 4 4 PAC135T Safety Trigger Operation 4 5 Operating TIDS EE 4 6 Changing Consumable Palris oie i e seni ign 4 6 Nigro eeepc 4 8 Selle ce 4 10 Sele lle rM ED EE 4 11 Cut Chart 80A Standard Consumables sss 4 12 Cut Chart 40A Consumables eee eee eee 4 13 COMMON g Doder EE E 4 14 powermax1100 Operator Manual 4 1 OPERATION CONTROLS AND INDICATORS Green POWER ON LED When illuminated indicates that all control circuits are activated the torch safety interlock is satisfied an
11. U K 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 France 10 All e de l Isara F 95000 Cergy Pontoise France Tel 33 1 34 24 03 05 Fax 33 1 34 25 09 64 Italy Via Torino 2 20123 Milan Italy Tel 39 02 725 46 312 Fax 39 02 725 46 400 EMC INTRODUCTION The 230 400V CE power supply has been built in compliance with standard EN50199 To ensure that the eguipment works in a compatible manner with other radio and electronic systems the eguipment should be installed and usedin accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 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 plasma equipment should be used only in an industrial environment It may be difficult to ensure electromagnetic compatibility in a domestic environment INSTALLATION AND USE The user is responsible 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
12. bowl 4 Unscrew the filter element 5 Clean the filter element with alcohol then blow it out with air Clean the bowl with household soap only 6 Replace the filter element and filter bowl 7 Reconnect the gas supply hose 5 2 powermax1100 Operator Manual MAINTENANCE PARTS Removal Cleaning and Replacement of the Cooling Air Filter Powermax1100 systems are normally shipped without an air filter If your Powermax1100 has the air filter option the filter will need cleaning periodically Excessively dirty or dusty environments can block the filter if installed and cause the power supply to overheat and shut down A A SHOCK HAZARD Always turn off the power unplug the cord and wait 5 minutes before removing any power supply cover If the power supply is directly connected to a line disconnect switch place switch in the OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures 1 Turn the Powermax1100 power switch to the OFF 0 position unplug the power cord or turn off the wall receptacle and disconnect the gas supply 2 Remove the screws that secure the power supply cover to the chassis 3 Remove the cover and remove the cooling air filter from the clips by sliding the filter to the left and then up
13. kg with 50 ft 15 m lead 2 4 powermax1100 Operator Manual SPECIFICATIONS PAC135T Hand Torch Assembly 9 1 231 mm TOT DA mm nasi il D mm o pM LU 3 5 89 mm Pee BCE 30 mm Figure 2 3 PAC135T Torch with Dimensions PAC135M Machine Torch Assembly m 14 356 mm 3 3 I 88mm 10 8 g 274 mm 18 45 mm 1 2 IT 30mm 35 mm 55 Figure 2 4 PAC135M Torch with Dimensions S MARK The Powermax1100 conforms to C standard EN50192 The mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The hand torches must have shielded consumable parts to maintain mark compliance powermax1100 Operator Manual 2 5 SPECIFICATIONS IEC SYMBOLS USED Direct Current DC AV Alternating current AC H Plasma cutting torch JD AC input power connection The terminal for the external protective earth conductor Lax HHF An inverter based power source N JE Anode work clamp Temperature switch ee Pressure switch M Plasma torch in the TEST position cooling and cutting gas exiting nozzle I Power is on O Power is off h Volt amp curve drooping characteristic 2 6 powermax1100 Operator Manual Section 3 SETUP In this section Upon si e dit aec So am E DU UD RN ema els SE 3 2 I IC
14. see Earthing of Workpiece 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 a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment ELECTROMAGNETIC COMPATIBILITY 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 the 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 Ma
15. supplies that have the machine interface option a WARNING A Do not connect the cutting machine interface START signal if using an ON OFF pendant e Plug the machine interface cable into the connector on the rear panel and connect the machine interface cable to the cutting machine Signal START start plasma XFER start machine motion Output Normally open 24 VAC open circuit voltage Normally open Dry contact closure when arc at START terminals transfers 120 VAC maximum at machine Requires dry contact closure to activate interface relay or switching device Rear pane sockets 3 4 12 14 Green Black Red Black Figure 3 15 Machine Interface Cable 023206 and Signals 3 12 powermax1100 Operator Manual SETUP Arc Voltage If arc voltage is necessary for activating a torch height control the customer must supply an 18 AWG single pair unshielded cable rated for 300V or greater The arc voltage signal should be connected only by qualified service personnel A ns SHOCK HAZARD Always turn off the power unplug the cord and wait 5 minutes before removing any power supply cover If the power supply is directly connected to a line disconnect switch place switch in the OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures 1 Disconnect power from Powermax1100 2
16. 2 Pr vention deS INCENCIES Ne 1a 2 Pr vention des chocs lectriques ss 1a 2 Prevention des asla lal 1a 3 Protection contre le DAUM m e 1a 4 Mise alamasse el a Br nada annee 1a 4 Rappels de SENTE MIT n 1a 4 Proth ses GEREEST aed 1a 4 SECTION 2 SPECIFICATIONS E 2 1 rigare le e MER ienne U 2 2 SPSCHICALON Pope 2 3 PAG 139 BUA TOICIISS cabrio ana awesome EN 2 4 IEC Symbols Used EE 2 6 powermax1100 Operator Manual iii TABLE OF CONTENTS SECTION d E AE 3 1 ele EE 3 2 E T 3 2 Hoisting MEQUIFEMGING T 3 3 Voltage ene TE TEE 3 4 Power Cords 208 240 480V 200 230 400V and 600V Power Supplies 3 5 Power Cords 230 400V CE Power Supplies sisi 3 6 Changing the Strain Relief Sleeve sise 3 6 Single Phase and Three Phase Power Configurations 3 7 SeU eT eals PUGS MER EOD 3 8 Power Requirements EE 3 8 Grounding Heouirementa EE 3 8 Work Cable and Clamp EE 3 9 Gas Supply Req irementS EE 3 9 Gas Supply Le EE 3 10 Torch Lead C nneCtioN NER PC 3 11 Machine Interface with PAC135M eee 3 12 SECTION 4 e j5 Me e 4 1 Contr ls and nie e EE 4 2 EI Eileen EE 4 3 Operating H 4 6 Cut Chart 80A Standard Consumables sese 4 12 Cut Chart 40A EE EE 4 13 Common C tNg Pellis T 4 14 SECTION 5 MAINTENANCE PARTS cesses ss
17. 25 Shipped in CE power supply rear panels Note Field upgrade kits must be installed by qualified service personnel POWER SUPPLIES 208 240 480V 10 30 50 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 085000 Hand No No 085012 Hand Yes No 085013 Machine No Yes 085014 Machine Yes Yes POWER SUPPLIES 200 230 400V 10 30 50 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 085002 Hand No No 085034 Hand Yes No 085035 Machine No Yes 085036 Machine Yes Yes POWER SUPPLIES 230 400V CE 30 50 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 085003 Hand No No 085023 Hand Yes No 085025 Machine No Yes 085024 Machine Yes Yes Note Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations 5 12 powermax1100 Operator Manual APPENDIX A STANDARDS INDEX STANDARDS INDEX The Standards Index contains a list of publications dealing with plasma arc cutting equipment safety practices 1 11 12 13 14 16 ANSI Standard 249 1 Safety in Welding and Cutting obtainable from the American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 NIOSH Safety and Health in Arc Welding and Gas Welding and Cutting obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 OSHA Safety and Health Standards 29FR 1910 ob
18. 50 Up to 100 A No 8 No 11 100 200 A No 10 No 11 12 200 400 A OH No 12 No 13 Over 400 A No 14 No 14 Replace the glasses goggles or helmet when the lens becomes pitted or broken Warn other people in the area not to look directly at the arc unless they are wearing glasses goggles or a helmet Prepare the cutting area in a manner that reduces the reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection nstall protective screens or curtains to reduce ultraviolet transmission Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing which covers all exposed areas Ouffless trousers to prevent entry of sparks and slag Toxic Fume Prevention Keep the cutting area well ventilated Remove all chlorinated solvents from the cutting area before cutting Certain chlorinated solvents decompose when exposed to ultraviolet radiation to form phosgene gas Wear proper breathing mask and use proper ventilation when cutting galvanized metal Do not cut containers with toxic materials inside Clean containers that have held toxic materials thoroughly before cutting WARNING Toxic Fumes Do not cut metal or painted metals containing zinc lead cadmium or beryllium unless the operator or anyone else subjected to
19. ANCE PARTS PAC135M Torch Assembly and 14 ft 4 3 m Lead 085062 PAC135M Torch Assembly and 25 ft 7 6 m Lead 085063 PAC135M Torch Assembly and 35 ft 10 6 m Lead 085064 PAC135M Torch Assembly and 50 ft 15 2 m Lead 085065 Index No Part No Description Qty 1 020243 Sleeve Torch Position 1 2 129240 Torch Lead 14 ft 4 3 m 1 2 129241 Torch Lead 25 ft 7 6 m 1 2 129242 Torch Lead 35 ft 10 6 m 1 2 129243 Torch Lead 50 ft 15 2 m 1 3 128122 antenne Plug Assembly PAC135 Torch Quick Disconnect 1 4 008268 Plug 3 Socket Female 1 5 108034 Receptacle Housing 2 Position 26 22AWG 1 120473 Electrode 1 120474 Ring Swirl 1 120516 Shield PAC135M Machine Torch 1 120476 Nozzle PAC135 80A Shield 1 120483 Cap Retaining 1 6 120508 Torch Main Body PAC135M 1 T 026020 O Ring Silicon 864 X 070 1 8 108035 Pin Housing 2 Position 26 22AWG 1 9 108040 Contact PAC135M Cap On Sensor Switch 1 10 046056 Tubing 5 8 ID 4 11 046072 Heatshrink 1 2 ID 2 9 Used only in 085062 assembly Used only in 085064 assembly Used only in 085063 assembly Used only in 085065 assembly Note See page 5 8 for detail of consumable parts Wh s
20. ENT Risque d explosion Argon hydrog ne et m thane L hydrog ne et le m thane sont des gaz inflammables et potentiellement explosifs Conserver l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de m thane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasma d argon hydrog ne ou de m thane AVERTISSEMENT D tonation de l hydrog ne lors du coupage de l aluminium Lors du coupage de l aluminium sous l eau ou si l eau touche la partie inf rieure de la pi ce d aluminium de l hydrog ne libre peut s accumuler sous la pi ce couper et d tonner lors du coupage plasma e Installer un collecteur d a ration au fond de la table eau afin d liminer les risques de d tonation de l hydrog ne Se r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration HYPERTHERM Syst mes plasma 1a 1 10 6 98 S CURIT Y e z AN LES CHOCS ELECTRIQUES PEUVENT ETRE FATALS Toucher une pi ce lectrique sous tension peut provoquer Installer et mettre la terre l quipement selon les un choc lectrique fatal ou des br lures graves instructions du pr sent manuel et conform ment aux La mise en fonctionnement du syst me plasma ferme un codes lectriques locaux et nationaux circuit lectrique entre la torche et la pi ce couper La e Inspecter fr quemment le cordon d alimentation prim
21. Power supply voltage links are incorrect See voltage configuration settings in Section 3 3 2 Line voltage is too low The following table represents the operating range of the Powermax1 100 power supplies Have an electrical technician check incoming power powermax 1100 Operator Manual Problem 4 The power supply shuts off immediately after it is switched on 5 The power supply shuts off approximately 5 seconds after it is switched on 6 The fuse on the incoming power line fails during cutting 7 The POWER ON LED is illuminated the TEMP LED stays illuminated and the torch will not fire powermax1100 Operator Manual MAINTENANCE PARTS Cause Solution Note When the power supply operates at the Lower Limit the line voltage LED will illuminate and the power supply will function with some performance degradation At 20 of the System Line Voltage the line voltage LED will illuminate but the torch will not function To avoid performance deterioration the input voltage should be within 10 of the System Line Voltage System Lower Limit Line Voltage Upper Limit 170VAC 200VAC 235VAC 178VAC 208VAC 239VAC 195VAC 230VAC 270VAC 204VAC 240VAC 276VAC 340VAC 400VAC 470VAC 408VAC 480VAC 552VAC 510VAC 600VAC 690VAC 4 1 The retaining cap is loose Tighten the retaining cap 4 2 The torch is defective See Technical Questions on page 5 7 5 1 Power supply voltage links are incorrect See voltage configura
22. RODUCTS MANUFACTURED BY IT OR OTHERS INCLUDING WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE EITHER EXPRESS OR IMPLIED EXCEPT AS PROVIDED HEREIN This warranty is in lieu of any and all warranties express or implied by law or otherwise and Distributors are not authorized to give any other warranty purporting to be binding upon HYPERTHERM upon resale of Products to their customers IN NO EVENT shall HYPERTHERM be liable for incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any Equipment sold hereunder ii powermaxt100 Operator Manual TABLE OF CONTENTS ELECTROMAGNETIC COMPATIBILITY sisiiicicctcsnsnannanesotewcutvisvsisvsrssasesasestinnucncuewstewwecnswnnunnnmciins i WARRANTY ii SECTION SAG WE 1 1 About Notes Cautions amp E e e GC 1 2 Safety INS T GN M TTT 1 2 Eye S ee el 1 2 Sdn eiee 1 2 Toxic Fume FEV e EE 1 2 Fire ZT Te T 1 2 Electric Shock Prevention E 1 2 Edel endi OM E 1 3 Kiel e REE eee ee E O EERE 1 4 ET OUINIG AG TT 1 4 Safety Reminders geseet AER RAEE 1 4 Electronic Health Support Equipment ssh 1 4 SECTION 1A S CURIT 2 a men 1a 1 Au sujet des Notes Attention et avertissement 1a 1 Consignes dE ee P 1a 2 Protection deS TT E 1a 2 ge de Re ET EE 1a 2 Prevention des vapeurs T XI J G S vave niae ases 29 ceog sv t EvE olea pa aE Vd AD AMOR M scis 1a
23. 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 WARRANTY A WARNING A Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty GENERAL HYPERTHERM Inc warrants that Products shall be free from defects in materials and workmanship under proper and normal use for which such Equipment is recommended for a period of two 2 years except only with respect to the Torch for which the warranty period shall be one 1 year from the date of its delivery to you HYPERTHERM at its sole option shall repair replace or adjust free of charge any Products covered by this warranty which shall be returned with HYPERTHERM s prior authorization which shall not be unreasonably withheld properly packed to HYPERTHERM Ss place of business in Hanover New Hampshire all costs insurance and freight prepaid and which examination proves not to be free from defects in materials and workmanship HYPERTHERM shall not be liable for any repairs replace ments or adjustments of Products covered by this warranty except those made pursuant to this para graph or with HYPERTHERM s written consent This
24. The TEMP LED will remain extinguished GAS TEST POWER ON AMPS PRESSURE GAUGE REGULATOR REGULATOR CAP Figure 4 2 Powermax1100 Operating Indicators and Adjustments 4 Adjust the gas pressure REGULATOR to 65 psi 4 5 bar e Pull the REGULATOR CAP out Push the GAS TEST switch in e Turn the REGULATOR CAP while still pushing in the GAS TEST switch e After adjusting to 65 psi 4 5 bar release the GAS TEST switch e Push the REGULATOR CAP back in Note If using 50 ft 15 2 m torch leads adjust the pressure to 70 psi 4 8 bar 5 Adjust the AMPS knob to the desired setting See Cut Chart later in this section if necessary powermax1100 Operator Manual 4 3 OPERATION 6 Attach the work clamp securely to the workpiece Do not attach it to the portion that will fall away Figure 4 3 Proper Work Clamp Connection WARNING The PAC135 torches are contact start torches that produce a plasma arc immedi ately after the torch start switch closes Always hold the hand torch away from your body as a precaution against accidental torch firing Be aware of this haz ardous potential Failure to do so can result in serious bodily injury 7 The Powermax1100 is now ready to operate When you are ready to cut place the tip of the torch at the edge of the workpiece Pull back on the trigger switch to start the arc See PAC135T Safety Trigger Operation later in this section for proper operation of the safety trigger To begin c
25. air or shop air can be used as long as it is clean dry and oil free When properly set and maintained the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality The Powermax1100 can also cut with nitrogen when extended electrode life is a priority This instruction manual provides information for the user to set up and operate the system and perform limited maintenance on the power supply This manual also provides a detailed list of safety practices so that the system can be safely operated and maintained READ THE SAFETY SECTION Section 1 FIRST The Powermax1100 service manual provides higher level troubleshooting and a more complete parts list Figure 2 1 Powermax1100 Hand Plasma Cutting System 2 2 powermax1100 Operator Manual SPECIFICATIONS Power Supply Rated Open Circuit Voltage OCV UJ Rated Output Current D Rated Output Voltage U Duty Cycle X 104 F 40 C Ambient temperature s Apparent Input Power S Input Voltage U Input Current 1 112 kw OUWOUL eee EE une ER Gas Quality Alt sss ite tente Gas Quality Nitrogen Gas Inlet Pressure Gas FIOW EE EE Power Supply pressure regulator setting Dimensions and Weight
26. aire pi ce couper et tout autre l ment en contact avec cette pour s assurer qu il n est ni endommag ni fendu piece font partie du circuit lectrique Remplacer imm diatement un cordon endommag Un e Ne jamais toucher le corps de la torche la pi ce couper c ble d nud peut tuer ou l eau de la table eau pendant le fonctionnement du e Inspecter et remplacer les cables de la torche qui sont syst me plasma us s ou endommag s e Ne pas saisir la pi ce couper ni les chutes lors du Pr vention des chocs lectriques coupage Laisser la pi ce couper en place ou sur la Tous les syst mes plasma Hypertherm utilisent des hautes table de travail le c ble de retour connect lors du tensions pour le coupage souvent de 200 400 V On doit coupage prendre les pr cautions suivantes quand on utilise le Avant de v rifier de nettoyer ou de remplacer les pi ces syst me plasma de la torche couper l alimentation ou d brancher la prise e Porter des bottes et des gants isolants et garder le corps de courant et les v tements au sec Ne jamais contourner ou court circuiter les verrouillages Ne pas se tenir s asseoir ou se coucher sur une surface de s curit mouill e ni la toucher quand on utilise le syst me Avant d enlever le capot du syst me ou de la source de plasma courant couper l alimentation lectrique Attendre ensuite S isoler de la surface de travail et du sol en utilisant des 5 minutes pour que les c
27. ange the consumable parts if necessary See Operating Tips in Section 4 The gas pressure is incorrect See Operating Instructions in Section 4 to adjust the gas pressure if necessary The gas filter at the rear of the supply contains excessive moisture Drain the filter bowl and clean the filter See Routine Maintenance earlier in this section When using extended consumables the torch nozzle is being pressed against the electrode Maintain a torch to work distance of approximately 1 8 3 mm when using extended consumables The torch is defective See Technical Questions on page 5 7 10 1 The gas filter at the rear of the supply contains excessive moisture Drain the filter bowl and clean the filter See Routine Maintenance earlier in this section powermax 1100 Operator Manual MAINTENANCE PARTS Problem Cause Solution 11 The torch cuts poorly 11 1 Power supply voltage links are incorrect See voltage configuration settings in Section 3 11 2 Torch consumables are worn See Operating Tips in Section 4 11 3 Line voltage is too low See Cause Solution 3 2 TECHNICAL QUESTIONS If you are unable to fix the problem with your Powermax1100 by following this basic troubleshooting guide or if you need further assistance 1 Call your distributor He will be able to help you or refer you to an authorized Hypertherm repair facility 2 Call the nearest Hypertherm office listed in the front of this manual
28. ble from the Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada NWSA booklet Welding Safety Bibliography obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances obtainable from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 ANSI Standard 288 2 Practices for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 Canadian Electrical Code Part 1 Safety Standards for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Rexdale Ontario Canada M9W1 R3 powermax1100 Operator Manual a 1 AERATION MANIFOLD APPENDIX B AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM Introduction When plasma arc cutting aluminum at the water table surface or below water free hydrogen gas may be generated by the cutting process The high temperature of the plasma process causes disassociation of oxygen and hydrogen from the water in the water table The hot aluminum which has a high affinity for oxygen then combines with the oxygen leaving free hydrogen An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the fl
29. ch lead or work cable around your body Stay as far away from the power supply as possible 1 4 5 98 HYPERTHERM Plasma Systems Section ta S CURIT IDENTIFIER LES CONSIGNES A DE SECURITE Les symboles indiqu s dans cette section sont utilis s pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce soit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et Suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE SECURITE Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non autoris es sur la machine peuvent engendrer des probl mes de s curit et raccourcir la dur e d utilisation de l quipement DANGER AVERTISSEMENT PR CAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSE MENT sont situ es sur la machine pour signaler certains dangers sp
30. cifiques Les messages d AVERTISSEMENT pr c dent les instructions d utilisation expliqu es dans ce manuel et signalent les risques de blessures ou de mort au cas o ces instructions ne seraient pas suivies correctement Les messages de PR CAUTION pr c dent les instructions d utilisation contenues dans ce manuel et signalent que le mat riel risque d tre endommag si les instructions ne sont pas suivies correctement Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur proximit loigner toute mati re inflammable une distance d au moins 10 m du poste de coupage Tremper le m tal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des mat riaux combustibles Ne jamais couper des r cipients pouvant contenir des mati res inflammables avant de les avoir vides et nettoy s correctement A rer toute atmosph re potentiellement inflammable avant d utiliser un syst me plasma Lors de l utilisation d oxyg ne comme gaz plasma un syst me de ventilation par aspiration est n cessaire Pr vention des explosions Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s e Ne pas couper de r cipients contenant des mati res combustibles LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION AVERTISSEM
31. d the system is ready for operation e Yellow LINE VOLTAGE LED When illuminated indicates that the AC line voltage is below proper operating limits Yellow TEMP LED When illuminated indicates that the power supply temperature has exceeded operating limits Green GAS PRESSURE LED When illuminated indicates that the gas pressure is within operating limits GAS TEST Switch When pushed in allows the operator to adjust the pressure setting e AMPS Output Adjustment Knob Adjusts output current between 30 and 80 amps Pressure Regulator Regulates input gas pressure to the power supply e Pressure Gauge Indicates gas pressure at the power supply e ON I OFF 0 Power Switch Activates the power supply and its control circuits LINE GAS GAS VOLTAGE TEMP PRESSURE TEST POWER ON Pressure Gauge Pressure Regulator Figure 4 1 Powermax1100 Controls and Indicators OPERATION OPERATING INSTRUCTIONS A WARNING Before operating this system read the Safety section of this manual thoroughly 1 Ensure that the work environment and your clothing meet the safety requirements outlined in the Safety section 2 Follow the instructions in the Setup section Verify that the input gas supply pressure is set to 90 psi 6 2 bar 3 At the rear of the power supply set the power switch to the ON I position The POWER ON and GAS PRESSURE LEDs should illuminate The LINE VOLTAGE LED will blink and then extinguish
32. des locaux ou nationaux en vigueur LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER e EN CAS DE DOMMAGES c Les bouteilles de gaz contiennent du gaz haute pression Si une bouteille est endommag e elle peut exploser Manipuler et utiliser les bouteilles de gaz comprim conform ment aux codes locaux ou nationaux Ne jamais utiliser une bouteille qui n est pas plac e la verticale et bien assujettie Le capuchon de protection doit tre plac sur le robinet sauf si la bouteille est en cours d utilisation ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des cl s ou d autres outils pour d bloquer le robinet des bouteilles LE BRUIT PEUT PROVOQUER DES PROBLEMES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs Utiliser un casque de protection homologu lors de l utilisation du syst me plasma Pr venir les personnes aux alentours des risques encourus en cas d exposition au bruit e PACEMAKERS ET PROTHESES AUDITIVES x Les champs magn tiques produits par les courants a haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes portant ce type d appareil doivent consul
33. e to the power supply 1 Use a hoisting strap rated for a minimum hoisting weight of 400 pounds 182 kg Approved hoisting straps have attachedlabels with ratings 2 Ensure the power supply cover is in place prior to hoisting 3 Route the strap between the two handles as shown in Fig 3 1 4 Bringthe strap ends together over the center of the power supply and connect them to the hoisting machine 5 Hoistandlowerthe power supply slowly and smoothly e Hoisting Approved hoisting Machine strap x Ce Ur Figure 3 1 Powermax1100 Power Supply Hoisting Setup powermax1100 Operator Manual 3 3 SETUP VOLTAGE CONFIGURATIONS A anp A SHOCK HAZARD Always turn off the power unplug the cord and wait 5 minutes before removing any power supply cover If the power supply is directly connected to a line disconnect switch place switch in the OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures The 208 240 480V Powermax1100 power supplies are shipped to operate at 480 volts The 200 230 400V and 230 400V CE Powermax1100 power supplies are shipped to operate at 400 volts To operate at an alternate voltage remove the rear panel and configure the wires and jumpers on TB2 and TB3 as shown below Notes When switching from the 480V or 400V configuration use the spare j
34. ear you to avoid any danger from sparks and hot metal When the pierce is complete bring the torch head to a perpendicular position and proceed with the cut 2 Rotate the torch to an upright position Figure 4 9 Piercing on POWErMAXT100 Operator Manual OPERATION Gouging The Powermax1100 can be used for gouging mild steel by using the optional gouging nozzle and gouging shield e Always wear full protection Awelding helmet with at least a 8 lens shade Hypertherm recommends using a 10 lens shade when gouging Welding gloves Awelding jacket The arc is fully exposed and will cause serious burns if the skin is not covered e Install the gouging nozzle and shield the same as a standard cutting nozzle and shield See Changing Consumable Parts earlier in this section Adjust the air pressure to 60 65 psi 4 1 4 5 bar with air flowing from the torch Note that this is lower than the cutting pressure Tilt the torch approximately 45 from the surface to be gouged and push the torch in the desired direction Multiple passes or wearing may be necessary to gouge wider and deeper sections Direction of travel Figure 4 10 Gouging powermax1100 Operator Manual 4 11 3 98 OPERATION CUT CHART 80A STANDARD CONSUMABLES The following recommended settings are for mechanized cutting Torch to work distance is 1 16 inch 1 6 mm for all cuts E d Shield Retaining Cap Nozz
35. ed a Release the safety to return to the Safety On position as shown in step 1 Figure 4 4 PAC135T Torch Safety Trigger Operation powermax1100 Operator Manual 4 5 OPERATION OPERATING TIPS Changing Consumable Parts WARNING A SHOCK HAZARD Always turn off power and unplug cord from wall before changing consumable parts If power supply is directly connected to a line disconnect switch place line disconnect switch to OFF position Do not rely on the cap on sensor circuit to remove power It is provided strictly for safety backup In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures 1 Unscrew the retaining cap The nozzle will be released when the retaining cap is removed 2 Check the shield for external signs of wear The shield should be clean and clear of metal debris The gas holes along the edge of the shield should not be blocked with debris The center hole should not have any nicks or gouges and should show no signs of arcing activity 3 Unscrew the shield from the retaining cap Inspect the gas holes from the inside The holes should be clear of metal debris If the gas holes are blocked by debris try to open them by pushing a pin through each one from the outside of the shield to the inside If the shield is still good screw it back on to the retaining cap If it is damaged replace it w
36. ent Recommended Voltage Phase 11 2 kw Output Slow Blow Fuse Size 200 VAC 1 96 amps 125 amp 208 VAC 1 92 amps 125 amp 230 VAC 1 84 amps 110 amp 240 VAC 1 80 amps 110 amp 400 VAC 1 48 amps 70 amp 480 VAC 1 40 amps 60 amp 200 VAC 3 56 amps 80 amp 208 VAC 3 53 amps 70 amp 230 VAC 3 49 amps 70 amp 230 VAC CE 3 33 amps 40 amp 240 VAC 3 46 amps 60 amp 400 VAC 3 28 amps 35 amp 400 VAC CE 3 19 amps 30 amp 480 VAC 3 23 amps 30 amp 600 VAC 3 20 amps 30 amp GROUNDING REQUIREMENTS To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax1100 must be properly grounded through the power cord according to your local or national electrical codes The power supply chassis is electrically conductive and can present a shock hazard if it is not properly grounded through the line voltage disconnect box Single phase service must be of the 3 wire type with a green or green yellow wire for protective earth ground It must comply with local electrical requirements Do not use a 2 wire service Refer to Grounding in the Safety section Three phase service must be of the 4 wire type with a green yellow wire for protective earth ground 3 8 powermax1100 Operator Manual SETUP Figure 3 11 Proper Work Clamp Connection WORK CABLE AND CLAMP The work clamp must be attached to the workpiece when plasma cutting Ensure that the work clamp and the workpiece make good metal to metal contact Attach the work clam
37. er disconnecting the main power to allow capacitors to discharge Never expose cylinders to excessive heat sparks slag or open flame Never use hammers wrenches or other tools to open stuck cylinder valves Never operate the plasma system unless the power supply unit covers are in place Exposed power supply connections present a severe electrical hazard Pressure Regulators e Be certain that all pressure regulators are in proper Explosion Prevention working condition Never use a regulator for any gas other than that for A WARNING Compressed Gas which it is intended Never use a regulator that leaks creeps excessively or is physically damaged in any way The plasma system uses compressed gas Observe proper precautions when handling and using compressed gas equipment and cylinders Never attempt to lubricate a regulator with oil or grease Do not use the plasma system if explosive dust or vapors may be present A WARNING Hydrogen Detonation cm d i inum in Do not cut pressurized cylinders or any closed kill Goz 9 container When cutting aluminum underwater or with the water touching the underside of the aluminum S WARNING Hydrogen Explosion Hazard free hydrogen gas may collect under the workpiece and detonate during plasma cutting If your system uses hydrogen remember that this is a flammable gas that presents an explosion operations Installing an aeration manifold on the floor of
38. g Shield Retaining Cap Nozzle Electrode 120510 120483 120509 120473 S 7 Figure 4 5 Consumables Description of Consumables e Shielded 80A For cutting above 40A Shielded nozzle allows the torch tip to be dragged directly on the workpiece e Shielded 40A For optimal cutting on thinner materials at or below 40A Extended For increased visibility and access for special applications The nozzle is not shielded Maintain a standoff distance from the workpiece of approximately 1 8 3 mm when cutting above 40A to avoid accelerated consumable parts wear Use only with the machine torch in CE countries e Gouging For metal removal without cutting Use for weld removal or setup Nozzle shield may be placed directly on the workpiece powermaxt100 Operator Manual 4 7 1 98 OPERATION Cutting 4 8 Do not fire the pilot arc into the air needlessly doing so causes a significant reduction of the nozzle and electrode life If arc transfer to the workpiece does not occur within 5 seconds the pilot arc will shut off Re lease the torch trigger and press it again to reset the pilot arc timer Start cutting from the edge of the workpiece Fig 4 6 To penetrate fully and cut cleanly through the workpiece pause momentarily at the beginning and at the end of each cut 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 t
39. g the Powermax1100 readthe Safety section of this manual CLAIMS Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance call Customer Service at 1 800 643 0030 in the U S and Canada or your authorized Hypertherm distributor Claims for defective or missing merchandise All units shipped from Hypertherm undergo rigorous quality control inspections for defects If any of the merchandise is defective or missing call your authorized Hypertherm distributor If you need additional assistance call Customer Service at 1 800 643 0030 in the U S and Canada or your authorized Hypertherm distributor 3 2 powermax1100 Operator Manual SETUP HOISTING REQUIREMENTS In the event that the power supply has to be hoisted follow the steps below WARNING U The Powermax1100 power supply weighs up to 100 pounds 45 kg when fully configured with torch torch leads and wheels The fully configured 600V power supply weighs nearly 200 pounds 91 kg Use a hoisting machine with a hoisting strap through both handles to hoist the power supply Always hoist the power supply with its cover secured in place Do not hoist the power supply by one handle it is not designed to support the weight of the power supply Failure to heed this warning could result in personal injury and damag
40. g the plasma system is presented in notes such as shown in this paragraph Cautions Information in bold type and surrounded by a box describes a situation that may cause damage to the plasma system A A WARNINGS A Warnings describe situations that present a physical danger to the operator and advice to avoid or correct the situation Each type of warning includes applicable danger symbols such as a hand burn electrical shock fire explosion etc WARNING Instant On A WARNING Electric Shock Torches Instant on torches produce a plasma Never touch the torch body workpiece or the water in arc immediately after the torch switch a water table when operating the plasma system is pushed When using a water table be sure that it is correctly Always hold a hand torch away from connected to earth ground your body as a precaution against Operating the plasma system completes an electrical accidental torch firing Be aware of circuit between the torch and the workpiece and this hazard which has potential for anything touching the workpiece The workpiece is part serious bodily injury of the electrical circuit HYPERTHERM Plasma Systems 1 1 5 98 SAFETY Eye Protection Wear dark safety glasses or goggles with side shields or a welding helmet in accordance with applicable national or local codes to protect eyes against the plasma arc s ultraviolet and infrared rays Lens Shade Arc Current C AWS USA 1SO 48
41. hould 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 at the same time The operator should be insulated from all such bonded metallic components Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other 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 circuit 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 increase 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 given in IEC TC26 sec 94 and IEC TC26 108A CD Arc Welding Equipment Installation and Use
42. ilter Oil vapor filter From air To supply Powermax1100 Figure 3 12 Recommended Three Stage Air Filtration System Nitrogen Supply Quality Nitrogen must be supplied to the Powermax1100 at 99 995 purity If the purity level of the nitrogen is too low cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Note These conditions also occur if there are leaks in the gas supply hoses or connections The nitrogen supply can be compressed gas cylinders or liquid containers GAS SUPPLY CONNECTION Use a 3 8 inch 9 5 mm ID inert gas hose to connect the gas supply air or nitrogen to the power supply filter To connect the hose install a 1 4 NPT nipple to the filter block as shown in Fig 3 13 Apply liquid pipe sealant to the threads to ensure a leak free installation A nipple and adapters are included in the consumable parts kit CAUTION Never use Teflon tape when installing the nipple or adapters Bits of tape can break off and enter the air line and harm the pressure regulator pressure switch and valve 1 4 NPT Nipple Gas Supply Hose Connection Figure 3 13 Rear Panel Gas Supply Connection to Filter 3 10 powermax1100 Operator Manual SETUP TORCH LEAD CONNECTION To connect the torch lead to the power supply 1 Alignthe connector key plug on the torch lead with the connector receptacle key slot on the power supply and push in until the pin
43. ins Supply Cutting equipment should 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 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 should 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 for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations powermax1100 Operator Manual 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 s
44. ith a new one 4 Inspect the nozzle for damage or wear If the hole in the nozzle is worn or oval shaped replace the nozzle 5 Using the electrode wrench supplied in the consumable parts kit unscrew the electrode from the torch body The swirl ring will be released when the electrode is removed 6 Inspect the electrode If the center of the electrode has a pit more than 1 16 inch 1 6 mm deep replace it 7 Inspect the swirl ring It should be clean and the holes along the side should not be plugged If the swirl ring is damaged replace it 8 Inspect the O ring on the torch It should be lubricated and undamaged If it is dry lubricate it with a thin film of the lubricant provided in the consumable parts kit If it is damaged replace it 9 Replace the consumable parts as shown in Fig 4 5 10 When the retaining cap is tightened the circuit between the pin contacts located on the torch head will close indicating that the torch is again ready for operation Plug the power cord back in or place the line disconnect switch to the ON position e powermaxtoo0 Operator Manual OPERATION e gt Shielded 80A 40A Machine Shield Retaining Cap Nozzle 120516 120483 80A 120476 80A DT Electrode Swirl Ring PAC135T z 120473 120474 Torch Retaining Cap Nozzle 120520 40A 120515 40A Hand Shield 120475 026020 Extended Deflector Retaining Cap Nozzle Electrode 120519 120483 120518 120517 Gougin
45. le Electrode Swirl Ring 120516 120483 80A 120476 80A 120473 120474 Ne af Recommended Material Arc Arc Travel Pierce Thickness Material Current Voltage Speed Delay in mm A V ipm mm min S 3 16 4 8 Mild steel 80 115 160 4060 0 1 4 6 4 Mild steel 80 117 110 2800 0 25 3 8 9 5 Mild steel 80 116 57 1450 0 50 1 2 12 7 Mild steel 80 120 38 965 0 75 5 8 15 9 Mild steel 80 124 25 635 1 75 3 4 19 0 Mild steel 80 124 20 510 n a 7 8 22 2 Mild steel 80 132 14 355 n a 1 25 4 Mild steel 80 133 11 280 n a 3 16 4 8 Stainless Steel 80 120 160 4060 0 25 1 4 6 4 Stainless Steel 80 121 100 2540 0 50 3 8 9 5 Stainless Steel 80 122 53 1345 1 00 1 2 12 7 Stainless Steel 80 123 32 810 1 25 5 8 15 9 Stainless Steel 80 123 25 635 1 75 3 4 19 0 Stainless Steel 80 126 18 460 n a 1 25 4 Stainless Steel 80 133 10 255 n a 1 8 3 2 Aluminum 80 119 340 8640 0 1 4 6 4 Aluminum 80 120 140 3560 0 25 3 8 9 5 Aluminum 80 122 90 2285 0 50 1 2 12 7 Aluminum 80 129 60 1525 1 00 3 4 19 0 Aluminum 80 131 31 790 n a Recommended travel speeds are 10 20 slower than maximum These slower speeds will produce optimum cut quality 4 12 powerimaxti100 Operator Manual OPERATION CUT CHART 40A CONSUMABLES Use 40 amp consumables on thin material to obtain a narrower kerf width and to minimize the heat affected zone The following recommended settings are for mechanized cutting Torch to work distance is 1 16 inch 1 6 mm for a
46. liminate the danger of tripping Noise Protection The plasma cutting process can generate high levels of noise Depending on the arc current material being cut acoustics and size of the cutting room distance from the torch and other factors acceptable noise levels as defined by national or local codes may be exceeded by your plasma system Always wear proper ear protection when cutting or gouging with the plasma system Grounding Input Power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply be sure to properly connect the power cord ground wire Conform to Canadian Standards Association CSA standards by placing the power cord 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 Work Cable Attach the work cable securely to the workpiece or the work table by making good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to an earth ground in accordance with appropriate national or local electrical codes Safety Reminders Never bypass or shortcut the safety interlocks on any of the plasma system units Except in Hypertherm s largest mechanized system
47. ll cuts E Shield Retaining Cap Nozzle Electrode Swirl Ring K 120516 120520 40A 120515 40A 120473 120474 A Recommended Material Arc Arc Travel Pierce Thickness Material Current Voltage Speed Delay ga or in mm A V ipm mm min S 26 ga 0 5 Mild steel 30 116 510 12950 0 22 ga 0 8 Mild steel 30 116 360 9140 0 20 ga 0 9 Mild steel 30 116 240 6100 0 18 ga 1 2 Mild steel 30 118 210 5330 0 16 ga 1 5 Mild steel 30 118 120 2050 0 14 ga 1 9 Mild steel 40 117 200 5080 0 25 10 ga 3 4 Mild steel 40 121 100 2540 0 50 3 16 4 8 Mild steel 40 116 70 1780 1 00 1 4 6 4 Mild steel 40 119 42 1070 1 25 3 8 9 5 Mild steel 40 126 19 480 n a 1 2 12 7 Mild steel 40 131 14 355 n a 26 ga 0 5 Stainless steel 30 116 520 13200 0 22 ga 0 8 Stainless steel 30 116 260 6600 0 20 ga 0 9 Stainless steel 30 117 170 4320 0 18 ga 1 2 Stainless steel 40 116 310 7870 0 16 ga 1 5 Stainless steel 40 117 200 5080 0 14 ga 1 9 Stainless steel 40 115 170 4320 0 25 10 ga 3 4 Stainless steel 40 118 70 1780 0 50 3 16 4 8 Stainless steel 40 119 48 1220 1 00 1 4 6 4 Stainless steel 40 120 35 890 1 50 3 8 9 5 Stainless steel 40 125 16 410 n a 1 2 12 7 Stainless steel 40 126 11 280 n a 1 32 0 8 Aluminum 30 117 600 15240 0 1 16 1 6 Aluminum 30 117 240 6100 0 3 32 2 4 Aluminum 40 117 250 6350 0 25 1 8 3 2 Aluminum 40 117 170 4320 0 50 1 4 6 4 Aluminum 40 122 53 1350 1 50 3 8 9 5 Aluminum 40 132 28 710 n a Recomme
48. n the power supply off quickly in an emergency situation Conform to all local electrical codes for primary wiring sizes and types Inspect the primary power cord frequently for damage or cracking of the cover Bare wiring can kill Do not use a system with a damaged power cord Replace a damaged power cord immediately Inspect the torch leads Replace if frayed or damaged 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 5 98 HYPERTHERM Plasma Systems SAFETY Never use a cylinder that is not upright and secured in place Electric Shock Prevention continued Before changing the torch parts disconnect the main power or unplug the power supply After changing torch parts and replacing the retaining cap plug in the power supply again Never move or transport a cylinder without its protective valve cover in place Never use a gas cylinder or its contents for any purpose other than that for which it is intended Never bypass or shortcut the safety interlocks Never lubricate cylinder valves with oil or grease Before removing a power supply cover for maintenance disconnect the main power at the wall Never allow electrical contact between the plasma arc disconnect switch or unplug the power supply To and a cylinder avoid exposure to severe electrical hazard wait five minutes aft
49. nded travel speeds are 10 20 slower than maximum These slower speeds will produce optimum cut quality powermax1100 Operator Manual 4 13 OPERATION Cut Chart Notes The cut charts are optimized to provide the best cut angle least dross and best cut surface finish Remember that cut charts are intended to provide a good starting point for each cutting assignment Every cutting system reguires fine tuning each cutting set up to the materials on site in order to obtain optimum cut guality e Maximum recommended mechanized cutting capacity with 80A consumables 1 2 inch 12 mm on mild steel and 3 8 inch 9 5 mm on stainless steel and aluminum e Amanual machine motion signal must be given in mechanized applications when cutting material thinner than 18 gauge 1 2 mm e See page 4 7 or Section 5 for additional consumable parts Compressed air or nitrogen must be available to the power supply filter pressure regulator at a flow rate of 400 scfh 6 7 scfm 189 l min at a pressure of 90 psi 6 2 bar The dynamic flowing pressure when operating is 65 psi 4 5 bar If torch leads are 50 ft 15 2 m the dynamic pressure when operating is 70 psi 4 8 bar If the pressure to the power supply falls below 40 psi 2 8 bar the torch will extinguish e After several minutes of running the torch retaining cap may become hot To cool it push in and hold the GAS TEST switch until the cap cools down e The duty cycle or the amount of
50. ondensateurs se d chargent tapis isolants secs ou des couvertures assez grandes Ne jamais faire fonctionner le syst me plasma sans que pour viter tout contact physique avec le travail ou le sol les capots de la source de courant ne soient en place S il s av re n cessaire de travailler dans ou pr s d un Les raccords expos s de la source de courant sont endroit humide proc der avec une extr me prudence extr mement dangereux e Installer un sectionneur avec fusibles appropri s Lors de l installation des connexions attacher tout d abord proximit de la source de courant Ce dispositif permet la prise de terre appropri e l op rateur d arr ter rapidement la source de courant en Chaque syst me plasma Hypertherm est concu pour tre cas d urgence utilis uniquement avec des torches Hypertherm e En cas d utilisation d une table eau s assurer que cette sp cifiques Ne pas utiliser des torches inappropri es qui derni re est correctement mise la terre pourraient surchauffer et pr senter des risques pour la s curit LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES zb N Le coupage peut produire des vapeurs et des gaz toxiques Ne pas couper des m taux peints ou contenant des qui r duisent le niveau d oxyg ne dans l air et peuvent mati res toxiques comme le zinc galvanis le plomb le provoquer des blessures voire la mort cadmium ou le b ryllum moins que la zone de travail C
51. onserver le poste de coupage bien a r ou utiliser un Soit tr s bien ventil e et que l op rateur porte un masque masque respiratoire homologu respiratoire Les rev tements et m taux contenant ces Ne pas proc der au coupage pr s d endroits o mati res peuvent produire des vapeurs toxiques lors du s effectuent le d graissage le nettoyage ou la coupage vaporisation Certains solvants chlor s se d composent Ne jamais couper de r cipients pouvant contenir des sous l effet des rayons ultraviolets et forment du mati res inflammables avant de les avoir vid s et phosg ne nettoy s correctement 1a 2 HYPERTHERM Systemes plasma 5 27 99 S CURIT V Torches allumage instantan L arc plasma s allume imm diatement apr s que la torche Soit mise en marche L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de m tal pr s de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes Protection des yeux Les rayons de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d crans lat raux ou encore masque de soudu
52. oor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Figure b 1 Make an Aeration Manifold with two inch 50 mm PVC tubing with one inch 25 mm Distribution Lines connected to it Drill 1 8 inch 3 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distribution lines and install the lines so that oxygen is delivered to all parts of the cutting area Connect the manifold to a shop air line Set a pressure regulator to obtain a steady stream of bubbles 9 Aeration Manifold e e e e D e e e e D Distribution Lines Regulated air in Figure b 1 Aeration Manifold b 1 powermax1100 Operator Manual
53. orch too fast or you do not have sufficient power to fully penetrate the workpiece Hold the torch lightly on the metal if using shielded consumables or just above the metal Holding the torch firmly to the workpiece causes the shield to stick and makes smooth cutting difficult The arc transfers to the workpiece once the torch is within 1 8 inch 3 mm of the workpiece Pulling the torch through the cut is easier than pushing it Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line Fig 4 8 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 When cutting thin material reduce the amps until you get the best quality cut To cut circles use a template or a radius cutter attachment Fig 4 7 Figure 4 6 Starting a Cut powermax1100 Operator Manual OPERATION Figure 4 7 Cutting a Circle Figure 4 8 Dragging the Torch powermax1100 Operator Manual 4 9 OPERATION Piercing Hold the torch so that the tip is approximately 1 16 inch 1 6 mm away from the workpiece before firing the torch This method maximizes the life of the nozzle e Hold the torch at an angle to the workpiece away from yourself pull back on the trigger and slowly rotate the torch to an upright position This is particularly important when cutting thicker material Make sure that the torch is pointed away from you and the people n
54. p as close as possible to the area being cut to reduce exposure to electric and magnetic fields EMF Do not attach the work clamp to the portion of the workpiece to be cut away GAS SUPPLY REQUIREMENTS The gas supply for the Powermax1100 can be either air or nitrogen Air can be supplied as shop compressed air or cylinder compressed air Nitrogen can be supplied from compressed gas cylinders or liquid containers A high pressure regulator on either type of supply must be used and must be capable of delivering the following 400 scfh 6 7 scfm 189 I min at a pressure of 90 psi 6 2 bar to the filter on the power supply The filter location is shown in Fig 3 13 A WARNING Xe we R Do not allow the gas inlet pressure to the filter on the power supply to exceed 120 psi 8 2 bar The plastic filter bowl is rated for 150 psi 10 3 bar and may explode if this pressure is exceeded See the label on the filter bowl for other safety warnings Air Supply Quality The cylinder or shop compressed air supply mustbe clean dry and oil free If air supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens powermax1100 Operator Manual 3 9 SETUP Additional Air Filtration Use a three stage coalescing filtration system as shown in Fig 3 12 when site conditions introduce moisture oil or other contaminants into the air line Water particle filter Oil f
55. powermax1100 Plasma Arc Cutting System Operator Manual 802730 Revision 1 CE EN50199 EN50192 powermax1100 Plasma Arc Cutting System Operator Manual IM 273 P N 802730 for systems beginning with serial number 1100 010000 Revision 1 July 1999 Hypertherm Inc Hanover NH http www hypertherm com email info hypertherm com Copyright 1999 Hypertherm Inc All Rights Reserved Hypertherm HyDefinition HT HyLife LongLife MAX PAC and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Offices Worldwide Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA Tel 603 643 3441 Main Office Fax 603 643 5352 All Departments Tel 800 643 9878 Technical Service Tel 800 737 2978 Customer Service email info hypertherm com General Information email service 9 hypertherm com Technical Customer Services Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 European Technical Support Organization ETSO Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm
56. re avec des verres teint s appropri s pour prot ger les yeux des rayons ultraviolets et infrarouges de l arc Puissance des verres teint s Courant de l arc AWS U ISO 4850 Jusqu 100 A N 8 N 11 100 200 A N 10 Ne 11 12 200 400 A Ne 12 N 13 Plus de 400 A N 14 N 14 Protection de la peau Porter des v tements de s curit pour se prot ger contre les br lures que peuvent causer les rayons ultraviolets les tincelles et le m tal br lant LES RAYONS DE L ARC PEUVENT BRULER LES YEUX ET LA PEAU Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Pr parer la zone de coupage afin de r duire la r verb ration et la transmission de la lumi re ultraviolette Peindre les murs et autres surfaces de couleur sombre pour r duire la r flexion de la lumi re e Utiliser des crans et autres dispositifs de protection afin de prot ger les autres personnes de la lumi re et de la r verb ration e Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux MISE LA MASSE ET LA TERRE Cable de retour Bien fixer le cable de retour ou de masse la pi ce co
57. s all Hypertherm torches are designed with a safety interlock that prevents firing of the plasma arc when the retaining cap is loosened 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 potentially dangerous situation to the operator and any personnel in the area Hypertherm s warranty does not cover problems caused by the use of torches not made by Hypertherm Use only consumable parts and replacement parts made by Hypertherm Hypertherm s warranty does not cover problems caused by the use of parts not made by Hypertherm Never operate the plasma system with any of its covers not in place This would be hazardous to the operator and other people in the area and prevents the proper cooling of the equipment Electronic Health Support Equipment Plasma arc cutting and gouging systems create electric and magnetic fields that may interfere with the correct operation of electronic health support equipment such as pacemakers or hearing aids Any person who wears a pacemaker or hearing aid should consult a doctor before operating or being near any plasma system when it is in use To minimize exposure to EMF Keep both the work cable and the torch lead on one side of your body Keep your body from coming in between the torch lead and the work cable Route torch leads as close as possible to work cable Do not wrap the tor
58. s s seene 5 1 RLS UGH NA WEE 5 2 PUTTIN leed 5 2 Basic TEOUDIGSPOONPI D 5 4 RE ewe e E 5 7 ST L 5 8 Power Supplies 208 240 480V nan 5 12 Power een E AA 5 12 Power Supplies 200 400V CE en nent 5 12 APPENDIX A STANDARDS INDEX mm ee sese sssss ennenen eenn a 1 APPENDIX B AERATION MANIFOLD s sees b 1 iv powermax 1100 Operator Manual Section 1 SAFETY In this section About Notes Cautions and Warnings 1 1 Pressure Regulators 1 3 Safety Instructions EE 1 2 ale 1 3 Eye Protection 1 2 Noise Protection 1 4 Skin Protection eee 1 2 Grounding BEE 1 4 Toxic Fume Prevention 1 2 Input eT 1 4 Fire Prevention eet inerenti perte even 1 2 Work CAI ananas 1 4 Electric Shock Prevention 1 2 Work RT EE 1 4 Explosion Prevention 1 3 Safety Reminders sss 1 4 Compressed Gas Cylinders 1 3 Electronic Health Support Equipment 1 4 Before using this plasma arc system Each person who will operate this eguipment perform service or maintenance or supervise its use must read the safety instructions and warnings in this manual and the labels on the eguipment About Notes Cautions and Warnings Notes Throughout this manual useful information for operatin
59. s seat The top ofthe torch connector is marked TOP 2 Beforetightening turn the connector securing ring 1 4 turntothe leftto ensure thatthe securing ringthreads and the connector receptacle threads are aligned 3 Turnthe securing ring to the right to tighten PAC135M ON OFF Pendant Connection A Weier A Do not connect the cutting machine interface START signal if using the ON OFF pendant See page 3 12 To connect the on off pendant lead to the PAC135M machine torch pigtail 1 Align the pendantlead connector key plug with the connector receptacle key slot on the pigtail and push in until the pins seat 2 Turnthe connector securing ring to the rightto tighten PAC135M Torch ON OFF Switch Connection Data The PAC135M torch lead is supplied with a pigtail so that the on off pendant may be used If you want to use a different on off switch configuration note that the wiring configuration to the 3 socket female receptacle on the pigtail is as follows Socket A White Wire Socket B Not Used Socket C Black Wire PAC135M Torch Alignment Make sure that the machine torch is mounted at right angles to the workpiece in order to get a vertical cut Use a square to align the torch at 0 and 90 as shown in Fig 3 14 powermaxtioo Operator Manual m SETUP Figure 3 14 Aligning the Machine Torch with Square MACHINE INTERFACE WITH PAC135M Signals for arc transfer start and arc voltage are available on power
60. sleeve either push Power Cord Diameter Use the power cord through the smallest sleeve that it will go through or measure Over 7 8 22mm Largest sleeve the power cord diameter and use the 3 4 to 7 8 19mm to 22mm Second largest sleeve adjacent table Under 3 4 19mm Smallest sleeve To change a sleeve 3 Install new strain 4 Replace strain relief cap After installing power cord tighten cap Figure 3 8 Changing a Power Cord Strain Relief Insert 3 6 powermax1100 Operator Manual 1 Remove strain 2 Remove strain relief cap relief sleeve relief sleeve and press it into place SETUP SINGLE PHASE AND THREE PHASE POWER CONFIGURATIONS All Powermax1100 power supplies except the 230 400V CE and 600V power supplies can operate from either a single phase or three phase input The 230 400V CE and 600V power supplies operate only from a three phase input Power cords must meet the specifications described earlier in this section Follow applicable local or national wire color conventions See also EMC Compatibility and Mains Supply on page i for further CE compliance recommendations A Wang A SHOCK HAZARD Always turn off the power unplug the cord and wait 5 minutes before removing any power supply cover If the power supply is directly connected to a line disconnect switch place switch in the OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete
61. tainable from the U S Government Printing Office Washington D C 20402 ANSI Standard 287 1 Safe Practices for Occupation and Educational Eye and Face Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 241 1 Standard for Men s Safety Toe Footwear obtainable from the American National Standards Institute 1480 Broadway New York NY 10018 ANSI Standard 249 2 Fire Prevention in the Use of Cutting and Welding Processes obtainable from the American National Standards Institute 1480 Broadway New York NY 10018 AWS Standard A6 0 Welding and Cutting Containers Which Have Held Combustibles obtainable from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA Standard 70 1978 National Electrical Code obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 CSA Standard W117 2 Code for Safety in Welding and Cutting obtaina
62. ter un m decin avant de s approcher d un lieu o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques Garder loin de soi et du m me c t du corps le c ble de retour et le faisceau de la torche Faire passer le faisceau de la torche le plus pr s possible du c ble de retour Ne pas s enrouler le faisceau de la torche ou le c ble de retour autour du corps e Se tenir le plus loin possible de la source de courant 1a 4 10 16 98 HYPERTHERM Syst mes plasma Section 2 SPECIFICATIONS In this section Jade de TTE 2 2 Ee e Le EE 2 3 e Ee 2 3 FAG135 80A Helen 2 4 PAC135T Hand Torch Assembly sse 2 5 PAC135M Machine Torch Assembly 2 5 DIVAT TTT 2 5 IEC Symbols USOC WEE 2 6 powermax1100 Operator Manual 2 1 SPECIFICATIONS INTRODUCTION The Powermax1100 plasma cutting system uses an inverter power supply to provide a smooth DC output voltage producing excellent cut and gouge quality on mild steel stainless steel aluminum and other metals The Powermax1100 power supply provides constant current output variable from 30 to 80 amps for optimum performance on all thicknesses of metal up to 3 4 inch 20 mm thick At 80 amps the Powermax1100 can cut metals up to 1 inch 25 mm thick and will sever metals up to 1 1 4 inch 82 mm thick Air is the primary plasma gas providing low operating cost combined with high speed performance Cylinder
63. the water table is an effective way to eliminate the possibility of hydrogen detonation when cutting aluminum Refer to the Appendix section of this manual for instructions on how to fabricate an aeration manifold hazard Keep flames away from cylinders containing hydrogen mixtures and hoses that carry hydrogen mixtures Also keep flames and sparks away from the torch when using argon hydrogen as the plasma gas Hoses Compressed Gas Cylinders P y Label and color code all gas hoses in order to clearly identify the type of gas in each hose Consult Handle and use compressed gas cylinders in accor applicable national or local codes dance with safety standards published by the U S Compressed Gas Association CGA American Weld Never use the oxygen hose for any gas other than ing Society AWS Canadian Standards Association Oxygen CSA or applicable national or local codes Examine hoses at regular intervals for leaks wear loose connections or other hazard e Never use a cylinder that leaks or is physically damaged Replace hose that is damaged in any way HYPERTHERM Plasma Systems 1 3 5 98 SAFETY Hoses continued Keep hose lengths to a minimum to prevent damage reduce pressure drop and to prevent possible flow restrictions Prevent kinking by laying out hoses as straight as possible between termination points Coil any excess hose and place it out of the way to prevent damage and to e
64. the fumes wears respiratory equipment or an air supplied helmet Fire Prevention Make fire extinguishers available in the cutting area Remove all combustible materials from the immediate cutting area to a distance of at least 35 feet 10 m Quench freshly cut metal or allow metal to cool before handling it or bringing it into contact with combustible materials Never use a plasma system to cut containers with potentially flammable materials inside Such containers must be thoroughly cleaned prior to cutting Ventilate potentially flammable atmospheres before cutting with a plasma system When cutting with oxygen as the plasma gas an exhaust ventilation system is required Never operate the plasma system in an atmosphere which contains heavy concentrations of dust flammable gas or combustible liquid vapors unless properly vented Electric Shock Prevention A All Hypertherm plasma systems use high voltage up to 300 VDC to initiate the plasma arc Take the following precautions when operating the plasma system Wear insulated gloves and boots and keep body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Maintain proper insulation against electrical shock If you must work in or near a damp area use extreme caution Provide a wall mounted disconnect switch with properly sized fuses close to the power supply This switch allows the operator to tur
65. time the pilot or plasma arc can remain on in minutes within a 10 minute period is affected by many factors When the current is set at 80 amps the Powermax1100 has a 50 duty cycle at a temperature of 104 F 40 C At these conditions the plasma arc can remain on 5 minutes out of every 10 minutes without causing the temperature sensors to disable the unit The duty cycle increases to 10096 at a temperature of 104 F 40 C when the current is set below 57 amps To avoid performance deterioration of the Powermax1100 input voltage should be within 10 of the specified system line voltage setting e When using extended consumables maintain a torch to work distance of approximately 1 8 3 mm when cutting above 40A to avoid accelerated consumable parts wear The torch will extinguish if the nozzle is pressed back against the electrode COMMON CUTTING FAULTS e Ifthe workpiece is not totally penetrated The current may be too low The cut speed may be too high The torch parts may be worn The metal being cut may be too thick The work clamp may not be properly attached to the workpiece e If dross forms on the bottom of the cut The cutting speed may be too slow The torch parts may be worn The metal being cut may be too thick The current may be too low ou POWErMAXT100 Operator Manual Section 5 MAINTENANCE PARTS In this section Jeirgetel Eet e WEE 5 2 Routine Maintenance sn reel aient 5 2
66. tion settings in Section 3 5 2 Line voltage is too high See the table above 6 1 The power supply has exceeded the capacity of the fuse Check the fuse for proper amperage rating See Power Requirements in Section 3 Check power cable for a short circuit or loose connection 7 1 One of the internal thermostat switches has opened due to overheating Leave power supply on to allow the fan to cool the power supply down then shut the power supply down and restart Clean the internal air filter if installed See Removal Cleaning and Replacement of the Cooling Air Filter earlier in this section MAINTENANCE PaRTS Problem 8 The arc does not transfer after 5 seconds 9 The arc blows out but reignites when the torch switch is depressed 10 The torch sputters and hisses 8 1 8 2 8 3 8 4 9 1 9 2 9 3 9 4 9 4 Cause Solution The 5 second time out for the pilot arc has occurred Press the torch start button again The work clamp is not connected or it is broken Connect or repair the work clamp The work clamp is not making good metal to metal contact Verify that the work clamp is properly attached to the workpiece Remove paint or any coating on the workpiece before attempting to cut The workpiece is too far away from the torch Move the torch head closer 1 8 inch 3 mm maximum distance to the workpiece and start the torch again There are faulty consumable parts Inspect and ch
67. trode Wrench PAC135 Nipple 1 8 NPT QDisc Steel Bushing Reducer 1 4 X 1 8 Brass Box Consumable Parts Description Electrode PAC135 Nozzle PAC135 80A Nozzle PAC135 Gouging Shield PAC135 Hand Shield PAC135 Gouging O Ring 864 X 070 Lubricant Silicone 1 4 Oz Tube Electrode Wrench PAC135 Adapter 1 4NPT X G 1 4 Hose Box Consumable Parts powermax1100 Operator Manual 5 9 MAINTENANCE PaRTS PAC135T Torch Assembly and 25 ft 7 6 m Lead 085001 PAC135T Torch Assembly and 50 ft 15 2 m Lead 085061 Index No Part No Description Qty 002287 Handle Assembly PAC135T w screws 1 001615 Handle PAC135T 1 2 075497 6 X 5 8 Pillips Head Pan Head 5 3 002299 Safety Trigger Assembly PAC135T 1 4 005212 Switch Assembly Cap on Sensor 1 120473 Electrode Air PAC135 1 120474 Swirl Ring PAC135 1 120475 Shield PAC135 80A 1 120476 Nozzle PAC135 80A Shield 1 120483 Retaining Cap PAC135 1 5 120477 Torch Main Body PAC135T 1 6 026020 O Ring Silicon 864 X 070 1 7 129559 Torch Lead 25 ft 7 6 m 1 7 129560 Torch Lead 50 ft 15 2 m 1 8 005247 Push Button Switch Lo Profile 1 9 128122 Plug Assembly PAC135T Torch Quick Disconnect 1 10 074069 Splice 22 18 Butt 2 11 046056 Tubing 5 8 ID 4 12 046072 Heatshrink 1 2 ID 2 5 Used only in 085001 Used only in 085061 Note See page 5 8 for detail of consumable parts Figure 5 4 PAC135T Torch Assembly and Leads 5 10 powermax1100 Operator Manual 7 99 MAINTEN
68. umper in the clip located on the floor of the power supply e If using the 600V transformer option kit configure the Powermax1 100 for 480V Remove 8 screws to remove panel Rue A Approximate location of TB2 and TB3 Figure 3 3 200V or 208V Figure 3 4 230V or 240V Figure 3 5 400V or 480V Configuration Configuration Configuration 3 4 powermax1100 Operator Manual SETUP POWER CORDS 208 240 480V 200 230 400V and 600V POWER SUPPLIES The 208 240 480V and 200 230 400V power supplies are shipped without a power cord Use the tables below to choose the proper wire size for the appropriate length cord In the U S use a 3 conductor SO type cord for single phase and a 4 conductor SO type cord for three phase power supplies In other countries use cords that are certified by local or national codes Strip the power cord wires as shown in Fig 3 6 Cap or tin the conductor leads and use a 10 terminal on the ground wire The cord should be installed only by a licensed electrician The 600V conversion kit comes with a 10 AWG 7 ft 2 m power cord If changing the cord length use a 10 AWG power cord 208 240 480V Power supplies Input Phase Input Recommended Power Cord Wire Size AWG Voltage Current 10 ft 10 25 ft 25 50 ft 50 100ft 100 150 ft 4 200 230 400V Power supplies Input Phase Input Recommended Power Cord Wire Size mm
69. uper ou la table de travail de facon assurer un bon contact m tal m tal Ne pas fixer le c ble de retour la partie de la pi ce qui doit se d tacher Table de travail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s Alimentation S assurer que le fil de terre du cordon d alimentation est connect la terre dans le coffret du sectionneur S il est n cessaire de brancher le cordon d alimentation la source de courant lors de l installation du syst me s assurer que le fil de terre est correctement branch Placer tout d abord le fil de terre du cordon d alimentation sur le plot de mise la terre puis placer les autres fils de terre par dessus Bien serrer l crou de retenue S assurer que toutes les connexions sont bien serr es pour viter la surchauffe HYPERTHERM Syst mes plasma 1a 3 4 9 99 S CURIT S CURIT DES BOUTEILLES DE GAZ COMPRIM Ne jamais lubrifier les robinets des bouteilles ou les r gulateurs avec de l huile ou de la graisse Utiliser uniquement les bouteilles r gulateurs tuyaux et accessoires appropri s et con us pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz contenu dans chaque tuyau Se r f rer aux co
70. utting from within the workpiece see Piercing later in this section 8 As the torch moves across the workpiece the arc will transfer from the torch to the workpiece Move the torch in the desired direction at a speed which will ensure good cut quality When using shielded consumables drag the torch tip directly on the workpiece See Operating Tips and Cut Charts later in this section 9 When the cut is finished release the torch switch to extinguish the arc The arc will also extin guish when transfer to the workpiece is no longer sensed Pilot Arc Controller Optional In power supplies with the pilot arc controller option the torch will return to a pilot arc after finishing a cut if the torch switch remains pressed After 5 seconds the pilot arc will then extinguish if no arc transfer is sensed The pilot arc controller option is especially useful if you are cutting expanded metal See Powermax1100 Field Upgrade Kits and Optional Parts in Section 5 for part number information mo WEFMAXTION Operator Manual OPERATION PAC135T Safety Trigger Operation D Safety On position In this position the trigger cannot be pulled back so that the torch cannot be accidentally fired 2 Start pushing the safety forward Do not pull back on the trigger now wait until the safety reaches the Safety Off position as shown in step 3 2 Safety Off position In this position the trigger can be pulled back so that the torch can be fir
71. warranty shall not apply to any Product which has been mishandled incorrectly installed modified or assembled by you or any other person HYPER THERM shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable warranty period specified herein above THE FOREGOING SHALL CONSTITUTE THE SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPER THERM OF ITS WARRANTY PATENT INDEMNITY Except only in cases of Products not manufactured 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 HYPER THERM HYPERTHERM agrees to indemnify protect and hold harmless Distributors and their custom ers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because of the use in or about the construction or operation of Equipment or any design system formula combination article or material which infringes or alleges to infringe on any patent or other right Distributors shall notify HYPERTHERM promptly upon learning of any action or threatened action in connection with any such alleged infringement and each party may appoint its own counsel for any such action or threatened action DISCLAIMER OF OTHER WARRANTIES HYPERTHERM MAKES NO WARRANTIES REGARDING P

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