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powermax1650

1. 671 mm y pue E Ei Oy amp te ES 25 8 in ge 655 mm 2 LA Le 20 122 2 3 SPECIFICATIONS T100 torches Handheld cutting capacity at 100 amps Recommended capacity 1 1 4 inch 32 mm at 19 pm 482 mm per min Maximum capacity 1 1 2 inch 38 mm at 10 ipm 250 mm per min Severance capacity 1 3 4 inch 45 mm at low speed Mechanized cutting capacity at 100 amps Recommended pierce capacity up to 1 2 inch 13 mm Maximum pierce capacity 3 4 inch 19 mm Severance with an edge start 1 3 4 inch 45 mm at low speed Gouging capability Metal removal rate on mild steel 24 pounds 10 8 kg hour 7 2 pounds 3 3 kg with 25 ft 7 5 m lead T100 13 9 pounds 6 3 kg with 50 ft 15 m lead 20 6 pounds 9 4 kg with 75 ft 22 5 m lead 8 3 pounds 3 8 kg with 25 ft 7 5 m lead 11 0 pounds 5 0 kg with 35 ft 10 7 m lead T100M 2 15 0 pounds 6 8 kg with 50 ft 15 m lead 21 7 pounds 9 9 kg with 75 ft 22 5 m lead 2 4 powermaX1650 Operator Manual SPECIFICATIONS Torch dimensions T100 hand torch 8 9 226 mm 1 00 25 mm T100M 2 machine torch 15 47 393 mm 4 TENE O 1 38 60mm 203 mm 35 mm 32 pitch 125 3 2 mm width powermax1650 Operator Manual 2 5 SPECIFICATIONS Sym
2. 6 Slide quick release collar foward to lock the gas fitting in place Make sure that the gas fitting is secure 7 Make sure that the red dot on the connector is on top then plug in the electrical connector Close the ETR door powermaXxX1650 Operator Manual 3 9 SETUP Plasma gas supply The gas supply for the Powermax1650 can be shop compressed air or cylinder compressed air A high pressure regulator must be used on either type of supply and must be capable of delivering gas to the filter on the power supply at 550 scfh 9 2 scfm 260 l min minimum flow rate at a minimum pressure of 90 psig 6 1 bar Note If gas supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Do not allow the gas supply pressure to exceed 120 psi 8 3 bar The filter bowl may explode if this pressure is exceeded Additional gas filtration Use Hypertherm filter kit part number 128647 when site conditions introduce moisture oil or other particulates into the air line A 3 stage coalescing filtration system as shown should be used in extreme conditions Filter kit 128647 Gas supply Powermax1650 OR Water particle filter Oil filter Oil vapor filter Gas supply Powermax1650 3 10 powermaxX 1650 Operator
3. 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 vid s 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 Ne pas couper de r cipients contenant des mati res combustibles LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT 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 Lors du coupa
4. Stainless steel Are curent perm Pierce Material thickness Maximum travel speed Optimum travel speed 9 delay inches mm mmmn mmmn 5 os e 18027 10414 aca os 496 12598 8179 925 18GA 592 15037 8509 144 026 166A 15 374 9500 6172 344 026 16a 19 22 5613 3658 a 5 mea 34 2718 1778 3 16 1702 19 10 we 47 na 787 Aluminum A Fes Material thickness Maximum travel speed Optimum travel speed 99 delay mm PM mmmn PM f mmmn NA a NE 12 Vie 15 255 6807 4420 37327 24 2 7442 1826 a oso 1 32 204 5182 3378 i581 100 we a 78 1880 49 1945 Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality Optimum travel speeds 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 different cut assignment Every cutting system requires fine tuning for each cutting application in order to obtain the desired cut quality powermaXxX1650 Operator Manual 4 17 OPERATION FineCut consumables Torch to work distance for the following cut chart is 0 08 inches 2 032 mm for mild steel and 0 010 inches 0 254 mm for stainless steel Deflector Retaining Nozzl
5. Unshielded AO nn GOUGING 2 T100M 2 consumable configurations Shielded A tene ten Ohmic sensing retainirig CAPS imss iia ia ai Unshieldedi ae ee AAA AAA Set the mode switch ON ge cT Check the indicator lights iia Adjust the gas pressure and current setting Hand torch operation us ra rerit ie creep cep cb RE ERR SERERE LOREM oafety trigger operation ttc idee O Atiach the work clamp unitaire dt ii Start a cut from edge of the workpiece sn 4 10 Hand torch cutting technique Piercing CN PPP 5 Cuchia powermax1650 Operator Manual 4 1 OPERATION Controls and indicators Current amps 3l Si adjustment A Mode switch gas test knob Indicator L EDs ON OFF switch HJ o O C Pressure gauge EE A Pe Pressure regulator Indicator LEDs Green power ON LED When illuminated in
6. 54 77 20 08 Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality Optimum travel speeds 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 different cut assignment Every cutting system requires fine tuning for each cutting application in order to obtain the desired cut quality powermax1650 Operator Manual 4 19 OPERATION 40 to 60 amp mechanized unshielded consumables Torch to work distance for the following cut chart is 1 16 inch 1 5 mm for all cuts Deflector Retaining cap Nozzle Electrode Swirl ring T100M 2 120979 120928 220006 120926 120925 torch p Mild steel Are current Pierce Material thickness Maximum travel speed Optimum travel speed 9 delay inches mm mmmn PM sea os sso tee 8966 228a os 484 12294 55 8001 A 1 M 6 15 567 424 100 2769 129 025 346A 18 8980 212 5985 Stainless steel Pierce delay Inches PM mm min PM A 226a 453 11506 25 7498 128 025 186A 13 500 12700 325 8255 127 166A 15 367 9822 289 6071 128 025 146A 1 220 5588 14 3682 A
7. de l air au site selon les besoins Consulter un expert local pour mettre en ceuvre un plan du site afin d assurer une qualit de l air s re 1a 4 11 08 Hypertherm S CURIT F ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES Torches allumage instantan plasma coupe facilement les gants et la peau plasma s allume imm diatement apr s que la torche Rester loign de l extr mit de la torche soit mise en marche Ne pas tenir de m tal pr s de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes LES RAYONS DE L ARC PEUVENT BR LER LES YEUX ET LA PEAU Protection des yeux Les de 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 et encore masque de soudure avec des verres teint s appropri s pour prot ger les yeux des rayons ultraviolets et infrarouges de l arc 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 Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties
8. p1eoq 19414 IN uey Joyonpul ndynO 10jonpur soog eDpuq epoip juauoduloy JojeuBisog vao an 18 indu OV powermaXxX1650 Operator Manual MAINTENANCE AND PARTS Technical questions If you are unable to fix a problem with your Powermax by following the steps in Basic troubleshooting in this section or if you need further assistance 1 Call your Hypertherm distributor or authorized Hypertherm repair facility 2 Call the nearest Hypertherm Technical Service team listed in the front of this manual Parts Torch parts T100 hand torch assembly 25 ft 7 5 m T100 hand torch assembly 50 ft 15 m T100 hand torch assembly 75 ft 22 9 m T100M 2 machine torch assembly 75 ft 22 9 m T100M 2 machine torch 35 mm no gear rack 25 ft 7 5 m T100M 2 machine torch 35 mm no gear rack 35 ft 10 7 m T100M 2 machine torch 35 mm no gear rack 50 ft 15 m Shield cap T100M 2 ohmic contact 5 10 powermaX1650 Operator Manual MAINTENANCE AND PARTS Power Supply Parts 128740 Cover assembly CSA 14 screws included 128762 Cover assembly CE 14 screws included 075533 Cover screws Individual cover screw 128627 Air filter bowl with fittings 011092 Replacement filter element Accessories 128788 Stationary mounting kit 011092 Replacement filter for optiona
9. 240 ohms or greater or a typical industrial isolated input module which has an opto coupler built in Shown below are typical connections for a high side drive arrangement Driving a relay coil J16 J15 XFER START GND 24VDC BLK YEL RED BLK U V div _ V div B WHT Move the black BLK wire to ground GND and add a jumper wire as shown powermaxXx 1650 Operator Manual Shield Notes Start Signal 1 1 Customer supplied 24 VDC relay coil gt 240 ohms 2 Must use suppression diode 1A 100V such as IN4002 through IN4004 type across coil 3 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider 3 15 SETUP Driving an industrial isolated input module J16 J15 J19 XFER START BLK GND Move the black BLK wire to ground GND and add a jumper wire as shown 3 16 Isolated input Shield module Notes 1 Customer supplied isolated input module 2 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider powermaX1650 Operator Manual SETUP Driving a relay coil with an external power source Elio ene 61981
10. Solution One of the internal thermostat switches has opened due to overheating or extremely low temperature Leave the power supply ON to allow the fan to cool the power supply overheating Move the power supply to a warm location extreme cold The retaining cap is loose or removed from the torch Turn off the power supply and tighten or install the torch consumables See Section 4 Installing the consumables If the torch consumables become loose or are removed while the power supply is on turn off the power supply correct the problem and then turn on the power supply to clear this fault The work clamp is not connected to the workpiece the work clamp 15 broken there is a loose connection within power supply Connect or repair the work clamp The work clamp is not making good metal to metal contact Clean the area where the clamp contacts the workpiece The torch is too far from the workpiece Move the torch closer to the workpiece and start the torch again See Section 4 Torch operation powermaxX 1650 Operator Manual MAINTENANCE AND PARTS Basic troubleshooting continued Problem 7 The arc blows out but re ignites when the torch switch is pressed again 8 The arc sputters and hisses 9 Cut quality is not good powermaXxX1650 Operator Manual 7 1 7 2 7 3 8 1 8 2 8 3 9 1 Cause Solution The consumable parts are worn or damaged Inspect and change the cons
11. and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away Do not remove destroy or cover this label Replace if it is missing damaged or worn 11 08 SAFETY WARNING LABEL This warning label is affixed to some power supplies lt is important that the operator and maintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on the label 110647 Rev A www hypertherm com weee mmm 1 10 11 08 1 1 1 2 1 3 Cutting sparks can cause explosion or fire Do not cut near flammables Have a fire extinguisher nearby and ready to use Do not use a drum or other closed container as a cutting table Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered Turn off power before disassembling torch Do not grip the workpiece near the cutting path Wear complete body protection Hazardous voltage Risk of electric shock or burn Wear insulating gloves Replace gloves when wet or damaged Protect from shock by insulating yourself from work and ground Disconnect power before servicing Do not touch live parts Plasma fumes can be hazardous Do not inhale fume
12. o cortar al igual que aparatos de respiraci n con aire propio de aire est n capacitados y entrenados en el uso apropiado de tal equipo Nunca corte recipientes con materiales potencialmente t xicos adentro Primero vac e y limpie el recipiente adecuadamente Monitoree o compruebe la calidad del aire en el sitio como fuera necesario Consulte con un experto local para realizar un plan al sitio para garantizar la calidad de aire seguro 1b 4 11 08 Hypertherm SEGURIDAD UF EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS Antorchas de encendido instantaneo El arco de plasma puede cortar a trav s de guantes y El arco de plasma se enciende inmediatamente despu s de la piel con rapidez de activarse el interruptor de la antorcha Mant ngase alejado de la punta de la antorcha No sostenga el metal junto al trayecto de corte Nunca apunte la antorcha hacia Ud mismo o hacia otras personas lt A LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS NT OJOS Y EN LA PIEL Protecci n para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles ultravioleta e infrarrojo que pueden quemar los ojos y la piel Utilice protecci n para los ojos de conformidad con los c digos locales o nacionales aplicables Col quese protectores para los ojos gafas o anteojos protectores con protectores laterales y bien un casco de soldar con lentes con sombreado adecuado para pro
13. plasma se encuentre en funcionamiento Prevenci n ante el electrochoque Todos los sistemas por plasma de Hypertherm usan alto voltaje en el proceso de corte son comunes los voltajes CD de 200 a 400 Tome las siguientes precauciones cuando se utiliza el equipo de plasma Use guantes y botas aislantes y mantenga el cuerpo y la ropa secos No se siente se pare o se ponga sobre cualquier A slese el ctricamente de la pieza a cortar y de la tierra utilizando alfombrillas o cubiertas de aislamiento secas lo suficientemente grandes como para impedir todo contacto f sico con la pieza a cortar o con la tierra Si su nica opci n es trabajar en una rea h meda o cerca de ella sea muy cauteloso Instale un interruptor de corriente adecuado en cuanto a fusibles en una pared cercana a la fuente de energ a Este interruptor permitir al operador desconectar Al utilizar una mesa de agua aseg rese de que sta se encuentre correctamente conectada a la toma a tierra EL CHOQUE EL CTRICO PUEDE PROVOCAR LA MUERTE superficie h meda cuando est trabajando con el equipo r pidamente la fuente de energ a en caso de emergencia Instale este equipo y con ctelo a tierra seg n el manual de instrucciones y de conformidad con los c digos locales y nacionales Inspeccione el cord n de alimentaci n primaria con frecuencia para asegurarse de que no est dafiado ni agrietado Si el cord n de alimentaci n primaria est da
14. DE SEGURIDAD Los simbolos que se muestran en esta secci n se utilizan para identificar los posibles peligros Cuando vea un simbolo de seguridad en este manual o en su m quina recuerde que existe la posibilidad de que se produzcan lesiones personales y siga las instrucciones correspondientes para evitar el peligro 3x SIGA LAS INSTRUCCIONES DE SEGURIDAD Lea atentamente todos los mensajes de seguridad de este manual y las etiquetas de seguridad en su m quina Mantenga las etiquetas de seguridad de su m quina en buen estado Reemplace las etiquetas que se pierdan o se da en inmediatamente Aprenda a utilizar la m quina y a utilizar los controles de la manera correcta No permita que sea utilizada por alguien que no conozca su funcionamiento Mantenga su m quina en buenas condiciones de funcionamiento La realizaci n de modificaciones no autorizadas a la m quina puede comprometer la seguridad y la vida til de la m quina PELIGRO ADVERTENCIA PRECAUCI N Hypertherm usa las directivas del Instituto Americano de Normas Nacionales American National Standards Institute para las palabras y simbolos que se alan seguridad Las palabras PELIGRO y ADVERTENCIA se utilizan conjuntamente con un simbolo de seguridad La palabra PELIGRO se utiliza para identificar los mayores peligros Encontrar etiquetas de seguridad con las inscripciones PELIGRO y ADVERTENCIA en su m quina junto a peligros espec ficos Los
15. Products National and Local codes National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices Transfer of rights You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Proper disposal of Hypertherm products Hypertherm plasma cutting systems like all electronic products may contain materials or components such as printed circuit boards that cannot be discarded with ordinary waste lt is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes In the United States check all federal state and local laws In the European Union check the EU directives national and local laws For more information visit www hypertherm com weee In other countries check national and local laws 4 08 WARRANTY vi Hypertherm TABLE OF CONTENTS Electromagnetic combpatibility ccn ttr nitet tias aria i lacur RE iii Section 1 Safety Recognize safety information tnnt tant na a Follow safety I
16. and properly cleaned first Ventilate potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosion Prevention Do not use the plasma system if explosive dust or vapors may be present Do not cut pressurized cylinders pipes or any closed container Do not cut containers that have held combustible materials CUTTING CAN CAUSE FIRE OR EXPLOSION WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma Hydrogen Detonation with Aluminum Cutting When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation Refer to the Appendix section of this manual for aeration manifold details WARNING 1 2 11 08 Hypertherm SAFETY 3 A A ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause a fatal shock Install and ground this equipment according to the or severe burn instruction manual and in accordance with national Operating t
17. ce couper en place ou sur la table de travail le c ble de retour connect lors du Ne jamais toucher le corps de la torche la pi ce couper ou l eau de la table eau pendant le fonctionnement du syst me plasma Pr vention des chocs lectriques Tous les syst mes plasma Hypertherm utilisent des hautes coupage tensions pour le coupage souvent de 200 400 V On Avant de v rifier de nettoyer ou de remplacer les pi ces doit prendre les pr cautions suivantes quand on utilise le de la torche couper l alimentation ou d brancher la prise syst me plasma de courant Porter des bottes et des gants isolants et garder le corps Ne jamais contourner ou court circuiter les verrouillages et les v tements au sec de s curit L H Ne pas se tenir s asseoir ou se coucher sur une surface Avant d enlever le capot du syst me ou de la source de mouill e ni la toucher quand on utilise le syst me plasma courant couper l alimentation lectrique Attendre ensuite 5 minutes pour que les condensateurs se d chargent Ne jamais faire fonctionner le syst me plasma sans que les capots de la source de courant ne soient en place Les raccords expos s de la source de courant sont extr mement dangereux Lors de l installation des connexions attacher tout d abord la prise de terre appropri e Chaque syst me plasma Hypertherm est concu pour tre utilis uniquement avec des torches Hypertherm sp cifiques Ne pas
18. es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans conna tre 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 T IDENTIFIER LES CONSIGNES DANGER AVERTISSEMENT ATTENTION Hypertherm adopte les lignes directrices de l American National Standards Institute relativement aux termes aux symboles et la signalisation de s curit 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 AVERTISSEMENT sont situ es sur la machine pour signaler certains dangers sp cifiques Les messages de s curit DANGER pr c dent les directives associ es dans le manuel qui si elles ne sont pas suivies scrupuleusement entra nent des blessures graves voire mortelles 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 s curit ATTENTION pr c dent les directives associ es dans le manuel qui si elles ne sont pas suivies scrupuleusement peuvent entra ner des blessures secondaires ou endommager l quipement
19. it the installation also may be subject to approval by local authorities Seek advice from legal counsel and local regulatory experts if uncertain about compliance External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site When the external inter connecting cables are subject to oil dust or water contaminants hard usage ratings may be required When external interconnecting cables are subject to continuous movement constant flexing ratings may be required It is the responsibility of the end use customer or the OEM to ensure the cables are suitable for the application Since there are differences in the Hypertherm ratings and costs that can be required by local regulations for higher level systems it is necessary to verify that any external interconnecting cables are suitable for the end use installation site 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 Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other pro
20. los reglamentos y normas y este manual nunca debe interpretarse como si lo hiciera as Hypertherm 1b 11 11 08 SEGURIDAD 1b 12 Hypertherm 11 08 In this section Power SUpply Duty cycle ttt Dimensions and weight T100 torches ina Torch dimensions 1100 hand torch iiim eiie T100M 2 machine torch Symbols and E MT powermax1650 Operator Manual Section 2 SPECIFICATIONS SPECIFICATIONS Power supply Rated open circuit voltage Uo 300 VDC Output characteristic Drooping Detined as a plot of output voltage versus output current Rated output current Io 30A 100A Hypertherm Standard Rated Output 160 Voltage Us Duty cycle X at 104 F 40 C at U Volts AC rms X rated conditions Uy h Us lo 200 208 VAC 3PH 60 230 240 VAC 3PH 70 Tpasos 380 415 8090 time minutes 480 VAC 3PH 80 Tbase 10 minutes 600 3PH 8090 Operating temperature 140 to 1040 100 to 400 Rated phases PH and line frequency Hz PH Hz Standard and CE Model 3 50 60 Rated input voltage Uy rated input U4 Volts AC rms l Amps rms current 1 and at rated output 200 208 VAC 3PH 53 41 Us and l cutting only 230 240 VAC 3PH 46 38 380 415 VAC 3PH 27 24 1 VX used to determine 480 VAC 3PH 20 20 rating of power cord 600 VAC 3PH 21 19 Uy Volts A
21. may only be used in mechanized torch applications N IJ J Maintain a torch to work distance of 40A 80A 100A approximately 1 8 inch 3mm 220061 Use an ohmic sensing cap when a compatible torch height contoller is installed Unshielded 120979 120928 220006 60A i O ring 120979 120928 220007 120926 120925 058519 i EN 1 0 D 120979 120928 120980 100A 0 40 120979 220048 220064 220037 220051 4 6 powermaX1650 Operator Manual OPERATION Set the mode switch E Use to cut expanded metal Automatically reinitiates pilot LF Use to cut plate sheet metal m Optimum consumable life Use gouge or for non transfered arc operation Y Mo Turn ON the power Position the power switch to ON 1 as shown Note The cooling fan is automatic and will only operate when needed Check the indicator lights ES Check that the power ON lamp is illuminated Check that the gas pressure LED illuminates green Check that the remaining indicator lamps are NOT illuminated See Section 5 Maintenance and powermax1650 Operator Manual 4 7 2 OPERATION Adjust the gas pressure and current setting PEN o 60 y A 80 Set the current knob to gas test Push the regulator knob to lock it Q H Y AMPS il 5 N 80 Pull the regulator knob to unlock it Set the cutting current 30 amps minim
22. meets national or local electrical codes The plug must be connected to the power cord by a licensed electrician Power cord installation 1 Strip and prepare the power cord wires as shown below om d EMEN e peer L3 DEEE Ground PE e orm eem 10 Green Yellow 6 152 mm 2 Connect the power cord to the power switch Note CE power supplies L1 L2 and L3 are threaded through 2 ferrites before being attached ot the switch L1 L2 L3 Route power cord through strain 7 relief and tighten Power switch Strain relief Strain relief inserts 2 Ground PE powermax1650 Operator Manual 3 7 SETUP Torch installation 1 Turn OFF the power OFF 2 Remove the power cord from the power receptacle A 3 Open the Easy Torch Removal ETR door and route the lead through the end cap ZIEL Cmm A ETR door 3 8 powermax1650 Operator Manual SETUP 4 Align the marks on the strain relief 5 Pull back the quick release collar and insert the lead s gas fitting E 9
23. mensajes de seguridad de PELIGRO preceden instrucciones relacionadas en el manual que resultar n en lesi n grave o muerte si no se las sigue correctamente En este manual la palabra ADVERTENCIA va seguida de instrucciones que si no se siguen correctamente pueden provocar lesiones e inclusive la muerte Los mensajes de seguridad de CUIDADO o PRECAUCI N preceden mensajes relacionados con instrucciones en el manual que puede resultar en lesiones menores o da o a equipo si no se siguen correctamente O EXPLOSIONES Prevenci n ante el fuego Aseg rese de que el rea sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables coloc ndolos a por lo menos 10 metros del rea de corte Remoje los metales calientes o permita que se enfrien antes de que entren en contacto con materiales combustibles Nunca corte dep sitos que contengan materiales inflamables primero es necesario vaciarlos y limpiarlos debidamente Antes de realizar cortes en atm sferas potencialmente inflamables aseg rese de ventilar bien Al realizar cortes utilizando ox geno como gas plasma se requiere tener un sistema de ventilaci n de escape Prevenci n ante explosiones No corte en atm sferas que contengan polvo o vapores explosivos No corte dep sitos o tubos a presi n ni cualquier dep sito cerrado No corte dep sitos que hayan contenido m
24. of the product with a CE marking GOST R mark CE versions of Hypertherm products that include a GOST R mark of conformity meet the product safety and EMC requirements for export to the Russian Federation c Tick mark CE versions of Hypertherm products with a c Tick mark comply with the EMC regulations required for sale in Australia and New Zealand CCC mark The China Compulsory Certification CCC mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China Hypertherm WARNING LABEL This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on the label 1 1 1 2 1 3 2 1 2 2 2 3 3 1 3 2 3 3 Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS 249 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health Standards 29 CFR 1910 http www osha gov 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables 1 2 Have a fire extinguisher nearby and ready to use 1 3 Do not use a drum or other closed container as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when trigg
25. of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the 4 08 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 TS 62081 Arc Welding Equipment Installation and Use Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications Hypertherm Attention 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 You are responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Pr
26. pas utiliser dans des espaces clos Chasser les fum es avec la ventilation Les rayons d arc peuvent br ler les yeux et blesser la peau Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Se prot ger les oreilles contre le bruit Utiliser le masque de soudage avec le filtre ayant le bon indice de protection S entrainer Seul le personnel qualifi doit faire fonctionner cet quipement Utiliser les torches prescrites dans le manuel Tenir le personnel non qualifi et les enfants l cart Ne pas enlever d truire ou couvrir cette tiquette La remplacer si elle est manquante endommag e ou us e Hypertherm S CURIT INFORMATION SUR LE D POUSSI RAGE certains endroits la poussi re peut repr senter un risque d explosion potentiel certains endroits la poussi re peut repr senter un risque d explosion potentiel La norme NFPA 68 de la National Fire Protection Association des U dition 2007 Explosion Protection by Deflagration Venting tablit les exigences relatives la conception l emplacement l installation l entretien et l utilisation de dispositifs et de syst mes pour vacuer l air libre les gaz de combustion et les pressions apr s une ventuelle d flagration Communiquer avec le fabricant ou avec l installateur pour tout syst me de d poussi rage afin de conna tre les
27. shock or burn Wear insulating gloves Replace gloves when wet or damaged Protect from shock by insulating yourself from work and ground Disconnect power before servicing Do not touch live parts Hypertherm 7 Do not remove destroy or cover this label Replace if it is missing damaged or worn PN 110584 Rev C 4 1 4 2 4 3 SAFETY Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death Le coupage plasma peut tre pr judiciable pour l op rateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de s curit peut entrainer la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un fat ou un autre contenant ferm comme table de coupage 2 l arc plasma peut blesser et br ler loigner la buse de soi Il s allume instantan ment quand on 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 3 1 Porter des gants isolants Remplacer les g
28. table humide s che sous l eau Composition du mat riau fini de la surface et composition des rev tements Volume de mat riau enlev Dur e du coupage ou du gougeage Dimensions volume d air ventilation et filtration de la zone de travail quipement de protection individuelle Nombre de syst mes de soudage et de coupage en fonctionnement Autres proc d s du site qui peuvent produire des vapeurs Si les lieux de travail doivent tre conformes aux r glements nationaux ou locaux seuls les contr les ou les essais effectu s au site peuvent d terminer si celui ci se situe au dessus ou au dessous des niveaux admissibles Pour r duire le risque d exposition aux vapeurs liminer tout rev tement et solvant du m tal avant le coupage Utiliser la ventilation d extraction locale pour liminer les vapeurs de l air Ne pas inhaler les vapeurs Porter un respirateur adduction d air quand on coupe des m taux rev tus d l ments toxiques ou qui en contiennent ou sont susceptibles d en contenir S assurer que les personnes qui utilisent un mat riel de soudage ou de coupage ainsi que les dispositifs de respiration par adduction d air sont qualifi s et ont recu la formation sur la bonne utilisation d un tel mat riel Ne jamais couper les contenants dans lesquels il peut y avoir des mat riaux toxiques En premier lieu vider et nettoyer correctement le contenant Contr ler ou prouver la qualit
29. trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra de conformidad con los c digos el ctricos nacionales o locales apropiados SEGURIDAD DE TOMA A TIERRA Potencia primaria de entrada Aseg rese de que el alambre de toma a tierra del cord n de alimentaci n est conectado al terminal de tierra en la caja del interruptor de corriente Si la instalaci n del sistema de plasma supone la conexi n del cord n de alimentaci n primaria a la fuente de energ a aseg rese de conectar correctamente el alambre de toma a tierra del cord n de alimentaci n primaria Coloque en primer lugar el alambre de toma a tierra del cord n de alimentaci n primaria en el esp rrago luego coloque cualquier otro alambre de tierra sobre el conductor de tierra del cable Ajuste firmemente la tuerca de retenci n Aseg rese de que todas las conexiones el ctricas est n firmemente realizadas para evitar sobrecalentamientos SEGURIDAD DE LOS EQUIPOS DE GAS COMPRIMIDO Nunca lubrique reguladores o v lvulas de cilindros con aceite o grasa Utilice solamente cilindros reguladores mangueras y conectores de gas correctos que hayan sido dise ados para la aplicaci n espec fica Mantenga todo el equipo de gas comprimido
30. utiliser des torches inappropri es d utilisation d une table eau s assurer que cette qui pourraient surchauffer et pr senter des risques pour derni re est correctement mise la terre la s curit S isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol S il s av re n cessaire de travailler dans ou pr s d un endroit humide proc der avec une extr me prudence Installer un sectionneur avec fusibles appropri s proximit de la source de courant Ce dispositif permet l op rateur d arr ter rapidement la source de courant en cas d urgence L LECTRICIT STATIQUE PEUT ENDOMMAGER lt gt LES CARTES DE CIRCUITS IMPRIM S a LS On doit prendre les pr cautions qui s imposent quand on On doit ranger les cartes de circuits imprim s dans des manipule les circuits imprim s contenants antistatiques On doit porter un bracelet antistatique quand on manipule les cartes de circuits imprim s Hypertherm 1a 3 11 08 S CURIT L arc plasma est lui m me la source de chaleur utilis e pour le coupage Par cons quent bien que l arc plasma pas t reconnu comme une source de vapeurs toxiques le mat riau coup peut tre une source de vapeurs ou de gaz toxiques qui puisent l oxyg ne Les vapeurs produites varient selon le m tal coup Les m tau
31. work must be performed following applicable local and national codes 1 Disconnect the power from the power supply 2 Remove the screws that attach the power supply cover to the chassis Remove the cover 3 Route the cable through the strain relief at the rear of the power supply powermax1650 Operator Manual 3 13 SETUP 4 Find the power board Use insulated type 1 4 inch faston terminal ends to connect to J15 and J16 Signal Arc voltage torch height control Type Output Notes Full arc voltage No voltage divider 300 VDC maximum Signal not available on rear panel connector J15 VDC 16 VDC 5 Tighten the strain relief 6 Replace the cover 3 14 powermax1650 Operator Manual SETUP Changing XFER start machine motion from dry contact closure to voltage signal 24 VDC chassis ground reference at 100ma max is available at J19 on the powerboard to drive an isolated floating device such as a 24 VDC relay coil
32. y las piezas relacionadas en buen estado Coloque etiquetas y c digos de color en todas las mangueras de gas para identificar el tipo de gas que conduce cada una Consulte los c digos locales o nacionales aplicables LOS CILINDROS DE GAS PUEDEN EXPLOTAR SI EST N DA ADOS Los cilindros de gas contienen gas bajo alta presi n Un cilindro da ado puede explotar Manipule y utilice los cilindros de gas comprimido de acuerdo con los c digos locales o nacionales aplicables No use nunca un cilindro que est de pie y bien sujeto Mantenga la tapa de protecci n en su lugar encima de la v lvula excepto cuando el cilindro se encuentre en uso o conectado para ser utilizado No permita nunca el contacto el ctrico entre el arco de plasma y un cilindro No exponga nunca los cilindros a calor excesivo chispas escorias o llamas No emplee nunca martillos llaves otro tipo de herramientas para abrir de golpe la v lvula del cilindro 1b 6 11 08 Hypertherm SEGURIDAD n EL RUIDO PUEDE DETERIORAR LA AUDICI N La exposici n prolongada al ruido propio de las operaciones de corte y ranurado puede da ar la audici n Utilice un m todo de protecci n de los o dos aprobado al utilizar el sistema de plasma Advierta a las dem s personas que se encuentren en las cercan as acerca del peligro que supone el ruido excesivo UN ARCO PLASMA PUEDE DA AR TUBOS CONGELAD
33. 037 220051 torch Or o S RS q Mild steel Pierce Material thickness Maximum travel speed Optimum travel speed Arc current Arc voltage delay inches J mmmn PM mm 05 ve 28 2 3429 sos os 119 202 7 1055 159 17 2236 1447 aL E E T E 1549 1016 35 26 660 109 aa E Ame 228 7H 39 p 457 rue 4 2 305 Stainless steel Arec rrent Arevolt ge Pierce Material thickness Maximum travel speed Optimum travel speed 99 delay BL PL RO IC 92 3029 2008 L8 127 7 2006 30 159 52 1320 BE E ERN 166 BILAN NEAN Aluminum Pierce delay inches mm mmmn mmmin BI es 390 12 127 2 35 gt 365 NA Tv 254 es 70 1270 38 NES Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality Optimum travel speeds 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 different cut assignment Every cutting system requires fine tuning for each cutting application in order to obt
34. 11 OPERATION Piercing WARNING p SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others Fire the torch at an angle to the workpiece then slowly rotate it to an upright position When sparks are exiting from the bottom of the workpiece the arc has pierced through the material When the pierce is complete proceed with the cut 4 12 powermaX1650 Operator Manual OPERATION WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others Hold the torch so that the nozzle is within 1 16 in 1 5 mm from the workpiece before firing the torch Hold the torch at a 45 angle to the workpiece Pull the trigger to obtain a pilot arc Transfer the arc to the work piece Maintain an approximate 45 angle to the workpiece Feed into the gouge Le Direction of travel 45 Note A heat shield is available for added hand and torch protection part number 220049 powermax1650 Operator Manual 4 13 OPERATION Cut charts 100 amp mechanized shielded consumables Torch to work distance for the following cut chart is 1 8 in 3 2 mm for all cuts Shield Retaining cap Nozzle Electrode Swirl ring T100M 2 220047 220048 220011 220
35. 5 3 MAINTENANCE AND PARTS Filter element replacement 1 Use a screwdriver to remove the filter element from the filter Re install filter bowl the electrical power and the gas supply Remove the filter bowl A Pull down and hold the black release tab If you do not see the tab check the back of the filter bowl B Rotate the filter bowl in either direction until it releases C Pull the filter bowl down to remove it The bowl has an o ring around the top Do not discard the o ring If the o ring shows signs of wear or otherwise needs replacement verify that you have the correct o ring for the filter Each filter has a label on one side of the filter body For AFSO filters use part number 011105 For NAF3000 filters use part number 011094 housing Then install the new filter element Note Do not allow the filter element to turn when loosening the screw A Hold down the black tab and slide the filter bowl over the filter element B Align the marks on filter bowl and the filter body C Rotate the filter bowl until it locks in place powermaxXx 1650 Operator Manual Basic troubleshooting Problem 1 The ON OFF power switch is set 1 1 to ON and the power ON green lamp is not illuminated Note 1 2 The fan turns on automatically The fan may not be in operation when the power is ON 2 The power ON green low gas 2 1 pressure yellow is fl
36. 50 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 3 ANSI Standard 287 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 5 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 6 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 Hypertherm 7 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada 8 NFPA Standard 51B Cutting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 10 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 11 AWS Safety and Heal
37. 6010101 J16 J15 J19 B XFER START yo UV ON a E 2 gt ADT O gt Notes 1 Customer supplied 24 VDC relay coil gt 240 ohms 2 Customer supplied 24 VDC power source 3 Must use suppression diode 1A 100V such as IN4002 through IN4004 type across coil 4 Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider powermax1650 Operator Manual 3 17 SETUP Driving an industrial isolated input module with an external power source 16 A 216 J15 J19 XFER START 4 a E gt gt 616168161616 3 18 Shield n Y 24 VDC Isolated input module Notes 1 Customer supplied isolated input module Customer supplied 24 VDC power source Pins 5 and 6 are used only on systems that include the PowermaxEDGE cable with voltage divider powermaX1650 Operator Manual Section 4 OPERATION In this section Controls and indicators dicato Install the consumables T100 consumable configuratioris nter intent iia ai 4 4 NOIL
38. C rms Harmonic power factor Displacement power factor Power factor 200 208 VAC 3PH 0 94 0 98 230 240 VAC 3PH 0 94 0 98 380 415 VAC 3PH 0 94 0 99 480 VAC 3PH 0 94 0 99 600 VAC 3PH 0 78 0 99 7 Short Circuit Ratio CE model only Volts AC rms 3PH Rice 400 VAC 191 230 VAC 142 This equipment conforms to IEC 61000 3 12 provided that Rsce min 191 at 400VAC 3PH and 142 at 230 VAC 3PH IP code Degree of protection IP23CS provided by enclosure IP International Protection 2 No ingress foreign objects 212 5mm 0 5 in No harmful ingress spraying water circuits protected against ingress of tool 22 5 mm dia x 100 mm long 0 1 inch x 4 0 inch S fan stationary during water test WARNING DO NOT OPERATE IN THE RAIN Toppling tilting with or without wheel kit Up to 15 incline Gas type Air Nitrogen Gas quality Clean moisture free oil free Gas inlet pressure and flow 90 psig 6 1 bar 550 scfh 9 2 scfm 260 l min 2 2 powermaX1650 Operator Manual Duty cycle SPECIFICATIONS Duty cycle is the percentage of time during a 10 minute period that the power supply can cut continuously The diagram below depicts an 80 duty cycle mm mum gt gt 8 minutes cutting Dimensions and weight Weight of power supply without torch powermaxXx 1650 Operator Manual 2 minutes resting 16 8 in a 427 26 4 in 427 mm
39. Manual SETUP Gas supply installation Connect the air hose as follows 1 Air fitting For the standard model Install a 1 4 NPT gas fitting on to the air filter inlet The CE model provides a G1 4 adapter in the CE kit Use liquid pipe sealant on the threads CAUTION Never use PTFE tape when installing the nipple or adapters Bits of tape can break off and enter the air line and harm the pressure regulator pressure switch and valve Nipple Adapter is found in the consumables box located on the side of the power supply cover 2 Air hose Usean inert gas hose with a 3 8 inch 9 5 mm internal diameter Connect it to the gas fitting installed in step 1 Adjust the air pressure according to the procedure in Section 4 Operation T100M 2 torch alignment Mount the machine torch perpendicular to the workpiece in order to get a vertical cut Use a square to align the torch at 0 and 90 Torch powermaXxX1650 Operator Manual 3 11 SETUP ON OFF pendant connection For the machine torch T100 inputs for arc start are available through the machine interface connection on the rear of the power supply Plug the Hypertherm remote pendant see Section 5 Maintenance and parts for part numbers into the connector on the rear panel NC The ON OFF remote pendant will not operate when a hand torch is installed Machine interface connection
40. Maximum travel speed Optimum travel speed 9 delay ie is os 400 10160 6604 ea 145 368 94 346 075 os 7 1880 18 1 50 s 15s 888 21 141 Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality Optimum travel speeds 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 different cut assignment Every cutting system requires fine tuning for each cutting application in order to obtain the desired cut quality 4 16 powermaxXx 1650 Operator Manual 3 OPERATION 40 amp mechanized shielded consumables Torch to work distance for the following cut chart is 1 16 in 1 5 mm for all cuts Shield Retaining cap Nozzle Electrode Swirl ring 120930 120928 120932 120926 120925 Mild steel Ave l Arevolade Pierce Material thickness Maximum travel speed Optimum travel speed 9 delay inches PM mmmn mm min 564 os 636 16208 1054 os me 22Ga 500 12700 8255 GA 13 312 7925 5156 7 4 2896 344 025 146a 19 640 16256 5613 oso 10GA 181 3885 98 2489 ane ar 97 2404 63 1600 149 1 4 74 1880 1219 AT AAA pow qoe poe
41. NStruCtiONns rrr avc dcindc erect deter Cutting cari cause fire Or explosiOn ct etn trita tnt erba a rats z Electric shock can kill tt ttem Static electricity can damage circuit boards Toxic fumes can cause injury or death plasma arc can cause injury and Burns sinusite ennemis Arc rays can burn eyes and skin da ae a ina init E C rem rolelruidimm es Compressed gas equipment safety sen Gas cylinders can explode if damaged Noise can damage hearing see Pacemaker and hearing aid operation A plasma arc can damage frozen pipes sise Additional safety Information sisi een Warning labels ttes a ne nas Dustcoll cti n Informaticos reper cte stie dana sitet cie RE Cu cited alado Section 1a S curit Identifier les consignes de s curit in la 2 Suivre les instructions de s curit sn la 2 Le coupage peut provoquer un incendie ou une explosion ss 1 2 Les chocs lectriques peuvent tre fatals nn 1a 3 L lectricit statique peut endommager les cartes de circuits imprim s 1a 3 Les vapeurs toxiques peuvent provoquer des blessures OU 1 4 plasma peut provoquer des blessures ou des br lures la 5 Les rayons de l arc peuvent br ler les yeux et la peau ttntnnnnn 1a 5 Mise la masse et la terre nn 1a 6 S curit des boute
42. O pit nuria rmm 3 6 POW COS ii EE a E id M 3 6 Three phase power cord plug installation sn 3 7 Power Cord installation lei 3 7 Plug ASTANA TOM vaina noia cacao aid aia 3 7 Torch installation me 3 8 Plasma gas Supply aaah italiana 3 10 Additional gas filtration aida 3 10 Gas supply installation sn 3 11 1 2 torch alignment trente suis non id 3 11 viii powermaX1650 Operator Manual TABLE OF CONTENTS ON OFF pendant CONNECTION cisne 3 12 Machine interface connection ccce ceteri edite it 3 12 us 3 13 Changing XFER start machine motion from dry contact closure to voltage signal 3 15 Section 4 Operation Gontrols and indicator sans meo on mie dirt avi his ari 4 2 Indicator LES eio ee ie cde t t c d p ds 4 2 Iristallthie consumables nece titer reti i EE OH ORE pipa nasa 4 3 1100 consumable configurations itc erreur area 4 4 SIDE M 4 4 Unshieldedi usi ert AAA et e cR aed 4 4 Hise 4 4 GOUGING 4 5 T100M 2 consumable configurations scsi 4 5 ohielded tti AAA AAA O 4 5 FING CPP 4 6 O
43. OFF switch is activated Turn the start signal OFF Turn the power OFF and then ON again The consumables are stuck or jammed Turn the power OFF and check the consumables powermaX1650 Operator Manual MAINTENANCE AND PARTS ircuit diagram System c y910L J Josues jeuuojsueJ Josues eJnjejeduue quIsteay 1ndinQ o piousjos Y 591108 WDN LA 1osues aunssald 154 IN SL 251 ISL deg HEIS Josuas Jejsuei SN gdl JUJx mR NOM po i de 1eMod 1 AIUO 39 1951 cL 2 pueog x E 19414 INS ir D T 3 KHsoog 1491 UU pi 1 du ndino UUJ La JeMoq 40p98uu07 YOUMS 1991 1891 jeueu 1801 15008 JOSU9S NSS pJeoq p1eoq
44. OS Se puede hacer da o a los tubos congelados o se los puede reventar si uno trata de descongelarlos con una antorcha por plasma OPERACI N DE E MARCAPASOS Y DE AUD FONOS Los campos magn ticos producidos por las elevadas corrientes pueden afectar la operaci n de marcapasos y de audifonos Las personas que lleven marcapasos y audifonos deber n consultar a un m dico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magn ticos Mantenga el cable de trabajo y la manguera de la antorcha a un lado lejos del cuerpo Dirija la manguera antorcha lo m s cerca posible del cable de trabajo No envuelva el cable de trabajo ni la manguera de la antorcha en su cuerpo Mant ngase tan lejos de la fuente de energ a como sea posible Hypertherm 1b 7 11 08 SEGURIDAD S MBOLOS Y MARCAS Su producto de Hypertherm puede tener una o m s de las marcas que siguen en o cerca de la placa de datos Debido a diferencias y conflictos en reglamentos nacionales no todas las marcas se aplican a toda versi n del producto s S mbolo de marca S El s mbolo de marca S indica que la fuente de energ a y antorcha son aptas para operaciones que se llevan a cabo en entornos con peligro aumentado de choque o descarga el ctrica seg n IEC 60974 1 6 Marca CSA Los productos de Hypertherm con la marca CSA cumplen con los r
45. Signals for arc transfer and start are available through the machine interface connection on the rear of the power supply Plug the machine interface cable Part number 023206 into the connector on the rear panel Powermax1650 power supplies sold as part of the PowermaxEdge package include a machine interface cable with a voltage divider Li odd Refer to the following table when connecting the machine interface cable to the cutting machine Signal Start start plasma XFER start machine motion Normally open Dry contact closure Normally open 18VDC open circuit when the arc transfers 120VAC 1A voltage at START terminals REquires maximum at the machine interface relay dry contact closure to activate or switching device supplied by the customer li sockets Green black Red black 3 12 powermaxXx 1650 Operator Manual SETUP WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring removal of the power supply cover must be performed by a qualified technician Arc voltage If arc voltage is necessary for activating a torch height control the customer must supply an 18 AWG 1 0 mm2 single pair unshielded cable rated for 300V or greater All
46. a table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s MISE LA MASSE ET LA TERRE 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 e S assurer que toutes les connexions sont bien serr es pour viter la surchauffe 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 codes locaux ou nationaux en vigueur LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES Les bouteilles de gaz contiennent du gaz haute pression Si une bouteille est endommag e e
47. ain the desired cut quality 4 14 powermaX1650 Operator Manual 3 OPERATION 80 amp mechanized shielded consumables Torch to work distance for the following cut chart is 1 16 in 1 5 mm for all cuts Shield Retaining cap Nozzle Electrode Swirl ring 120930 120928 120927 120926 120925 Mild steel A Pa Pierce Material thickness Maximum travel speed Optimum travel speed 8 delay inches mm mmmn mmmn a 025 as ne 5486 140 355 085 106 2667 os os s ze s 1 2 127 60 1524 991 945 vem EEES EA 23 584 381 Stainless steel PR Arcvotage Pierce Material thickness Maximum travel speed Optimum travel speed delay inches mm mmmn IPM mmmn o as ne 5406 mo sse 186 oso ve ea 2815 om 3 38 5 197 Pepe Le 88 RE 559 ww 1 2 16 ws w 254 14 356 o 229 Aluminum A Re Pierce Material thickness Maximum travel speed Optimum travel speed 9 delay Finches PM mmmn PM mn 395 ve 2 25 7695 vam ea m 2996 os 3s 09 5x ir 195 37 w 199 37 19 488 Maximum travel speeds are the faste
48. aintenance of cutting equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation The cutting equipment should not be modified in any way except 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 Cutting cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components 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
49. alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 3 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 8 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 8 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger les oreilles contre le bruit Utiliser un masque de soudeur avec un filtre de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Utiliser exclusivement les torches indiqu es dans le manual Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev C Las chispas producidas por el corte pueden causar ex
50. and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields and a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays 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 to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs m o mentee to coma Europe amps ANSIZ49 1 2005 ANSI 249 1 2005 1910 133 8 5 EN168 2002 Less than 40 A 5 5 8 9 41 to 60 6 6 8 9 61 1080 8 8 8 9 81to125A 8 9 8 9 126 to 150A 8 9 8 10 151 to 175 A 8 9 8 11 176 to 250A 8 9 8 12 251 to 300 8 9 8 13 301 to 400 A 9 12 9 13 401 to 800 A 10 14 10 Hypertherm 1 5 11 08 SAFETY A GROUNDING SAFETY Work Cabl
51. ant ce type d appareil doivent consulter 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 Se tenir le plus loin possible de la source de courant 1a 7 11 08 S CURIT SYMBOLES ET MARQUAGE Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signal tique ou proximit En raison des diff rends et des conflits relatifs aux r glements nationaux toutes les marques ne sont pas appliqu es chaque version d un produit 1 8 Symbole marque 5 Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectu s dans les milieux risque accru de choc lectrique selon 60974 1 Marque CSA Les produits Hypertherm comportant la marque CSA r pondent aux r glements des tats Unis et du Canada relatifs la s curit du produit Les produits sont valu s mis l essai et certifi s par la CSA International En outre le produit peut porter une marque d un des laboratoires d essai reconnus sur le plan national NRTL accr dit aux tats Unis e
52. ants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 8 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger les oreilles contre le bruit Utiliser un masque de soudeur avec un filtre de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Utiliser exclusivement les torches indiqu es dans le manual Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev Plasma fumes can be hazardous Do not inhale fumes Use forced ventilation or local exhaust to remove the fumes Do not operate in closed spaces Remove fumes with ventilation Arc rays can burn eyes and injure skin Wear correct and appropriate protective equipment to protect head eyes ears hands
53. ashing and fault Red lamps are illuminated LD 2 2 2 3 3 The power on line voltage 3 1 yellow and fault red lamps are illuminated powermaXxX1650 Operator Manual MAINTENANCE AND PARTS Cause Solution The power cord is not plugged into the power receptacle Plug the power cord into the receptacle The disconnect power switch is not set to ON or there is no power available to the disconnect power switch box Turn on the power at the main power panel or at the disconnect power switch box The gas supply is turned OFF or not connected to the power supply Check that the gas is turned on and is connected to the power supply The gas supply pressure is too low Set the incoming gas supply pressure to 90 120 psig 6 2 8 3 bar Check that there are no leaks in the gas supply line Operating gas pressure is set too low for the selected mode Adjust the operating gas pressure See Section 4 for pressure settings The line voltage is too low too high or a phase is missing Have a qualified technician check the incoming power MAINTENANCE AND PARTS Basic troubleshooting continued Problem 4 The power ON green 4 1 temperature yellow and fault red lamps are illuminated go 5 The power ON green torch parts loose or removed yellow and fault red lamps are illuminated 5 1 6 The arc does not transfer to the 6 1 workpiece 6 2 6 3 Cause
54. ateriales combustibles LOS CORTES PUEDEN PROVOCAR INCENDIOS ADVERTENCIA Peligro de explosi n Arg n Hidr geno y metano El hidr geno y el metano son gases inflamables que suponen un peligro de explosi n Mantenga el fuego lejos de los cilindros y las mangueras que contengan mezclas de hidr geno o metano Mantenga la llama y las chispas lejos de la antorcha al utilizar metano o arg n hidr geno como plasma Al cortar aluminio bajo agua o con agua en contacto con el lado inferior del aluminio puede acumularse gas hidr geno bajo la pieza a cortar y detonar durante la operaci n de corte por plasma Instale un m ltiple de aireaci n en el fondo de la mesa de agua para eliminar la posibilidad de la detonaci n del hidr geno Consulte la secci n del ap ndice de este manual para conocer detalles acerca del m ltiple de aireaci n ADVERTENCIA Detonaci n de hidr geno con el corte de aluminio 1b 2 Hypertherm 11 08 SEGURIDAD e El contacto directo con piezas el ctricas conectadas puede provocar un electrochoque fatal o quemaduras graves Al hacer funcionar el sistema de plasma se completa un circuito el ctrico entre la antorcha y la pieza a cortar La pleza a cortar es una parte del circuito el ctrico como tambi n cualquier cosa que se encuentre en contacto con ella Nunca toque el cuerpo de la antorcha la pieza a cortar o el agua en una mesa de agua cuando el sistema de
55. ation Other site processes that may produce fumes If the workplace must conform to national or local regulations only monitoring or testing done at the site can determine whether the site is above or below allowable levels To reduce the risk of exposure to fumes Remove all coatings and solvents from the metal before cutting Use local exhaust ventilation to remove fumes from the air Do not inhale fumes Wear an air supplied respirator when cutting any metal coated with containing or suspected to contain toxic elements Assure that those using welding or cutting equipment as well as air supplied respiration devices are qualified and trained in the proper use of such equipment Never cut containers with potentially toxic materials inside Empty and properly clean the container first Monitor or test the air quality at the site as needed Consult with a local expert to implement a site plan to ensure safe air quality Hypertherm SAFETY UF A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant On Torches The plasma arc will cut quickly through gloves Plasma arc comes on immediately when the torch and skin switch 15 activated Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others ARC RAYS CAN BURN EYES AND SKIN Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet
56. bols and markings 5 mark The 5 mark indicates that the power supply and torch are suitable for use in environments with in creased hazard of electrical shock The hand torches must have shielded consumable parts to maintain S mark compliance CE mark The CE mark C constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE mark located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE mark IEC Symbols Used The following symbols may appear on the power supply data plate control labels and switches Direct current DC Alternating current AC Plasma torch cutting LY gouging jam AC input power connection The terminal for the external protective earth conductor inverter based power DE P K A source Plasma torch in the TEST position cooling and cutting gas exiting nozzle Power is ON Power is OFF Volt amp curve drooping characteristic powermaX1650 Operator Manual Section 3 SETUP In this section PORTE CO Pta iia 3 2 Cla anne ai 3 2 Contents Of box t et ttc i 3 2 Lifting th power SUpply xit h
57. completamente No retire las etiquetas de advertencia ni las cubra con pintura 1b 9 11 08 SEGURIDAD ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energ a Es importante que el operador y el t cnico de mantenimiento comprendan el sentido de estos simbolos de advertencia seg n se describen El texto numerado corresponde a los cuadros numerados de la etiqueta 110647 Rev A www hypertherm com weee mmm 1b 10 11 08 Las chispas producidas por el corte pueden causar explosiones o incendios Mantenga los materiales inflamables lejos del lugar de corte Tenga a mano un extinguidor de incendios y aseg rese de que alguien est preparado para utilizarlo No corte dep sitos cerrados El arco de plasma puede causar quemaduras y lesiones Apague la fuente de energ a antes de desarmar la antorcha No sostenga el material junto al trayecto de corte Proteja su cuerpo completamente Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque Col quese guantes aislantes No utilice guantes da ados o mojados Aislese de la pieza de trabajo y de la tierra Antes de trabajar en una m quina desconecte el enchufe de entrada la potencia primaria La inhalaci n de los humos provenientes del rea de corte puede ser nociva para la salud Mantenga la cabeza fuera de los gases t xicos U
58. d additional assistance call the nearest Hypertherm office listed in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Contents of the box Check the items against the illustration L Y Y CSA CE i E Mechanized k ES Mechanize Es Manual jt 144 Mechanized oe Setup 3 2 powermaxXx 1650 Operator Manual 2 SETUP Lifting the power supply The system with torch weighs up to 150Ib 68 kg Always lift the power supply by TWO handles using two people or a hoist Do not lift the power supply by ONE handle The handle can break resulting in injury and damage Hoist Approved hoisting strap Keep power supply as horizontal as possible Cover in place powermaXxX1650 Operator Manual 3 3 SETUP Locating the power supply Locate the Powermax1650 power supply with at least 10 inches 0 25 m of open space at the f
59. dance with the information below to achieve electromagnetic compatibility The limits required by EN60974 10 may be adequate to completely eliminate interfer ence when the affected equipment is in close proximity or has a high degree of sensitivity In such cases it may be necessary to use other measures to further reduce interference This cutting equipment is designed for use only in an industrial environment Installation and use The user 15 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 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 electro magnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equipment Hypertherm b Radio and te
60. dicates that power 15 applied to the system and the power switch 16 ON 1 Gas pressure LED Yellow When flashing indicates that the gas pressure is below 65 psig 4 5 bar for cutting or 40 psig 2 8 bar for gouging Green When illuminated indicates that there is acceptable gas pressure for torch operation Yellow torch cap LED When illuminated indicates that the retaining cap is loose or not installed NOTE This condition must be corrected and the power turned OFF and then ON again to clear the LED Yellow temperature LED When illuminated indicates that the power supply temperature has exceeded its operating limit Red fault LED When illuminated indicates that a fault condition exists which prevents system operation A yellow LED should also be illuminated to identify the type of fault Yellow line voltage LED When illuminated indicates that line voltage is below 170 VAC above 680 VAC or missing a phase powermaX1650 Operator Manual OPERATION Install the consumables WARNING Instant On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn through gloves and skin Make sure the power is OFF before changing the consumables The instructions for hand torches are shown below If you are using a machine torch you may need to install it on the cutting table prior to installing the consumables amp lt Shie
61. duct not supplied by Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement and Hypertherm s obligation to indemnify shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim Limitation of liability In no event shall Hypertherm be liable to any person or entity for any incidental consequential indirect or punitive damages including but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise and even if advised of the possibility of such damages Liability cap In no event shall Hypertherm s liability whether such liability is based on breach of contract strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the Hypertherm WARRANTY use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim Insurance At all times you will have and maintain insurance in such quantities and types and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the
62. e ou us e 1a 9 11 08 S CURIT TIQUETTE DE S CURIT 1 Cette tiquette est affich e sur la source de courant Il est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Les num ros de la liste correspondent aux num ros des images 110647 Rev A www hypertherm com weee 1 10 11 08 Les tincelles de coupage peuvent provoquer une explosion ou un incendie Ne pas couper pr s des mati res inflammables Un extincteur doit se trouver sur les lieux et pr t tre utilis Ne pas utiliser un ou un autre contenant ferm comme table de coupe L arc plasma peut blesser et br ler ne jamais pointer la buse vers soi s amorce instantan ment quand on appuie sur la g chette Couper l alimentation avant de d monter la torche Ne pas saisir la pi ce pr s de la trajectoire de coupage Se prot ger enti rement le corps Tension dangereuse Risque de choc lectrique ou de br lure Porter des gants isolants Remplacer les gants s ils sont humides ou endommag s Se prot ger contre les chocs en s isolant de la pi ce et de la terre Couper l alimentation avant d entretenir Ne pas toucher les pi ces sous tension Les fum es du plasma peuvent tre dangereuses Ne pas inhaler les fum es Utiliser une ventilation forc e ou par aspiration la source pour liminer les fum es Ne
63. e Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to an earth ground in accordance with appropriate national or local electrical codes 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 connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and fittings designed for the specific application Maintain all compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes 1 6 11 08 GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas oylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accordance with applicable national or local codes Never use a cylinder
64. e Electrode Swirl ring T100M 2 cap torch 220329 120926 120925 For use with CE systems Use an ohmic sensing cap when a compatible torch height controller is installed E 220404 220061 Mild steel AR ent Arc voltage Material thickness Approximate travel 45 Stainless steel Arc current Arc voltage 195 184 30 314 __ 80 150 150 N 4 18 powermaX1650 Operator Manual OPERATION 100 amp mechanized unshielded consumables Torch to work distance for the following cut chart is 3 16 in 4 8 mm for all cuts Deflector Retaining cap Nozzle Electrode Swirl ring T100M 2 120979 220048 220064 220037 220051 torch Mild steel Pierce Material thickness Maximum travel speed E travel speed Arc current current Aro voltage Aro voltage de 155 Stainless steel de mmmn TPM 185 ve Lu 85 3142 10 12 127 2057 58 100 3146 5 8 159 pss a 7 NA nn Aluminum Pierce Material thickness Maximum travel speed Optimum travel speed Arc current Arc voltage delay inches PM mm min mm min iw os ve ea 25 6477 166 916 is 05 se 5 15 3886 99 2814 2717 1778 3147 10 39 159 77 1955 1270 180 15 ws 51 1295 154
65. e seguridad del producto requeridos para venta en China Q 1b 8 Hypertherm 11 08 ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energ a Es importante que el operador y el t cnico de mantenimiento comprendan el sentido de estos simbolos de advertencia seg n se describen El texto numerado corresponde a los cuadros numerados de la etiqueta 2 1 2 2 2 3 3 1 3 2 Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS 249 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health SEGURIDAD Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables 1 2 Have a fire extinguisher nearby and ready to use 1 8 Do not use a drum or other closed container as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulat
66. eglamentos de Estados Unidos y Canad para la seguridad del producto Estos productos fueron evaluados comprobados y certificados por CSA Internacional Alternativamente el producto puede tener la marca seg n uno de los otros Laboratorios de Prueba Reconocidos nacionalmente NRTL siglas en ingl s acreditados en ambos Estados Unidos y Canad tales como Underwriters Laboratories Incorporated UL T V Marcas CE Las marcas CE significan una declaraci n del fabricante de conformidad a las directivas y est ndares aplicables Europeos S lo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo la Compatibilidad Electromagn tico Europea EMC Los filtros EMC que necesitan cumplir con la Directiva Europea EMC est n incorporados dentro de las versiones del producto con la marca CE A Marca GOST R Las versiones de los productos Hypertherm CE que incluye la marca de conformidad GOST R cumplen con la seguridad del productos y los requisitos EMC para exportarse a la Federaci n Rusa Marca c Tick Las versiones CE de los productos Hypertherm con la marca c Tick cumple con los reglamentos EMC requeridos para venta en Australia y Nueva Zelandia Marca CCC La marca de Certificaci n Obligatoria China CCC en ingl s indica que el producto ha sido comprobado y se lo ha encontrado que cumple con los reglamentos d
67. ensa de mu eca conectada a tierra cuando maneje tablillas PC Hypertherm 1b 3 11 08 SEGURIDAD El arco plasma es por si solo la fuente de calor que se usa para cortar Seg n esto aunque el arco de plasma no ha sido identificado como la fuente de humo t xico el material que se corta puede ser la fuente de humo o gases t xicos que vacian el ox geno El humo producido var a seg n el metal que est cort ndose Metales que pueden liberar humo t xico incluyen pero no est n limitados a acero inoxidable acero al carb n cinc galvanizado y cobre En algunos casos el metal puede estar recubierto con una sustancia que podr a liberar humos t xicos Los recubrimientos t xicos incluyen pero no est n limitados a plomo en algunas pinturas cadmio en algunas pinturas y rellenos y berilio Los gases producidos por el corte por plasma varian bas ndose en el material a cortarse y el m todo de cortar pero pueden incluir ozono xidos de nitr geno cromo hexavalente hidr geno y otras substancias si est n contenidas dentro o liberadas por el material que se corta Se debe tener cuidado de minimizar la exposici n del humo producido por cualquier proceso industrial Seg n la composici n qu mica y la concentraci n del humo al igual que otros factores tales como ventilaci n puede haber el riesgo de enfermedad f sica tal como defectos de natividad o c ncer Es la responsabilidad del due
68. ered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away Cutting sparks can cause explosion or fire Do not cut near flammables Have a fire extinguisher nearby and ready to use Do not use a drum or other closed container as a cutting table Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered Turn off power before disassembling torch Do not grip the workpiece near the cutting path Wear complete body protection Hazardous voltage Risk of electric
69. ersions of Hypertherm s products do not comply with European EMC requirements and they do not have a CE marking on the data plate Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate These include Australia New Zealand Countries in the European Union Russia iv 4 08 It is important that the product and its certification test mark be suitable for the end use installation site When Hypertherm products are shipped to one country for export to another country the product must be configured and certified properly for the end use site Higher level systems When a system integrator adds additional equipment such as cutting tables motor drives motion controllers or robots to a Hypertherm plasma cutting system the combined system may be considered a higher level system A higher level system with hazardous moving parts may constitute industrial machinery or robotic equipment in which case the OEM or end use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm It is the responsibility of the end use customer and the OEM to perform a risk assessment for the higher level system and to provide protection against hazardous moving parts Unless the higher level system is certified when the OEM incorporates Hypertherm products into
70. exigences applicables avant d installer un tel syst me neuf ou d apporter des modifications importantes aux proc d s ou aux mat riaux utilis s un syst me de d poussi rage existant Consultez l autorit comp tente locale pour d terminer si une dition de la NFPA 68 a t adopt e par r f rence dans vos codes du b timent locaux Voir le document NFPA68 pour obtenir des d finitions et des explications des termes r glementaires tels que d flagration autorit comp tente adopt par r f rence valeur du pire cas indice de d flagration et autres termes Note 1 L interpr tation d Hypertherm de ces nouvelles exigences est que sauf valuation particuli re du site pour d terminer que toute la poussi re produite n est pas combustible l dition 2007 de la NFPA 68 exige l utilisation d vents d explosion concus pour la valeur du pire des cas voir annexe F qui pourrait provenir de la poussi re de sorte que l on puisse concevoir la dimension et le type d vent d explosion La NFPA 68 ne stipule pas particuli rement le proc d de coupage plasma particulier ou autres proc d s de coupage thermique comme le prescrivent ces nouveaux r glements tous les syst mes de d poussi rage Note 2 Les utilisateurs des manuels d Hypertherm doivent consulter tous les r glements et lois f d raux et locaux applicables et s y conformer Hypertherm n a pas l intention en publiant un manuel d Hypertherm de demander des me
71. 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 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 Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux Indi rotection Courant de l arc Indica He ou 29CFR Europe A minimum le confort 1910 133 a 5 EN168 2002 ANSI Z49 1 2005 ANSI Z49 1 2005 Moins de 40 A 5 5 8 9 41 60A 6 6 8 9 61480A 8 8 8 9 81 125A 8 9 8 9 126 150A 8 9 8 10 151 175 A 8 9 8 11 176 250 A 8 9 8 12 251 300 8 9 8 13 301 400 A 9 12 9 13 401 800 A 10 14 10 Hypertherm 1a 5 11 08 S CURIT C ble de retour Bien fixer le c ble de retour ou de masse la pi ce couper ou la table de travail de fa on assurer un bon contact m tal m tal Ne pas fixer le cable de retour la partie de la pi ce qui doit se d tacher Table de travail Raccorder l
72. fiado reempl celo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha y reempl celas cuando se encuentren da adas No toque la pieza ni los recortes cuando se est cortando Deje la pieza en su lugar o sobre la mesa de trabajo con el cable de trabajo conectado en todo momento Antes de inspeccionar limpiar o cambiar las piezas de la antorcha desconecte la potencia primaria o desenchufe la fuente de energ a Nunca evite o descuide los bloqueos de seguridad Antes de retirar la cubierta de una fuente de energ a o del gabinete de un sistema desconecte la potencia primaria de entrada Espere 5 minutos despu s de desconectar la potencia primaria para permitir la descarga de los condensadores Nunca opere el sistema de plasma sin que las tapas de la fuente de energ a est n en su lugar Las conexiones expuestas de la fuente de energ a presentan un serio riesgo el ctrico Al hacer conexiones de entrada conecte el conductor de conexi n a tierra en primer lugar Cada sistema de plasma Hypertherm est dise ado para ser utilizado s lo con antorchas Hypertherm espec ficas No utilice antorchas diferentes que podr an recalentarse y ser peligrosas 79 5 a cS Use precauciones adecuadas cuando maneje tablillas impresas de circuito ELECTRICIDAD EST TICA PUEDE DA AR TABLILLAS DE CIRCUITO Almacene las tablillas PC en recipientes antiest ticos Use la def
73. g from the edge of the workpiece Pause at the edge until the arc has completely cut through the workpiece Then proceed with the cut powermaX1650 Operator Manual Hand torch cutting technique Firing the torch unnecessarily reduces nozzle and electrode life When cutting make sure that sparks are exiting from the bottom of the workpiece If sparks are spraying up from the workpiece you are moving the torch too fast or without sufficient power Hold the torch vertically and watch the arc as it cuts along the line OPERATION Unshielded consumables Maintain a torch to work distance of approximately 3 16 in 4 8 mm Shielded consumables Do not push down on the torch when cutting Drag the torch lightly across the workpiece to maintain a steady cut It is easier to pull the torch through the cut than to push it To cut thin material reduce the amps until you get the best quality cut For straight line cuts use a straight edge as a guide To cut circles use a template or the Hypertherm plasma cutting guide part number 027668 Postflow After the torch trigger switch is released the gas will continue to flow for 30 seconds to cool the torch and consumables Note The torch will restart if you activate the trigger switch during the postflow To stop the postflow activate and quickly release the torch trigger powermaXxX1650 Operator Manual 4
74. ge 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 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 AVERTISSEMENT D tonation de l hydrog ne lors du coupage de l aluminium 1a 2 11 08 Hypertherm S CURIT LES CHOCS LECTRIQUES PEUVENT TRE 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 codes lectriques locaux et nationaux un circuit lectrique entre la torche et la pi ce couper Inspecter fr quemment le cordon d alimentation primaire A 1 n 1 H La couper et tout autre l ment en contact avec pour assurerqu il n est ni endommag ni fendu cette pi ce font partie du circuit lectrique Remplacer imm diatement un cordon endommag Un c ble d nud peut tuer Inspecter et remplacer les c bles de la torche qui sont us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du coupage Laisser la pi
75. he plasma system completes an and local codes electrical circuit between the torch and the Inspect the input power cord frequently for damage workpiece The workpiece and anything touching or cracking of the cover Replace a damaged the workpiece are part of the electrical circuit power cord immediately Bare wiring can kill Never touch the torch body workpiece or the Inspect and replace any worn or damaged torch water in a water table when the plasma system leads is operating Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place Electric Shock Prevention or on the workbench with the work cable attached All Hypertherm plasma systems use high during the cutting process voltage in the cutting process 200 to 400 VDC Before checking cleaning or changing torch parts are common Take the following precautions disconnect the main power or unplug the power when operating this system supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only
76. hmic sensing retaining Pri a 4 6 Eier 4 6 Set the mode SWIECh siii c ra cda m ni i eid ead t 4 7 ON the power oci c cincti ctt ditt e netus imet 4 7 Check the indicator Sii aa 4 7 Adjust the gas pressure and current setting 4 8 torch operation s uiti tas 4 9 Safety trigger Operation sirios ia 4 9 Attach the Work Clamp 4 10 Start a cut from the edge of the workpiece ss 4 10 Hand torch cutting technique scsi ci a 4 11 M 4 12 QOUJIN M RR 4 13 CUP CAS e Et 4 14 Section 5 Maintenance and parts Routine dor MIN E Iei t P M 5 2 Inspect the consumables nee 5 3 Filter element replacement sn 5 4 Controls dni leia 5 5 E 5 6 oystemicircHit o cec ciaas 5 9 Technical questions otr 5 10 pn cM LEE 5 10 Ii LL 5 10 Fower Supply Pals 5 11 ACCESSOMCS 5 11 powermax1650 Operator Manual ix TABLE OF CONTENTS powermaX1650 Operator Manual Section 1 SAFETY In this section Recognize safety informatiori an itc ad 1 2 Follow Safety inst
77. i tnit naaa iii 3 3 Locating the power supply ic icono at 3 4 Power CONNGCHON Essen onni S Tiai 3 4 Engine e ta 3 5 Creme 3 6 Power Gord S e 3 6 Three phase power cord and plug installation 3 7 Power Cord installation iiri o e T cn b ss 3 7 Torch installation nihit eret initia eb nieto e ra m ian dianas 3 8 Plasma gas supply viana 3 10 Additional gas filtration 3 10 Gas supply installatlon ee 3 11 Bee AC 3 11 ONOFF pendant connection tr irc if i cic dn 3 12 Machine interface Connection ftp d HER EET RAE RR Rr reped 3 12 9 ARO 3 13 Changing XFER start machine motion from dry contact closure to voltage signal 3 15 powermax1650 Operator Manual 3 1 SETUP Upon receipt 1 Check that all items on your order have been received Contact your distributor if any items are missing or damaged 2 If there is evidence of damage refer to Claims below All communications regarding this equipment must include the model number and serial number located on the back of the power supply 3 Read the Safety section of this manual before setting up and operating this Hypertherm system 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 nee
78. iepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm S Pte Ltd 82 Genting Lane Media Centre Annexe Block 01 01 Singapore 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit A 5th Floor Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax 7 1 09 Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service Hypertherm Japan Ltd 801 Samty Will Building 2 40 Miyahara 1 Chome Yodogawa ku Osaka 532 0003 Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax Hypertherm Brasil Ltda Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114 000 Guarulhos SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm M xico S A de C V Avenida Toluca No 444 Anexo 1 Colonia Olivar de los Padres Delegaci n lvaro Obreg n M xico D F C P 01780 52 55 5681 81009 Tel 52 55 5683 2127 Fax ELECTROMAGNETIC COMPATIBILITY EMC EMC Introduction Hypertherm s CE marked equipment is built in compliance with standard EN60974 10 The equipment should be installed and used in accor
79. illes de gaz comprim essent tente ttnntnttn tentent 1a 6 Les bouteilles de gaz comprim peuvent exploser en cas de 1a 6 Le bruit peut provoquer des probl mes auditifs 1a 7 Pacemakers et proth ses auditives nn 1a 7 Un arc plasma peut endommager les tuyaux gel s sesenta 1a 7 MALGUAGS e LP la 8 SEO tmu ML Ed 1a 9 Information sur le d poussi rage 1a 11 Section 1b Seguridad Reconocimiento de informaci n de seguridad rra rro 1b 2 Siga las instrucciones de seguridad 1b 2 Los cortes pueden provocar incendios o explosiones ins 1b 2 powermax1650 Operator Manual vii TABLE OF CONTENTS El choque el ctrico puede provocar la muerte sn 1b 3 Electricidad est tica puede da ar tablillas de circuito eee 1b 3 Humos t xicos pueden causar lesiones o 1b 4 El arco de plasma puede causar lesiones y quemaduras 1b 5 Los rayos del arco pueden producir quemaduras en los ojos 1b 5 Seguridad de toma aiii a 1b 6 Seguridad de los equipos de gas comprimido 1b 6 Los cilindros de gas pueden explotar si est n da ados seen 1b 6 El
80. ing yourself from work and ground 3 8 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 8 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away 7 Do not remove destroy or cover this label Replace if it is missing damaged or wom PN 110584 Rev C Le coupage plasma peut tre pr judiciable pour l op rateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de s curit peut entrainer la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un f t ou un autre contenant ferm comme table de coupage 2 l arc plasma peut blesser et br ler loigner la buse de soi Il s allume instantan ment quand on l amorce 2 1 Couper l
81. ique peut endommager les cartes de circuits imprim s Les vapeurs toxiques peuvent provoquer des blessures OU la mort plasma peut provoquer des blessures ou des br lures Les rayons de l arc peuvent br ler les yeux et la peau Mise la masse et la terre coin S curit des bouteilles de gaz comprim sese recrear rra Les bouteilles de gaz comprim peuvent exploser en cas de dommages Le bruit peut provoquer des probl mes auditifs Pacemakers et proth ses auditives nn Un arc plasma peut endommager les tuyaux gel s sesenta Symboles et marquage tiquettes desc a ae ae nce ae meee ate It eid utu one an tf Information Sur le d poussi rage trt tnter sante itte ditta iaaiiai Hypertherm 1a 1 11 08 S CURIT DE S CURIT 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 S CURIT 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
82. l air filtration kit 50 ft 15M work cable with clamp and strain relief powermaXxX1650 Operator Manual 5 11 MAINTENANCE AND PARTS 5 12 powermaX1650 Operator Manual
83. ld Retaining cap m Nozzle amp Electrode Swirl ring O Note tighten only powermax1650 Operator Manual 4 3 0 OPERATION 7100 consumable configurations Shielded 120929 120928 120932 058519 120926 120925 120929 120928 120931 4 100 25 4 D 220065 220048 220011 220037 220051 Unshielded The unshielded consumables available for the T100 hand torch only for use with non CE systems are the same as those used for the T100M 2 See the illustrations later in this section FineCut 30A 50A O ring 058519 1 1 i 1 2 0 i 120928 220329 120926 220327 120979 For use with CE systems The 220327 swirl ring is intended for manual cutting with FineCut consumables 4 4 powermax1650 Operator Manual Gouging 60A 80A 9 120977 120928 220059 120926 120925 m 120977 220048 220063 T100M 2 consumable configurations Shielded 40A 120930 120930 i 80A 2 120930 120928 120927 i w qy 8 220047 220048 220011 220037 220051 powermaXxX1650 Operator Manual OPERATION O ring 058519 OPERATION FineCut 30A O ring O 058519 220325 220404 2200617 In CE countries unshielded Ohmic sensing retaining caps consumables
84. levision transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hearing aids f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used in 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 con sidered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of reducing emissions Mains supply Cutting equipment must be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply 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 4 08 ELECTROMAGNETIC COMPATIBILITY EMC M
85. lle 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 1a 6 11 08 Hypertherm S CURIT 1 LE BRUIT PEUT PROVOQUER DES PROBL MES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs e 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 UN ARC PLASMA PEUT gt ENDOMMAGER LES TUYAUX GEL S Les tuyaux gel s peuvent tre endommag s ou clater si l on essaie de les d geler avec une torche plasma Hypertherm pacemakers er NES PROTH SES AUDITIVES Les champs magn tiques produits par les courants haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes port
86. luminum Are eurent PRE Pierce Material thickness Maximum travel speed Optimum travel speed 9 dely f mehes mm mmmn J mmmn 5 ovem sa 14926 8296 15 255 5994 3886 O ao o 025 3732 24 261 6620 4818 Maximum travel speeds are the fastest speeds possible for cutting the material without regard to cut quality Optimum travel speeds 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 different cut assignment Every cutting system requires fine tuning for each cutting application in order to obtain the desired cut quality 4 20 powermaxX 1650 Operator Manual 3 In this section Routine maintenance Inspect the consumables Filter element replacement Controls and indicators Basic troubleshooting ss System circuit diagram sss Technical questions Torch Datsun tente Power supply ACCESS ica ii powermax1650 Operator Manual Section 5 MAINTENANCE AND PARTS MAINTENANCE AND PARTS Routine maintenance WARNING ELECTRIC SHOCK CAN KILL Disconnect the electrical power before performing any maintenance All work requiring removal of the power supply cover must be performed by a qualified tech
87. me cases the metal may be coated with a substance that could release toxic fumes Toxic coatings include but are not limited to lead in some paints cadmium in some paints and fillers and beryllium Gases produced by plasma cutting vary based on the material to be cut and the method of cutting but may include ozone oxides of nitrogen hexavalent chromium hydrogen and other substances if such are contained in or released by the material being cut Caution should be taken to minimize exposure to fumes produced by any industrial process Depending upon the chemical composition and such as ventilation there may be a risk of physical illness such as birth defects or cancer It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations The air quality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed 1 4 11 08 concentration of the fumes as well as other factors TOXIC FUMES CAN CAUSE INJURY OR DEATH Duration of cutting or gouging Size air volume ventilation and filtration of the work area Personal protective equipment Number of welding and cutting systems in oper
88. n your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the controls properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION Hypertherm uses American National Standards Institute guidelines for safety signal words and symbols A signal word DANGER or WARNING is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific hazards DANGER safety messages precede related instructions in the manual that will result in serious injury or death if not followed correctly WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions in this manual that may result in minor injury or damage to equipment if not followed correctly Fire Prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied
89. nician Each Use oda ems SN be A 40 5 0 6 0 WS 30 E EN Check the consumables for Check the gas pressure wear and proper installation Each Week Check the torch cap on safety switch observe that red fault LED and yellow torch cap LED illuminate when cap is loosened J 3 Months IN Check the trigger for damage Check the torch body for cracks or exposed wires plug if damaged Replace power cord or Replace torch lead Check the pressure hose filter element and connections for leaks if damaged Clean the inside of the power supply with air pressure or vacuum powermaxX 1650 Operator Manual Inspect the consumables MAINTENANCE AND PARTS Part Check for Action Roundness of through hole Nozzle Center hole Good Replace Mu UR AU gt Max 1 32 inch Electrode 0 8 mm Center surface Maximum pit depth Replace 1 32 inch 0 8 mm Swirl ring External surfaces Damage or debris Replace Central bore I D Does electrode slide easily Replace Gas holes Blocked holes Replace Torch o ring External surfaces Damage or wear Replace Dry surface Apply a thin film of silicone grease part number 027055 powermaxXx 1650 Operator Manual
90. o del equipo y instalaci n el comprobar la calidad de aire en el lugar donde se est usando el equipo para garantizar que la calidad del aire en el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales HUMOS T XICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables espec ficas al sitio tales como Dise o de mesa mojada seca bajo agua La composici n del material el acabado de la superficie y la composici n de los recubrimientos Volumen que se quita del material La duraci n del corte o ranura Tamafio volumen del aire ventilaci n y filtraci n del lugar de trabajo Equipo de protecci n personal N mero de sistemas de soldar y cortar en la operaci n Otros procesos del lugar que pueden producir humo Si el lugar de trabajo debe cumplir reglamentos nacionales o locales solamente el monitoreo o las pruebas que se hacen en el lugar pueden determinar si el sitio est encima o debajo de los niveles permitidos Para reducir el riesgo de exposici n a humo Quite todos los recubrimientos y solventes del metal antes de cortar Use ventilaci n extractora local para quitar humo del aire No inhale el humo Use un respirador con fuente propia de aire cuando corte cualquier metal recubierto con o sospechado de contener elementos t xicos Garantice que aqu llos usando equipo de soldar
91. oduct in your environment General Hypertherm Inc warrants that its Products shall be free from defects in materials and workman ship if Hypertherm is notified of a defect i with respect to the power supply within a period of two 2 years from the date of its delivery to you with the exception of Powermax brand power supplies which shall be within a period of three 3 years from the date of delivery to you and 1 with respect to the torch and leads within a period of one 1 year from its date of delivery to you and with respect to torch lifter assemblies within a period of one 1 year from its date of delivery to you and with respect to laser heads within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise damaged Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall be returned with Hypertherm s prior authorization which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hype
92. our se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger les oreilles contre le bruit Utiliser un masque de soudeur avec un filtre de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Utiliser exclusivement les torches indiqu es dans le manual Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev C Les fum es du plasma peuvent tre dangereuses Ne pas inhaler les fum es Utiliser une ventilation forc e ou par aspiration la source pour liminer les fum es Ne pas utiliser dans des espaces clos Chasser les fum es avec la ventilation Les rayons d arc peuvent br ler les yeux et blesser la peau Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Se prot ger les oreilles contre le bruit Utiliser le masque de soudage avec le filtre ayant le bon indice de protection S entra ner Seul le personnel qualifi doit faire fonctionner cet quipement Utiliser les torches prescrites dans le manuel Tenir le personnel non qualifi et les enfants l cart Ne pas enlever d truire ou couvrir cette tiquette La remplacer si elle est manquante endommag
93. plosiones o incendios Mantenga los materiales inflamables lejos del lugar de corte Tenga a mano un extinguidor de incendios y aseg rese de que alguien est preparado para utilizarlo No corte dep sitos cerrados El arco de plasma puede causar quemaduras y lesiones Apague la fuente de energ a antes de desarmar la antorcha No sostenga el material junto al trayecto de corte Proteja su cuerpo completamente Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque Col quese guantes aislantes No utilice guantes dafiados o mojados A slese de la pieza de trabajo y de la tierra Hypertherm 3 3 4 1 4 2 5 1 Antes de trabajar en una m quina desconecte el enchufe de entrada o la potencia primaria La inhalaci n de los humos provenientes del rea de corte puede ser nociva para la salud Mantenga la cabeza fuera de los gases t xicos Utilice ventilaci n forzada o un sistema local de escape para eliminar los humos Utilice un ventilador para eliminar los humos Los rayos del arco pueden producir quemaduras en los ojos y en la piel Utilice un sombrero y gafas de seguridad Utilice protecci n para los o dos y abr chese el bot n del cuello de la camisa Utilice un casco de soldar con el filtro de sombreado adecuado Proteja su cuerpo completamente Antes de trabajar en la m quina o de proceder a cortar capacitese y lea las instrucciones
94. pondent aux num ros des images 1 1 1 2 2 1 2 2 2 3 3 1 3 2 3 3 Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS 249 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health Standards 29 CFR 1910 http www osha gov 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 1 2 Have a fire extinguisher nearby and ready to use 1 3 Do not use a drum or other closed container as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 8 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc
95. powermax1650 Plasma Arc Cutting amp Gouging System Operator Manual 804480 Revision 4 na 1118 The world leader in plasma cutting technology Register your new Hypertherm system Register your product on line at www hypertherm com registration for easier technical and warranty support You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation For your records Serial number Purchase date Distributor Maintenance notes powermax1650 Operator Manual P N 804480 Revision 4 November 2013 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2013 Hypertherm Inc All Rights Reserved Hypertherm and powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service technical service Qhypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service Qhypertherm com Customer Service Email Hypertherm Automation 5 Technology Drive Suite 300 West Lebanon NH 03784 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technolog
96. que se usen con un sistema existente de colecci n de polvo seco Consulte su Autoridad que Tenga Jurisdicci n iniciales en ingl s AHJ local para determinar si cualquier edici n de la NFPA 68 ha sido adoptada por referencia en los c digos de construcci n locales Remitase a la NFPA 68 para definiciones y explicaciones de los t rminos reguladores como deflagraci n AHJ adoptada por referencia el valor Kst ndice de deflagraci n y otros t rminos Nota 1 La interpretaci n de Hypertherm de estos nuevos requisitos es que a no ser que se haya completado una evaluaci n espec fica del sitio para determinar que todo polvo generado no es combustible la edici n del 2007 de la NFPA 68 requiere el uso de respiraderos de explosi n dise ados para el peor caso del valor Kst vea anexo F que pudiera ser generado por el polvo de manera que el tama o y tipo del respiradero de explosi n pueda dise arse La NFPA 68 no identifica espec ficamente corte por plasma u otros procesos de cortes termales como si requirieran sistemas de respiraderos de deflagraci n pero en realidad aplica estos nuevos requisitos a todos los sistemas de colecci n de polvos secos Nota 2 Los usuarios de los manuales de Hypertherm deber an consultar y cumplir con todas las leyes y reglamentos federales estatales y locales aplicables Hypertherm al publicar todo manual de Hypertherm no intenta urgir acci n que no est en cumplimiento con todos
97. r ido puede deteriorar la audiCl n acie ctn ntt at cet t d 1b 7 Operaci n de marcapasos y de 1b 7 Un arco plasma puede da ar tubos congelados sn 1b 7 Simbolos y marcas oit eiie tbe ree ie eti vend d feles e dcr dest cete bees eire d nane 1b 8 Etiquetas de advertercla iau ocio nieder tnc n RED a ee EE 1b 9 Informaci n sobre la colecci n de polvo SCO eee 1b 11 Section 2 Specifications POW6RSUDDIV 2 2 Duty iere ccce aa 2 3 Dimensions And weight teet nei indecl pite ni sra nata tabo 2 3 T100 torches irrita da m i e don 2 4 Torch AIM NSIQNSE cati rice ra redeo inane adan 2 5 Symbols and markings trece aaa 2 6 Dur Et 2 6 eie ette ER e ratae ted aeo edad ee rade te 2 6 symbols USO tnr ters du stent ertt na in 2 6 Section 3 Setup 3 2 3 2 Contente DOX a te ein einen 3 2 Lifting the power supply 3 3 LOCATING EP 3 4 cia caia caia aaa dai 3 4 ee da 3 5 CU
98. r local building codes Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration adopted by reference the Kst value deflagration index and other terms Note 1 Hypertherm s interpretation of these new requirements is that unless a site specific evaluation has been completed to determine that all dust generated is not combustible the 2007 edition of NFPA 68 requires the use of explosion vents designed to the worst case Kst value see annex F that could be generated from dust so that the explosion vent size and type can be designed NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems but it does apply these new requirements to all dry dust collection systems Note 2 Users of Hypertherm manuals should consult and comply with all applicable federal state and local laws and regulations Hypertherm does not by the publication of any Hypertherm manual intend to urge action that is not in compliance with all applicable regulations and standards and this manual may never be construed as doing so Hypertherm 1 11 11 08 SAFETY 1 12 Hypertherm 11 08 Section 1a S CURIT Dans cette section Identifier les consignes de Suivre les instructions de s curit nn Le coupage peut provoquer un incendie ou une Explosion ss Les chocs lectriques peuvent tre fatals sn L lectricit stat
99. rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away Les tincelles de coupage peuvent provoquer une explosion ou un incendie Ne pas couper pr s des mati res inflammables Un extincteur doit se trouver sur les lieux et pr t tre utilis Ne pas utiliser un f t ou un autre contenant ferm comme table de coupe L arc plasma peut blesser et br ler ne jamais pointer la buse vers soi L arc s amorce instantan ment quand on appuie sur la g chette Couper l alimentation avant de d monter la torche Ne pas saisir la pi ce pr s de la trajectoire de coupage Se prot ger enti rement le corps Tension dangereuse Risque de choc lectrique ou de br lure Porter des gants isolants Remplacer les gants s ils sont humides ou endommag s Se prot ger contre les chocs en s isolant de la pi ce et de la terre Couper l alimentation avant d entretenir Ne pas toucher les pi ces sous tension Hypertherm 7 Do not remove destroy or cover this label Replace if it is missing damaged or worn PN 110584 Rev C 4 1 4 2 4 3 5 1 S CURIT Le coupage plasma pe
100. ritical components that have been authorized by the accredited testing laboratory Once the product has left the Hypertherm factory the certification test marks are invalidated if any of the following occurs The product is significantly modified in a manner that creates a hazard or non conformance Safety critical components are replaced with unauthorized spare parts iii 4 08 WARRANTY Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification CE marking constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking Differences in National Standards Differences in standards include but are not limited to Voltages Plug and cord ratings Language requirements Electromagnetic compatibility requirements These differences in national standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product For example the CSA v
101. ront back and fan side of the power supply for proper ventilation Power connection The Powermax1 650 is a universal power supply that configures itself to operate with AC voltages from 200 to 600 3PH 230 400 3PH for the CE model Use a line disconnect switch for each power supply so that the operator can turn off the power supply quickly in an emergency Locate the switch so it is easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses rated per local and national electrical codes CSA model Three phase CE model Three phase Input voltage 230 400 Input current during arc stretch 3 4 powermaX1650 Operator Manual SETUP Engine drives When using an engine drive to power the Powermax1650 The engine drive must be dedicated to powering the plasma cutting system Engine drive operation 1 Set the engine drive output to 3 phase AC 2 Plug Powermax1650 power cord into the power outlet 3 Set the engine drive to the maximum output see table below Use unshielded consumables if you experience difficulty cutting thicker material CSA power supplies only CSA power supplies 3 Phase 50 60 hz 200 600 480 recommended for best performance CE power supplies 3 Phase 50 60 hz 230 400 400 recommended for best performance 2 Powermax1650 Engine drive ra
102. rtherm repair facility all Hypertherm WARRANTY costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty Distributors OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or near the data plate Each certification test mark means that the product and its safety critical components conform to the relevant national safety standards as reviewed by that testing laboratory Hypertherm places a certification test mark on its products only after that product is manufactured with safety c
103. ructions M 1 2 Cutting can cause fire or 1 2 Electric shock can Kill iscsi inicia de dai ia 1 3 Static electricity can damage circuit boards inner 1 3 Toxic fumes Can Cause injury OF Death iii a dats 1 4 A plasma are can cause injUry and DUrns entran ru d nude iraniens 1 5 Arc rays Can burn eyes and skin inner 1 5 GOUNCING iim 1 6 Compressed gas equipment safety eene ea 1 6 Gas cylinders can explode if damaged merca aa 1 6 Noise can damage NGA iG sis tnter treten tenebra nta nates tni eain bd annt datus ns 1 7 Pacemaker and hearing aid operation ss 1 7 A plasma arc can damage frozen pipes sise 1 7 Additional safety information sise 1 7 Symbols A O IMArkIN DS ici dei 1 8 Warning labels 5 25 dudit in mnaamnimananmanudaunaunnumnntnnenuie 1 9 Dry dust collection information inner cire manie 1 11 Hypertherm 1 1 11 08 SAFETY RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine understand the potential for personal injury and follow the related instructions to avoid the hazard FOLLOW SAFETY INSTRUCTIONS Y Read carefully all safety messages in this manual and safety labels on your machine Keep the safety labels o
104. s Use forced ventilation or local exhaust to remove the fumes Do not operate in closed spaces Remove fumes with ventilation Arc rays can burn eyes and injure skin Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away Do not remove destroy or cover this label Replace if it is missing damaged or worn Hypertherm SAFETY DRY DUST COLLECTION INFORMATION At some sites dry dust can represent a potential explosion hazard The U S National Fire Protection Association s 2007 edition of NFPA standard 68 Explosion Protection by Deflagration Venting provides requirements for the design location installation maintenance and use of devices and systems to vent combustion gases and pressures after any deflagration event Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system Consult your local Authority Having Jurisdiction AHJ to determine whether any edition of NFPA 68 has been adopted by reference in you
105. st speeds possible for cutting the material without regard to cut quality Optimum travel speeds 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 different cut assignment Every cutting system requires fine tuning for each cutting application in order to obtain the desired cut quality powermaXxX1650 Operator Manual 4 15 OPERATION 60 amp mechanized shielded consumables Torch to work distance for the following cut chart is 1 16 in 1 5 mm for all cuts Shield Retaining cap Nozzle Electrode Swirl ring T100M 2 120930 120928 120931 120926 120925 torch D 933500 0209 Mild steel Pierce Material thickness Maximum travel speed Optimum travel speed Arc current Arc voltage delay mches IPM mmmn mo E E Umum LU 184 34 264 6 5859 188 025 64 132 3953 56 2184 141 075 38 95 63 1600 41 1041 348 vm i27 27 585 a we 19 2 99 ww Stainless steel Pierce Material thickness travel speed Optimum travel speed Arc current Arc voltage delay inches mm O US 025 64 95 127 200 57 159 34 199 Aluminum Alias Pierce a
106. sures qui ne sont pas conformes aux r glements et normes applicables et ce manuel ne peut jamais tre interpr t dans ce sens Hypertherm 1a 11 11 08 S CURIT 1 12 Hypertherm 11 08 Seccion 1b SEGURIDAD En esta secci n Reconocimiento de informaci n de seguridad 1b 2 Siga las instrucciones de seguridad sine 1b 2 Los cortes pueden provocar incendios o explosiones nn 1b 2 El choque el ctrico puede provocar la muerte seen rear 1b 3 Electricidad est tica puede da ar tablillas de circuito ss 1b 3 Humos t xicos pueden causar lesiones o muerte sn 1b 4 El arco de plasma puede causar lesiones y quemaduras seen 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la 1b 5 Seguridad de toma a terrassement 1b 6 Seguridad de los equipos de gas comprimido sn 1b 6 Los cilindros de gas pueden explotar si est n da ados coccion 1b 6 El ruido puede deteriorar la audici n coimas ant 1b 7 Operaci n de marcapasos y de 1b 7 Un arco plasma puede da ar tubos congelados eere 1b 7 SIMBOLOS DC M ERE 1b 8 Etiquetas Ce adv rtenti s 15 9 Informaci n sobre la colecci n de polvo SCO een 1b 11 Hypertherm 1b 1 11 08 SEGURIDAD RECONOCIMIENTO DE INFORMACION
107. t au Canada comme les Underwriters Laboratories Incorporated UL ou TUV Marque CE La marque CE signifie la d claration de conformit du fabricant aux directives et normes europ ennes applicables Seules les versions des produits Hypertherm portant la marque CE plac e sur la plaque signal tique ou proximit ont t mises l essai de conformit la directive europ enne sur la basse tension et la compatibilit lectromagn tique europ enne CEM Les filtres CEM qui doivent se conformer la directive CEM europ enne sont int gr s aux versions du produit portant la marque CE Marque GOST R Les versions CE des produits Hypertherm qui portent la marque de conformit GOST R r pondent aux exigences de s curit du produit et de en vue de l exportation la F d ration russe Marque c Tick Les versions CE des produits Hypertherm portant la marque c Tick sont conformes aux r glements CEM prescrits pour la vente en Australie et en Nouvelle Z lande Marque CCC La marque de certification obligatoire en Chine CCC indique que le produit a t mis l essai et d clar conforme aux r glements de s curit du produit prescrits pour la vente en Chine Hypertherm 11 08 TIQUETTE DE S CURIT Cette tiquette est affich e sur la source de courant Il est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Les num ros de la liste corres
108. teger sus ojos de los rayos ultravioleta e infrarrojos del arco Protecci n para la piel Vista ropa de protecci n para proteger la piel contra quemaduras causadas por la radiaci n ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro de combusti n retardada y que cubra todas las partes expuestas Pantalones sin dobladillos para impedir que recojan chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar rea de corte Prepare el rea de corte para reducir la reflexi n y la transmisi n de la luz ultravioleta Pinte las paredes y dem s superficies con colores oscuros para reducir la reflexi n Utilice pantallas o barreras protectoras para proteger a los dem s de los destellos Advierta a los dem s que no debe mirarse el arco Utilice carteles o letreros El n mer matiz Corriente de E fumero de matz cae OSHA 29CFR Europa arco amps ANS comodidad 1910 133 a 5 EN168 2002 dl ANSI Z49 1 2005 Menos de 40 A 5 5 8 9 41 a 60 A 6 6 8 9 61a80A 8 8 8 9 81a125A 8 9 8 9 126a150A 8 9 8 10 151a175A 8 9 8 11 176a250A 8 9 8 12 251 300 8 9 8 13 301 a400 A 9 12 9 13 401 a800A 10 14 10 Hypertherm 1b 5 11 08 SEGURIDAD Cable de trabajo La pinza del cable de
109. th Fact Sheets American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 www aws org technical facts 1 7 11 08 SAFETY SYMBOLS AND MARKINGS Your Hypertherm product may have one or more of the following markings on or near the data plate Due to differences and conflicts in national regulations not all marks are applied to every version of a product s S mark symbol us 1 8 11 08 The 5 mark symbol indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock per IEC 60974 1 CSA mark Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety The products were evaluated tested and certified by CSA International Alternatively the product may have a mark by one of the other Nationally Recognized Testing Laboratories NRTL accredited in both the United States and Canada such as Underwriters Laboratories Incorporated UL or T V CE marking The CE marking signifies the manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions
110. that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose oylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve Hypertherm SAFETY NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing Use approved ear protection when using plasma system Warn others nearby about the noise hazard A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch PACEMAKER AND HA HEARING AID OPERATION 3 Pacemaker and hearing aid operation can be affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 5
111. tilice ventilaci n forzada o un sistema local de escape para eliminar los humos Utilice un ventilador para eliminar los humos Los rayos del arco pueden producir quemaduras en los ojos y en la piel Utilice un sombrero y gafas de seguridad Utilice protecci n para los o dos y abr chese el bot n del cuello de la camisa Utilice un casco de soldar con el filtro de sombreado adecuado Proteja su cuerpo completamente Antes de trabajar en la m quina o de proceder a cortar capacitese y lealas instrucciones completamente No retire las etiquetas de advertencia ni las cubra con pintura Hypertherm SEGURIDAD INFORMACI N SOBRE LA COLECCI N DE POLVO SECO En algunos sitios el polvo seco puede representar un peligro potencial de explosi n La edici n del 2007 de U S National Fire Protection Association iniciales en ingl s NFPA La Asociaci n Americana Nacional de Protecci n Contra Incendios del est ndar 68 Protecci n de Explosi n por medio de Respiradero de Deflagraci n proporciona requisitos para el dise o ubicaci n instalaci n mantenimiento y uso de aparatos y sistemas para dar salida a gases de combusti n y presiones despu s de todo evento de deflagraci n Consulte con el fabricante o instalador de cualquier sistema de colecci n de polvo seco para los requisitos aplicables antes de que instale un sistema nuevo de colecci n de polvo seco o haga cambios significativos en el proceso o materiales
112. ting Performance output current 30 kw 100A Full arc stretch 100A Limited arc stretch 15k 80A Limited arc stretch w 60 A Full arc stretch powermax1650 Operator Manual 3 5 SETUP Grounding To ensure personal safety and proper operation and to reduce electromagnetic interference EMI the Powermax1650 must be properly grounded through the power cord according to local and national electrical codes Three phase service must be of the 4 wire type with a green or green yellow wire for protective earth ground and must comply with local and national electrical requirements Refer to Section 1 Grounding Safety Power cords Use a cord that 1 certified by local and national codes The cord should be installed by a licensed electrician Refer to the length requirements listed below Recommended extension cord gauge size AWG mm2 lt 10 ft 10 25 ft 25 50 ft 50 100 ft 100 150 ft lt 3m 3 75 75 15 15 30 30 45 m CSA model Input voltage Phase AWG mm AWG mm AWG mm AWG 200 208 VAC 230 VAC 400 VAC 480 VAC 600 VAC Input voltage Phase Note The unit was tested with a 2 m power cord to verify EMC standard EN50199 compliance 3 6 powermaxX 1650 Operator Manual SETUP Three phase power cord and plug installation The Powermax1 650 power supplies are shipped with a 6 AWG 4 wire UL CSA power cord on CSA units A 10 mm2 4 wire HAR power cord is provided on CE units To operate the Powermax1 650 use a plug that
113. um 3 50 7 8 PSI IT Dni 40 50 6 0 BAR 1 35 50 ft M 12 15 m U 15 25 ft um 7N 4 5 7 5 m Qm XY 15 50ft 4 5 15 m Set the pressure as shown above based on the cutting mode and torch lead length 4 8 powermax1650 Operator Manual OPERATION Hand torch operation WARNING Instant On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn through gloves and skin Keep away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others Never use with the pendant switch Safety trigger operation powermaXxX1650 Operator Manual 4 9 OPERATION WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others SO Attach the work clamp securely to the workpiece Remove rust paint or other coatings to ensure good electrical contact Attach the work clamp as close as possible to the area being cut to reduce exposure to electromagnetic fields EMF Do not attach the work clamp to the portion that will fall away ig Start a cut from the edge of the workpiece Hold the torch vertical at the edge of the workpiece Start cuttin
114. umables as necessary See Inspect the consumables in this section See Section 4 Torch operation The gas pressure is incorrect Adjust the operating gas pressure See Section 4 Check and adjust the gas pressure Check that the gas supply pressure to the power supply is not less than 90 psig 6 1 bar at a flow of 9 2 scfm 260 l min The gas filter element outside the power supply 15 contaminated Replace the filter element See Air filter element replacement in this section The gas filter element outside the power supply 15 contaminated Replace the filter element There is water in the air line Drain the air filter s and or add additional air filtration to the power supply See Section 3 Additional gas filtration Worn or incorrectly installed consumables Inspect the consumables Replace them if necessary Consumables are worn or the torch 15 being used incorrectly See Inspect the consumables in this section See Section 4 Hand torch operation MAINTENANCE AND PARTS Basic troubleshooting continued Problem 10 The power ON green and fault red lamps are flashing 11 The power ON green and fault red lamps are illuminated after the power is turned on 12 The power ON green and fault red lamps are illuminated for 10 seconds after the trigger is activated 10 1 12 1 Cause Solution Self diagnostic failure The system needs repair The start signal is ON when the ON
115. ut tre pr judiciable pour l op rateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de s curit peut entrainer la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un ou un autre contenant ferm comme table de coupage 2 l arc plasma peut blesser et br ler loigner la buse de soi Il s allume instantan ment quand on l amorce 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 3 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 8 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection p
116. with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard Wear insulated gloves and boots and keep your body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS J 4 Use proper precautions when handling printed Store PC boards in anti static containers cigun boarde e Wear a grounded wrist strap when handling PC boards Hypertherm 1 3 11 08 SAFETY The plasma arc by itself is the heat source used for cutting Accordingly although the plasma arc has not been identified as a source of toxic fumes the material being cut can be a source of toxic fumes or gases that deplete oxygen Fumes produced vary depending on the metal that is cut Metals that may release toxic fumes include but are not limited to stainless steel carbon steel zinc galvanized and copper In so
117. x qui peuvent d gager des vapeurs toxiques comprennent entre autres l acier inoxydable l acier au carbone le zinc galvanis et le cuivre Dans certains cas le m tal peut tre rev tu d une substance susceptible de d gager des vapeurs toxiques Les rev tements toxiques comprennent entre autres le plomb dans certaines peintures le cadmium dans certaines peintures et enduits et le b ryllium Les gaz produits par le coupage plasma varient selon le mat riau couper et la m thode de coupage mais ils peuvent comprendre l ozone les oxydes d azote le chrome hexavalent l hydrog ne et autres substances pr sentes dans le mat riau coup ou en manent On doit prendre les pr cautions qui s imposent pour r duire au minimum l exposition aux vapeurs produites par tout processus industriel Selon la composition chimique et la concentration des vapeurs ainsi que d autres facteurs comme la ventilation il peut y avoir un risque de ll incombe au propri taire du mat riel et du site de v rifier la qualit de l air dans le secteur o l on utilise le mat riel et de s assurer que la qualit de l air sur les lieux de travail r pond aux normes et r glementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT maladie physique comme des malformations ou le cancer Le niveau de qualit de l air dans tout lieu de travail d pend des variables propres au site comme Type de

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