Hypertherm MAXPRO200 User Manual
®
MAXPRO200
Preventive Maintenance Program
Instruction Manual
808800 | Revision 0 | English |
Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
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Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
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Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
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Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
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#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
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82 51 701 0358 Fax
MAXPRO200, Phoenix, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other
countries. All other trademarks are the property of their respective holders.
© 2014 Hypertherm Inc.
MAXPRO200
Preventive Maintenance Program
Instruction Manual
808800
Revision 0
June, 2014
Hypertherm Inc.
Hanover, NH 03755 USA
Contents
Preventive maintenance overview ............................................................................................................................ 3
Cleaning and inspection plan .................................................................................................................................... 3
Cleaning and inspection schedule ....................................................................................................................................... 4
Daily cleaning and inspection instructions .......................................................................................................................... 5
Verify inlet pressures ........................................................................................................................................................ 5
Inspect all air filters ...........................................................................................................................................................5
Verify coolant level and condition ..................................................................................................................................5
Inspect and lubricate o-rings .........................................................................................................................................6
Inspect the water tube and torch for damage ............................................................................................................6
Weekly cleaning and inspection instructions .....................................................................................................................7
Inspect hoses and leads .................................................................................................................................................7
Inspect for gas leaks ........................................................................................................................................................7
Verify coolant flow ............................................................................................................................................................. 7
Check coolant level .......................................................................................................................................................... 7
Clean inside the power supply ......................................................................................................................................8
Check for coolant system leaks ..................................................................................................................................... 8
Inspect the main contactor .............................................................................................................................................9
Perform coolant flow test ................................................................................................................................................9
Inspect gas line connections ....................................................................................................................................... 12
Inspect for hose restrictions ........................................................................................................................................ 12
Inspect cables ................................................................................................................................................................. 12
Inspect the ground connections ................................................................................................................................. 12
Inspect the table-to-workpiece connection ............................................................................................................. 12
Component replacement plan ................................................................................................................................. 13
Component replacement schedule ................................................................................................................................... 13
Mechanized torches ...................................................................................................................................................... 13
Hand held torches ......................................................................................................................................................... 13
Environmental and application impacts .................................................................................................................................... 16
Poor compressed air quality ........................................................................................................................................ 16
MAXPRO200 Preventive Maintenance Program Instruction Manual 808800 1
Contents
Short cut cycle time .......................................................................................................................................................17
Consumable overuse .....................................................................................................................................................17
Metal dust inside power supply cabinet ....................................................................................................................18
Dirty external work environment ...................................................................................................................................18
Part numbers for MAXPRO200 cables, hoses, and leads ...........................................................................................20
System information .....................................................................................................................................................21
Model number ..........................................................................................................................................................................21
Serial number ...........................................................................................................................................................................21
System voltage ........................................................................................................................................................................21
Coolant requirements ............................................................................................................................................................21
Notes ...............................................................................................................................................................................22
Maintenance log for MAXPRO200 Manual Gas plasma systems ..................................................................24
2 MAXPRO200 Preventive Maintenance Program Instruction Manual 808800
Preventive maintenance overview
Congratulations on the purchase of your Hypertherm MAXPRO200 plasma system.
Hypertherm designs its plasma systems to withstand the demands of rugged industrial environments for many years of
service. To maintain optimal system performance, minimize overall operating costs, and prolong system life, regular
preventive maintenance practices must be followed. When properly maintained, your Hypertherm plasma system will
serve you for many years and provide consistent operational performance. Hypertherm has developed this Preventive
Maintenance Program (PMP) specifically for your MAXPRO200 plasma system.
If you have questions about how to maintain your Hypertherm plasma system, contact your regional Hypertherm Technical
Service team. Contact information for each regional office is available at:
http://www.hypertherm.com/en/About_us/Contact_us/index.jsp
The PMP has two parts: a cleaning and inspection plan and a component replacement plan.
Cleaning and inspection plan
This plan consists of a daily, weekly, and monthly schedule of cleaning and inspection tasks. Detailed instructions in
support of each task are included in the PMP to help guide your production and maintenance personnel in understanding
what to do and what to look for during each prescribed task.
Table 1on page 4 outlines the cleaning and inspection schedule. A monthly log sheet, found on the back cover of this
manual, allows you to make photocopies so your production staff can record the tasks they have performed and can
anticipate the tasks they must perform before the end of the month.
MAXPRO200 Preventive Maintenance Program Instruction Manual 808800 3
Cleaning and inspection schedule
In general, Daily and weekly tasks are tasks that the operator might perform while the monthly tasks are more likely to be
performed by maintenance personnel.
Table 1
Maintenance Task or Activity
Verify inlet pressures X
Inspect all air filters X
Verify coolant level and condition X
Inspect and lubricate o-rings X
Inspect the water tube and torch for damage X
Inspect hoses and leads X
Inspect for gas leaks X
Verify coolant flow X
Check coolant level X
Clean inside the power supply X
Check for coolant system leaks X
Inspect the main contactor X
Perform coolant flow test X
Inspect gas line connections X
Inspect for hose restrictions X
Inspect cables X
Daily Weekly Monthly
Inspect the ground connections X
Inspect the table-to-workpiece connection X
4 MAXPRO200 Preventive Maintenance Program Instruction Manual 808800
Daily cleaning and inspection instructions
1
3
4
Full Line
1
4
Verify inlet pressures
1. With gas flowing in the 004 diagnostic mode (Flow gas at full pressure), verify
that the pressure at each supply regulator is set to 6.2 bar (90 psi).
2. For complete instructions about setting supply regulators, see Setting the supply
gas regulators in your system’s instruction manual (807700).
Inspect all air filters
1. Inspect all air filters for moisture, oil, and particulates.
2. If moisture or oil is present, replace the air filter.
3. If a moderate amount of dust or other particulates is present, blow or
vacuum it out of the filter.
4. If there is a large build-up of dust or particulates, replace the air filter
(011093). Refer to Air filter element replacement in your system’s
instruction manual (807700) for replacement details.
Verify coolant level and condition
Verify that the coolant tank is full. If the level is below the full line, add Hypertherm premixed
coolant (028872). Record the number of gallons your system requires in Coolant requirements
on page 21.
Inspect the coolant tank for dirt and particulates. If either are present:
1. Drain the tank. Locate the coolant drain valve and use a 20 liter (5 gallon) container to catch the
coolant. Coolant will flow as soon as the drain is opened.
2. Close the drain when the coolant stops flowing.
3. Fill the tank with clean coolant or water and run the pump to flush
the system.
4. Drain the tank again.
5. Refill the coolant tank to the full line with clean coolant.
6. Run the system to fill hoses and leads with coolant.
7. If necessary, add more coolant to the tank. Refer to Fill the power
supply with coolant in your system’s instruction manual (807700) for
more details.
MAXPRO200 Preventive Maintenance Program Instruction Manual 808800 5
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