Hypertherm Powermax190c Troubleshooting

Plasma Arc Cutting System
Operator Manual 803650 Revision 3
powermax190c
®
Operator Manual
(P/N 803650)
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.
Hanover, NH USA
www.hypertherm.com
Revision 3 – January, 2004
powermax190c
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)
service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm UK, Ltd.
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
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 (ETSO – Technical Service)
00 800 49 73 7843 Tel (ETSO – Technical Service
toll-free in Europe)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
5/23/03

ELECTROMAGNETIC COMPATIBILITY (EMC)

Hypertherm Plasma Systems i
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built in compliance with standard EN50199. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.
The limits required by EN50199 may not be adequate to completely eliminate interfer­ence when the affected equipment is in close proximity or has a high degree of sen­sitivity. In such cases it may be necessary to use other measures to further reduce interference.
This plasma equipment is designed for use only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and using the plasma equipment according to the manufacturer's instructions. If electro­magnetic disturbances are detected then it shall be the responsibility of the user to re­solve the situation with the technical assis­tance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surround­ing area. The following shall be taken into account: a. Other supply cables, control cables, sig­nalling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids. f. Equipment used for calibration or mea­surement. g. Immunity of other equipment in the en­vironment. User shall ensure that other equipment being used in the environment is compatible. This may require additional pro­tection measures.
h. Time of day that cutting or other activi­ties are to be carried out.
The size of the surrounding area to be con­sidered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
METHODS OF REDUCING EMISSIONS
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.
Maintenance of Cutting Equipment
The cutting equipment must be routinely maintained according to the manufacturer's recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equip­ment is in operation. The cutting equipment should not be modified in any way except 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 compo-
nents and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
Earthing of Workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for exam­ple, ship's hull or building steelwork, a con­nection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the work­piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.
Note. The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be au­thorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC TC26 (sec)94 and IEC TC26/108A/CD Arc Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.

WARRANTY

9-01
ii Hypertherm Plasma Systems
WARNING
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.
WARNING
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 Product in your environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, 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 G3 Series power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you. 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 Hypertherm repair facility, all 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.
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 product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and 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, tort, 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 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 Products.
NATIONALAND 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.

TABLE OF CONTENTS

0
powermax19 0 c Operator Manual iii
Electromagnetic Compatibility .......................................................................................................................i
Warranty .......................................................................................................................................................ii
Section 1 Safety
Recognize Safety Information ...................................................................................................................1-2
Follow Safety Instructions .........................................................................................................................1-2
Cutting Can Cause Fire or Explosion........................................................................................................1-2
Electric Shock Can Kill ..............................................................................................................................1-3
Cutting Can Produce Toxic Fumes............................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns...............................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................1-4
Grounding Safety ......................................................................................................................................1-4
Compressed Gas Equipment Safety.........................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................1-5
Pacemaker and Hearing Aid Operation.....................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................1-5
Additional Safety Information ....................................................................................................................1-5
Warning Label ...........................................................................................................................................1-6
Section 1a Sécurité
Identifier les consignes de sécurité .........................................................................................................1a-2
Suivre les instructions de sécurité...........................................................................................................1a-2
Danger Avertissement Précaution.........................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion.....................................................................1a-2
Prévention des incendies, Prévention des explosions ..................................................................1a-2
Risque d’explosion argon-hydrogène et méthane .........................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium ..........................................................1a-2
Les chocs électriques peuvent être fatals ...............................................................................................1a-3
Prévention des chocs électriques..................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques ....................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures..................................................................1a-4
Torches à allumage instantané ......................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau ...........................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ...................................................1a-4
Mise à la masse et à la terre ...................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation ..............................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages..............................................1a-5
Le bruit peut provoquer des problèmes auditifs ......................................................................................1a-5
Pacemakers et prothèses auditives ........................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés ................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................1a-6
TABLE OF CONTENTS
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iv powermax19 0 c Operator Manual
Section 2 Specifications
Introduction ...............................................................................................................................................2-2
Specifications ............................................................................................................................................2-2
Power Supply.....................................................................................................................................2-2
PAC105 Torch ....................................................................................................................................2-3
IEC Symbols Used ....................................................................................................................................2-4
Section 3 Setup
Upon Receipt ............................................................................................................................................3-2
Claims .......................................................................................................................................................3-2
Location of Power Supply .........................................................................................................................3-2
Grounding Requirements ..........................................................................................................................3-3
Power Cord Plugs .....................................................................................................................................3-3
Power Hookup...........................................................................................................................................3-4
System Circuit Recommendations.....................................................................................................3-4
Extension Cord Recommendations ...................................................................................................3-4
Section 4 Operation
Controls and Indicators ............................................................................................................................4-2
Operation ..................................................................................................................................................4-3
1. Install Torch Consumables .............................................................................................................4-3
2. Attach the Work Clamp ..................................................................................................................4-3
3. Turn on Power................................................................................................................................4-4
4. Check the Indicator Lamps ............................................................................................................4-4
5. Begin Cutting .................................................................................................................................4-5
Operating Tips...........................................................................................................................................4-6
Starting a Cut from the Edge of the Workpiece..................................................................................4-6
Piercing ..............................................................................................................................................4-7
Hand Torch Cutting Technique ...........................................................................................................4-8
Inspecting and Replacing Consumables...................................................................................................4-9
Correct Alignment of Consumables ...................................................................................................4-9
Common Cutting Faults ..........................................................................................................................4-10
Duty Cycle and Overheating ...................................................................................................................4-10
Section 5 Maintenance and Parts
Routine Maintenance ................................................................................................................................5-2
Before Each Use................................................................................................................................5-2
Every Week........................................................................................................................................5-2
3 Months ............................................................................................................................................5-2
6 Months ............................................................................................................................................5-2
Basic Troubleshooting...............................................................................................................................5-3
Torch Lead and Work Lead Replacement .................................................................................................5-4
Torch Lead Connections ....................................................................................................................5-4
Work Lead Connection.......................................................................................................................5-4
TABLE OF CONTENTS
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powermax19 0 c Operator Manual v
Technical Questions ..................................................................................................................................5-5
Parts..........................................................................................................................................................5-6
Powermax190c Power Supplies ........................................................................................................5-6
Powermax190c Systems ...................................................................................................................5-6
Consumable Parts .............................................................................................................................5-6
PAC105 Torch Assembly and 20 ft (6.1 m) Torch Lead......................................................................5-7
Powermax190c Labels.......................................................................................................................5-8
Optional Parts ....................................................................................................................................5-8
TABLE OF CONTENTS
0
vi powermax19 0 c Operator Manual
Hypertherm Plasma Systems 1-1
Section 1
SAFETY
In this section:
Recognize Safety Information ...................................................................................................................1-2
Follow Safety Instructions .........................................................................................................................1-2
Cutting Can Cause Fire or Explosion........................................................................................................1-2
Electric Shock Can Kill ..............................................................................................................................1-3
Cutting Can Produce Toxic Fumes............................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns...............................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................1-4
Grounding Safety ......................................................................................................................................1-4
Compressed Gas Equipment Safety.........................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................1-5
Pacemaker and Hearing Aid Operation.....................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................1-5
Additional Safety Information ....................................................................................................................1-5
Warning Label ...........................................................................................................................................1-6
SAFETY
11-98
1-2 Hypertherm Plasma Systems
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual and safety labels on your machine.
• Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.
• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction.
• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.
DANGER WARNING CAUTION
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.
• 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 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 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.
WARNING
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.
SAFETY
8-98
Hypertherm Plasma Systems 1-3
Touching live electrical parts can cause a fatal shock or severe burn.
• Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.
Electric Shock Prevention All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:
• Wear insulated gloves and boots, and keep your body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet surface when using the plasma system.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.
• When using a water table, be sure that it is correctly connected to earth ground.
ELECTRIC SHOCK CAN KILL
• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.
• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch leads.
• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.
• Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.
• Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.
• When making input connections, attach proper grounding conductor first.
• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.
Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death.
• Keep the cutting area well ventilated or use an approved air-supplied respirator.
• Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.
• Do not cut metal coated or containing toxic materi­als, such as zinc (galvanized), lead, cadmium or
CUTTING CAN PRODUCE TOXIC FUMES
beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut.
• Never cut containers with potentially toxic materials inside – they must be emptied and properly cleaned first.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.
SAFETY
5/6/02
1-4 Hypertherm Plasma Systems
Instant-On Torches
Plasma arc comes on immediately when the torch switch is activated.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
Work Cable Attach the work cable securely to the workpiece or the work table with good metal-to­metal 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.
GROUNDING SAFETY
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.
Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet 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.
Lens Shade
Arc Current AWS (USA) ISO 4850
Up to 100 A No. 8 No. 11 100-200 A No. 10 No. 11-12 200-400 A No. 12 No. 13 Over 400 A No. 14 No. 14
ARC RAYS CAN BURN EYES AND SKIN
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.
SAFETY
11-98
Hypertherm Plasma Systems 1-5
• 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.
GAS CYLINDERS CAN EXPLODE IF DAMAGED
COMPRESSED GAS EQUIPMENT SAFETY
Gas cylinders 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 that is not upright and secured in place.
• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma arc and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag or open flame.
• Never use a hammer, wrench or other tool to open a stuck cylinder valve.
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135
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 Z87.1, 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
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
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.
Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
NOISE CAN DAMAGE HEARING
A PLASMA ARC CAN DAMAGE FROZEN PIPES
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.
PACEMAKER AND HEARING AID OPERATION
SAFETY
8-01
1-6 Hypertherm Plasma Systems
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. Cutting sparks can cause explosion or fire.
1.1 Keep flammables away from cutting.
1.2 Keep a fire extinguisher nearby, and have a watchperson ready to use it.
1.3 Do not cut on any closed containers.
2. The plasma arc can cause injury and burns.
2.1 Turn off power before disassembling torch.
2.2 Do not hold the material near cutting path.
2.3 Wear complete body protection.
3. Electric shock from torch or wiring can kill. Protect yourself from electric shock.
3.1 Wear insulating gloves. Do not wear wet or damaged gloves.
3.2 Insulate yourself from work and ground.
3.3 Disconnect input plug or power before working on machine.
4. Breathing cutting fumes can be hazardous to your health.
4.1 Keep your head out of the fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Use ventilating fan to remove the fumes.
5. Arc rays can burn eyes and injure skin.
5.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.
6. Become trained and read the instructions before working on the machine or cutting.
7. Do not remove or paint over (cover) warning labels.
2/12/01
HYPERTHERM Systèmes plasma 1a-1
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité .........................................................................................................1a-2
Suivre les instructions de sécurité...........................................................................................................1a-2
Danger Avertissement Précaution.........................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion.....................................................................1a-2
Prévention des incendies, Prévention des explosions ..................................................................1a-2
Risque d’explosion argon-hydrogène et méthane .........................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium ..........................................................1a-2
Les chocs électriques peuvent être fatals ...............................................................................................1a-3
Prévention des chocs électriques..................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques ....................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures..................................................................1a-4
Torches à allumage instantané ......................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau ...........................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ...................................................1a-4
Mise à la masse et à la terre ...................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation ..............................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages..............................................1a-5
Le bruit peut provoquer des problèmes auditifs ......................................................................................1a-5
Pacemakers et prothèses auditives ........................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés ................................................................................1a-5
Étiquette de sécurité ...............................................................................................................................1a-6
SÉCURITÉ
2/12/01
1a-2 HYPERTHERM Systèmes plasma
IDENTIFIER LES CONSIGNES DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels. Si vous trouvez un symbole de sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques.
SUIVRE LES INSTRUCTIONS DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine.
• Les étiquettes de sécurité doivent rester lisibles. Remplacer immédiatement les étiquettes manquantes ou abîmées.
• Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. Ne laisser personne utiliser la machine sans connaître son fonctionnement.
• Garder la machine en bon état. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement.
DANGER AVERTISSEMENT PRÉCAUTION
Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSE­MENT sont situées sur la machine pour signaler certains dangers spécifiques.
• Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement.
• Les messages de PRÉCAUTION précèdent les instructions d’utilisation contenues dans ce manuel et signalent que le matériel risque d’être endommagé si les instructions ne sont pas suivies correctement.
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage ne présente aucun danger. Conserver un extincteur à proximité.
• Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres récipients fermés et pressurisés.
• Ne pas couper de récipients contenant des matières combustibles.
LE COUPAGE PEUT PROVOQUER UN INCENDIE
OU UNE EXPLOSION
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche la partie inférieure de la pièce d’aluminium, de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération.
SÉCURITÉ
2/12/01
HYPERTHERM Systèmes plasma 1a-3
Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma.
Prévention des chocs électriques Tous les systèmes plasma Hypertherm utilisent des
hautes tensions pour le coupage (souvent de 200 à 400 V). On doit prendre les précautions suivantes quand on utilise le système plasma :
• Porter des bottes et des gants isolants et garder le corps et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette dernière est correctement mise à la terre.
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
• Installer et mettre à la terre l’équipement selon les instructions du présent manuel et conformément aux codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces de la torche, couper l’alimentation ou débrancher la prise de courant.
• Ne jamais contourner ou court-circuiter les verrouillages de sécurité.
• Avant d’enlever le capot du système ou de la source de courant, couper l’alimentation électrique. Attendre en
suite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout d’abord la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour être utilisé uniquement avec des torches Hypertherm spécifiques. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité.
Le coupage peut produire des vapeurs et des gaz toxiques qui réduisent le niveau d’oxygène dans l’air et peuvent provoquer des blessures, voire la mort.
• Conserver le poste de coupage bien aéré ou utiliser un masque respiratoire homologué.
• Ne pas procéder au coupage près d’endroits où s’effectuent le dégraissage, le nettoyage ou la vapori­sation. Certains solvants chlorés se décomposent sous l’effet des rayons ultraviolets et forment du phosgène.
• Ne pas couper des métaux peints ou contenant des matières toxiques comme le zinc (galvanisé), le plomb, le cadmium ou le béryllium, à moins que la zone de travail
LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES
soit très bien ventilée et que l’opérateur porte un masque respiratoire. Les revêtements et métaux contenant ces matières peuvent produire des vapeurs toxiques lors du coupage.
• Ne jamais couper de récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.
• Quand on utilise ce produit pour le soudage ou le coupage, il dégage des fumées et des gaz qui contiennent des produits chimiques qui, selon l’État de Californie, provoquent des anomalies congénitales et, dans certains cas, le cancer.
SÉCURITÉ
5/6/02
1a-4 HYPERTHERM Systèmes plasma
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche soit mise en marche.
L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres personnes.
Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher.
Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés.
MISE À LA MASSE ET À LA TERRE
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système, s’assurer que le fil de terre est correctement branché.
• Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. Bien serrer l’écrou de retenue.
• S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe.
Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.
Puissance des verres teintés
Courant de l’arc AWS (É.-U.) ISO 4850
Jusqu’à 100 A N
o
8N
o
11
100-200 A N
o
10 No11-12
200-400 A N
o
12 No13
Plus de 400 A N
o
14 No14
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
Protection de la peau Porter des vêtements de sécurité
pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles 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 Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.
SÉCURITÉ
2/12/01
HYPERTHERM Systèmes plasma 1a-5
• Ne jamais lubrifier les robinets des bouteilles ou les régulateurs avec de l’huile ou de la graisse.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et accessoires appropriés et conçus pour chaque application spécifique.
• Entretenir l’équipement et les pièces d’équipement à gaz comprimé afin de les garder en bon état.
• Étiqueter et coder avec des couleurs tous les tuyaux de gaz afin d’identifier le type de gaz contenu dans chaque tuyau. Se référer aux codes locaux ou nationaux en vigueur.
LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES
SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ
Les bouteilles de gaz contiennent du gaz à haute pression. Si une bouteille est endommagée, elle peut exploser.
• Manipuler et utiliser les bouteilles de gaz comprimé conformément aux codes locaux ou nationaux.
• Ne jamais utiliser une bouteille qui n’est pas placée à la verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma et une bouteille.
• Ne jamais exposer des bouteilles à une chaleur excessive, aux étincelles, aux scories ou aux flammes nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres outils pour débloquer le robinet des bouteilles.
Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit.
Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma.
LE BRUIT PEUT PROVOQUER DES
PROBLÈMES AUDITIFS
UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS
Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma.
Pour réduire les risques associés aux champs magnétiques :
• Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près possible du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
PACEMAKERS ET PROTHÈSES AUDITIVES
SÉCURITÉ
8-01
1a-6 HYPERTHERM Systèmes plasma
Étiquette de sécurité
Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images.
1. Les étincelles produites par le coupage peuvent provoquer une explosion ou un incendie.
1.1 Pendant le coupage, éloigner toute matière inflammable.
1.2 Conserver un extincteur à proximité et s’assurer qu’une personne soit prête à l’utiliser.
1.3 Ne jamais couper de récipients fermés.
2. L’arc plasma peut provoquer des blessures et des brûlures.
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas tenir la surface à couper près de la trajectoire de coupe.
2.3 Porter des vêtements de protection couvrant tout le corps.
3. Un choc électrique causé par la torche ou les câbles peut être fatal. Se protéger contre les risques de chocs électriques.
3.1 Porter des gants isolants. Ne pas porter de gants mouillés ou abîmés.
3.2 S’isoler de la surface de travail et du sol.
3.3 Débrancher la prise ou la source de courant avant de manipuler l’équipement.
4. L’inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé.
4.1 Garder le visage à l’écart des vapeurs.
4.2 Utiliser un système de ventilation par aspiration ou d’échappement localisé pour dissiper les vapeurs.
4.3 Utiliser un ventilateur pour dissiper les vapeurs.
5. Les rayons de l’arc peuvent brûler les yeux et provoquer des lésions de la peau.
5.1 Porter un casque et des lunettes de sécurité. Se protéger les oreilles et porter une chemise dont le col peut être déboutonné. Porter un casque de soudure dont la protection filtrante est suffisante. Porter des vêtements protecteurs couvrant la totalité du corps.
6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage.
7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité.
0
powermax19 0 c Operator Manual 2-1
Section 2
SPECIFICATIONS
In this section:
Introduction ...............................................................................................................................................2-2
Specifications ............................................................................................................................................2-2
Power Supply ..................................................................................................................................2-2
PAC105 Torch..................................................................................................................................2-3
IEC Symbols Used ....................................................................................................................................2-4
SPECIFICATIONS
2
2-2 powermax19 0 c Operator Manual
Introduction
The Powermax190c plasma cutting system uses a chopper power supply to cut mild steel, stainless steel, aluminum and other metals.
This operator manual provides information for the user to set up and operate the system and perform limited maintenance on the torch and power supply. This manual also provides a detailed list of safety practices so that the system can be safely operated and maintained. READ THE SAFETY SECTION
(Section 1) FIRST!
The Powermax190c Service Manual provides higher-level troubleshooting and a more complete parts list.
Specifications
Power Supply
Rated Open Circuit Voltage (OCV) (U0) ................335 VDC @ 120 VAC
320 VDC @ 230 VAC
Rated Output Current (I
2
) ......................................12 amps
Duty Cycle (X) at 104° F (40° C), at rated output voltage (U
2
), and at rated output current (I2)
using 20-amp service ............................................35% (U
2
=110 volts, I2=12 amps) See power supply data tag for more information on duty cycle.
Temperature Operating Range ..............................Power supplies will operate between 32° F
(0° C) and 104° F (+40° C).
Input Voltage (U
1
)/Input Current (I
1max
)
at 1.32 kw Output ..................................................120 VAC/20.3 amps 1-Ph, 60 Hz (Non CE)
230 VAC/10.0 amps 1-Ph, 50/60 Hz (CE)
Dimensions............................................................See figure on page 2-3.
Weight: Power Supplies with Serial Numbers < 10,000
120V Power Supply ...............................................43 lbs (19.5 kg)
46 lbs (20.9 kg) with torch
230V Power Supply ...............................................47 lbs (21.3 kg)
51 lbs (23 kg) with torch
Power Supplies with Serial Numbers 10,000
120V Power Supply ...............................................47 lbs (21.3 kg)
50 lbs (22.7 kg) with torch
230V Power Supply ...............................................54 lbs (24.5 kg)
58 lbs (26.3 kg) with torch
Gas Type ...............................................................Air (Compressor contained in power supply)
Air Pressure and Flow rate ....................................40 psi (2.8 bar) @ 53.4 scfh/0.89 cfm
(25 liters/min)
SPECIFICATIONS
0
powermax19 0 c Operator Manual 2-3
Work Lead
15.8"
(400 mm)
12"
(305 mm)
8.5"
(216 mm)
8.38"
(213 mm)
1.0"
(25 mm)
1.38" (35 mm)
PAC105 Torch
Power
Cord
PAC105 Torch
Recommended Cutting Capacity...........................1/8 inch (3 mm) @ 12A (35% duty cycle)
Maximum Cutting Capacity ...................................3/16 inch (4.5 mm) @ 12A (35% duty cycle)
Severance Cutting Capacity .................................1/4 inch (6 mm) @ 12A (35% duty cycle)
Air Pressure and Flow rate ....................................40 psi (2.8 bar) @ 53.4 scfh/0.89 cfm
(25 liters/min)
Weight ...................................................................3 pounds (1.4 kg)
SPECIFICATIONS
3
2-4 powermax19 0 c Operator Manual
S MARK
The 230V Powermax190c system conforms to standard EN50192. The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. The torch must have shielded consumable parts to maintain S mark compliance.
IEC Symbols Used
Direct current (DC).
Alternating current (AC).
Plasma cutting torch.
AC input power connection.
The terminal for the external protective (earthed) conductor.
An inverter-based power source.
Anode (+) work clamp.
Temperature switch.
Pressure switch.
Plasma torch in the TEST position (cooling and cutting gas exiting nozzle).
The power is on.
The power is off.
Volt/amp curve.
0
powermax19 0 c Operator Manual 3-1
Section 3
SETUP
In this section:
Upon Receipt ............................................................................................................................................3-2
Claims .......................................................................................................................................................3-2
Location of Power Supply .........................................................................................................................3-2
Grounding Requirements ..........................................................................................................................3-3
Power Cord Plugs .....................................................................................................................................3-3
Power Hookup...........................................................................................................................................3-4
System Circuit Recommendations ..................................................................................................3-4
Extension Cord ................................................................................................................................3-4
SETUP
0
3-2 powermax19 0 c Operator Manual
Upon Receipt
1. Verify that all parts and items on your order have been received. Alert your distributor if any parts or items are damaged or missing.
2. Inspect the power supply for any physical damage that may have occurred during shipping. If there is evidence of damage, refer to the Claims section below.
All communications regarding this equipment must include the model number and serial number located on the back of the power supply.
3. Before setting up and operating the system, read the Safety section of this manual.
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim
with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call Customer Service listed in the front of this manual or your authorized Hypertherm distributor.
Claims for defective or missing merchandise – If any of the merchandise is defective or missing, call your authorized Hypertherm distributor. If you need additional assistance, call Customer Service listed in the front of this manual or your authorized Hypertherm distributor.
Location of Power Supply
Locate the power supply near a wall receptacle. Allow at least 10 inches (0.25 m) of space at the front and back of the power supply for proper ventilation.
Note: Special installation may be required where gasoline or volatile liquids are
present. Consult local or national codes.
SETUP
1
powermax19 0 c Operator Manual 3-3
Grounding Requirements
To ensure personal safety, proper operation and to reduce electromagnetic interference (EMI), the power supply must be properly grounded:
• The power supply must be grounded through the power cord according to national or local electrical codes.
• Single-phase service must be of the 3-wire type with a green or green/yellow wire for protective earth ground and must comply with national or local electrical requirements. Do not use a 2-wire cord.
• Also see Grounding Safety in the Safety section of this manual.
Power Cord Plugs
The 120V power supplies are shipped with a plug on the power cord. The 230V units are shipped without a plug on the power cord. For the 230V machine, obtain a plug that meets national or local electrical codes. The plug should be connected to the power cord by a licensed electrician. Also, note that some 120V receptacles may require a plug that is different from the plug on the power cord. To install the required plug, refer to the figure below. The installed 120V plug and cords must conform to national or local electrical codes.
1 Power cord plug (120V shown)
• Cut cord close to plug. 2 230V plug 3 To load 1 (brass) terminal 4 To load 2 (brass) terminal 5 To ground (green) terminal 6 Outer shell 7 Cord grip
Strip cord insulation back in order to separate conductors. Strip conductor insulation back in order to make good contact with plug terminals. Make connections, reinstall outer shell and cord grip and secure with screws. Do not overtighten.
1
2
5
7
6
3
4
Cut cord here
SETUP
2
3-4 powermax19 0 c Operator Manual
Power Hookup
System Circuit Recommendations
120V power supply: An individual 30A branch circuit is recommended, protected by time-delay fuses
or circuit breaker
230V power supply: An individual 20A branch circuit is recommended, protected by time-delay fuses
or circuit breaker
Work lead and clamp
Torch
Power cord
Plug power cord into a properly grounded wall receptacle.
Extension Cord
Choose an extension cord that is larger in diameter than the power cord provided with the power supply. Actual voltage loss from cord impedance will vary with line and load conditions.
Use a cord that is certified by national or local codes. The cord should be installed by a licensed electrician following national or local codes.
Minimum recommended cord size:
120V power supply: 10 AWG (6 mm
2
) for up to 75 ft (23 m)
8 AWG (10 mm
2
) for up to 140 ft (46 m)
230V power supply: 2.5 mm
2
(14 AWG) for up to 23 m (75 ft)
4 mm
2
(12 AWG) for up to 46 m (140 ft)
Note: Special installation may be required where gasoline or volatile liquids are present. Consult
national or local codes.
0
powermax19 0 c Operator Manual 4-1
Section 4
OPERATION
In this section:
Controls and Indicators ............................................................................................................................4-2
Operation ..................................................................................................................................................4-3
1. Install Torch Consumables...........................................................................................................4-3
2. Attach the Work Clamp................................................................................................................4-3
3. Turn on Power .............................................................................................................................4-4
4. Check the Indicator Lamps..........................................................................................................4-4
5. Begin Cutting ...............................................................................................................................4-5
Operating Tips...........................................................................................................................................4-6
Starting a Cut from the Edge of the Workpiece ...............................................................................4-6
Piercing............................................................................................................................................4-7
Hand Torch Cutting Technique.........................................................................................................4-8
Inspecting and Replacing Consumables...................................................................................................4-9
Correct Alignment of Consumables.................................................................................................4-9
Common Cutting Faults ..........................................................................................................................4-10
Duty Cycle and Overheating ...................................................................................................................4-10
OPERATION
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4-2 powermax19 0 c Operator Manual
Controls and Indicators
Power Switch POWER ON
When illuminated, indicates that the power supply is energized and ready to operate. Lamp will extinguish if input power is not within specified range.
FAULT
The fault lamp will illuminate under the following conditions:
1. The torch retaining cap is removed or not securely screwed down. In this condition,
the power supply must be turned off and then turned on before operation can begin.
2. The power supply overheats.
In this condition, the fan will continue to run. Wait 15 minutes for the unit to cool, or until the FAULT lamp is extinguished.
3. The input voltage is not within specification: (120 VAC +/- 20%) or (230 VAC +/- 20%). after the input
voltage has been corrected The power supply must be turned off and then turned on before operation can continue.
OFF
ON
WARNING
Before operating this system, read the Safety section of this manual thoroughly!
OPERATION
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powermax19 0 c Operator Manual 4-3
Operation
1. Install Torch Consumables
Note: Hand-tighten only
WARNING – INSTANT-ON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
Plasma arc comes on immediately when the torch switch is activated. The plasma arc will quickly cut through gloves and skin. Make sure power is off before changing consumables.
2. Attach the Work Clamp
1. Attach the work clamp securely to the workpiece.
2. Attach the work clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields (EMF).
3. Do not attach it to the portion of the workpiece that will fall away.
Shield
120884
Cap
120898
Nozzle
120882
Electrode
120881
Swirl Ring
120880
PAC105 Torch
Shielded Consumables (for easier dragging or template cutting)
Cap
120898
Nozzle
120882
Electrode
120881
Swirl Ring
120880
PAC105 Torch
Unshielded Consumables
For CE compliance, do not use the unshielded consumables.
OPERATION
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4-4 powermax19 0 c Operator Manual
Operation (continued)
3. Turn on Power
O
I
OFF
ON
Position the power switch to ON (I)
4. Check the Indicator Lamps
Check that the POWER ON lamp is illuminated
Check that the FAULT lamp is extinguished. If the FAULT lamp is illuminated, verify that:
• The torch cap is screwed securely to the torch.
• The power supply is not overheated.
• The input voltage is within specification.
Correct any fault condition and restart the system.
POWER ON
FAULT
OPERATION
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powermax19 0 c Operator Manual 4-5
Operation (continued)
5. Begin Cutting
WARNING
INSTANT-ON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
Plasma arc comes on immediately when the torch switch is activated. The plasma arc will quickly cut 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.
Note: Torch illustrations typical
Avoid firing the torch when it is not in contact with the workpiece.
Pilot arc will extinguish if transfer to workpiece is not sensed within 5 seconds.
After cutting, there is approximately 12 seconds of post-flow to cool the torch nozzle. If the trigger is pulled during post-flow, the gas stops flowing and the pilot arc will be restarted.
OPERATION
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4-6 powermax19 0 c Operator Manual
Operating Tips
Starting a Cut from the Edge of the Workpiece
1. Hold the torch nozzle vertical at the edge of
the workpiece.
2. Start cutting from the edge of the workpiece.
Pause at the edge until the arc has completely cut through the workpiece.
The pilot arc will extinguish in approximately 5 seconds it there is no transfer to the workpiece.
3. Proceed with the cut.
The nozzle or shield may be dragged in direct contact with the workpiece or held at a slight standoff (1/16" or 1-2 mm) for increased capacity on thicker metals.
OPERATION
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powermax19 0 c Operator Manual 4-7
1. Fire the torch at an angle to the workpiece, then slowly rotate it to an upright position.
2. When sparks are exiting from the bottom of the workpiece, the arc has pierced through the material.
3. When the pierce is complete, proceed with the cut.
Operating Tips (continued)
Piercing
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" (1.5 mm) from the workpiece before firing the torch.
OPERATION
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4-8 powermax19 0 c Operator Manual
Operating Tips (continued)
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. The arc below the workpiece should lag the torch by approximately 15° from vertical.
Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line.
• Do not push down on the torch when cutting. Lightly drag the torch across the workpiece to maintain a steady cut.
• Pulling the torch through the cut is easier than pushing it.
• For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment.
OPERATION
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powermax19 0 c Operator Manual 4-9
Inspecting and Replacing Consumables
Part Verify Action if defective
Shield • Center hole is round. Replace
• Side holes not blocked Replace
Shielded • Threads are undamaged Replace Cap • Internal o-ring is in place and Replace
undamaged
Torch O-ring • No damage or wear Replace
• Lubricated Apply a thin film of silicone lubricant
Swirl Ring • No damage or wear Replace
• Side holes not blocked Replace
• O-ring inside of front opening Replace is undamaged
Electrode • Center surface not pitted more Replace
than 1/16" (1.5 mm) deep
Nozzle • Center hole is round. Replace
• Side holes not blocked Replace
Cap • O-ring inside of front opening Replace
is undamaged
Correct Alignment of Consumables
Check the torch safety switch: Listen for a “click” when the cap is replaced on the torch.
Note: Hand-tighten only
Cap
Cap
OPERATION
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4-10 powermax19 0 c Operator Manual
Common Cutting Faults
• The workpiece is not totally penetrated. Causes can be:
– The cut speed is too high. – The torch parts are worn. – The metal being cut is too thick. – The work clamp is not properly attached to the workpiece.
• Dross forms on the bottom of the cut. Causes can be:
– The cutting speed is too slow. – The torch parts are worn. – The metal being cut is too thick.
• Arc “sputters” and torch consumable life is reduced. Cause can be:
– Humid conditions in the cutting area causing moisture in the torch. The Powermax190c
internal compressor uses ambient air to produce the plasma cutting gas. If this air is moist, water droplets can be introduced to the torch. This condition is not harmful to the torch.
Duty Cycle and Overheating
• The duty cycle is the amount of time, in minutes, that a pilot or plasma arc can remain “on” within a 10-minute period when operating at 104° F (40° C).
– At 12 amps, the arc can remain on 3.5 minutes out of every 10 minutes without causing the
temperature sensors to disable the unit.
• If the power supply overheats, the FAULT lamp will illuminate, the arc will shut off and the cooling fan will continue to run.
• To resume cutting, wait for the FAULT lamp to extinguish (usually 15 minutes or less).
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powermax19 0 c Operator Manual 5-1
Section 5
MAINTENANCE/PARTS
In this section:
Routine Maintenance ................................................................................................................................5-2
Before Each Use .............................................................................................................................5-2
Every Week .....................................................................................................................................5-2
3 Months..........................................................................................................................................5-2
6 Months..........................................................................................................................................5-2
Basic Troubleshooting...............................................................................................................................5-3
Torch Lead and Work Lead Replacement .................................................................................................5-4
Torch Lead Connections ..................................................................................................................5-4
Work Lead Connection ....................................................................................................................5-4
Technical Questions ..................................................................................................................................5-5
Parts..........................................................................................................................................................5-6
Powermax190c Power Supplies......................................................................................................5-6
Powermax190c Systems .................................................................................................................5-6
Consumable Parts ...........................................................................................................................5-6
PAC105 Torch Assembly and 20 ft (6.1 m) Torch Lead ...................................................................5-7
Powermax190c Labels ....................................................................................................................5-8
Optional Parts..................................................................................................................................5-8
MAINTENANCE/PARTS
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Routine Maintenance
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.
Under severe conditions, routine maintenance should be performed more frequently.
Before Each Use
• Check the torch and consumables for wear. See Inspecting and Replacing Consumable Parts in Section 4.
Every Week
• Check the torch cap-on sensor system by listening for the micro-switch to “click” when the retaining cap is loosened.
3 Months
• Replace damaged or unreadable labels.
• Replace any cracked parts.
• Check the torch body and torch lead.
• Replace the torch lead if the insulation is broken.
6 Months
• Clean the inside of the power supply with air pressure or vacuum.
MAINTENANCE/PARTS
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powermax19 0 c Operator Manual 5-3
Basic Troubleshooting
1.1 Clean or replace worn consumables as necessary.
1.2 Check for proper installation of swirl ring.
1.3 Check for proper input voltage. Check that the power cord/extension cord is not under size per Section 3.
1.4 Check that the work clamp is connected to the workpiece.
1.5 Be certain that the torch tip is in close contact with the workpiece. The pilot arc will extinguish after 5 seconds if arc transfer is not established.
1. No pilot arc; difficulty in establishing an arc, difficulty in achieving arc transfer.
2.1 Place the Power switch to On (I)
2.2 Plug in the power cord.
2.3 Check line disconnect fuses and replace if needed or reset circuit breakers.
2. No cutting output; POWER ON LED extinguished, FAULT LED extinguished; fan not running
3.1 Check that the work clamp is connected.
3.2 Clean or replace worn consumables as necessary.
3.3 Over-heated compressor see Solution 4.2.
3. No cutting output; POWER ON illuminated; FAULT LED extinguished; fan running
4.1 Check that all torch consumable parts are in place and that the retaining cap is tight. In this fault condition, the power supply must be turned off and then turned on before operation can begin.
4.2 Thermostat in power supply may be open (overheating). Allow the fan to run; the thermostat closes when the unit has cooled (see Section 4, Duty Cycle and Overheating).
4.3 Input voltage not within specification (120 VAC +/- 20% or 230 VAC +/- 20%). In this fault condition, the power supply must be turned off and then turned on before operation can begin.
4.4 Refer to Service Manual IM-366 (803660) for more detailed troubleshooting.
4. FAULT LED illuminated
Problem Solution
MAINTENANCE/PARTS
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5-4 powermax19 0 c Operator Manual
Torch Lead and Work Lead Replacement
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.
Torch Lead Connections
1. Remove the power supply cover.
2. Insert the torch lead through the strain relief and secure with nut.
3. Connect the air line to the compressor (1).
4. Make electrical connections (2), (3) and (4) to the circuit board as shown below. Note: Do not tie any wires to the torch lead.
Work Lead Connection
1. Insert work lead through the strain relief, and install the strain relief into the front panel.
2. Connect the work lead (5) to the circuit board as shown below.
Work lead Torch lead
Nut
MAINTENANCE/PARTS
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powermax19 0 c Operator Manual 5-5
Technical Questions
If you are unable to fix the problem with your system by following this basic troubleshooting guide or if you need further assistance:
1. Call your distributor. He will be able to help you, or refer you to an authorized Hypertherm repair
facility.
2. Call Hypertherm's Technical Service group or the nearest Hypertherm office, listed in the front of this
manual.
3. See the Service Manual IM-366 (803660) for wiring diagrams, higher-level troubleshooting and more
parts list information.
MAINTENANCE/PARTS
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5-6 powermax19 0 c Operator Manual
Parts
Powermax190c Power Supplies
Part Number Description
070068 120 VAC, 1-Ph, 60 Hz 070070 230 VAC, 1-Ph, 50/60 Hz 070784 120 VAC, 1-Ph, 60 Hz (S/N 10,000) 070786 230 VAC, 1-Ph, 50/60 Hz (S/N 10,000)
Powermax190c Systems
Part Number Description
070067 120 VAC, 1-Ph, 60 Hz, with torch and 20 ft (6 m) torch lead 070069 230 VAC, 1-Ph, 50/60 Hz, with torch and 20 ft (6 m) torch lead 070783 120 VAC, 1-Ph, 60 Hz, with torch and 20 ft (6 m) torch lead (S/N ≥ 10,000) 070785 230 VAC, 1-Ph, 50/60 Hz, with torch and 20 ft (6 m) torch lead (S/N ≥ 10,000)
Consumable Parts
Part Number Description
120880 Swirl Ring 120881 Electrode 120882 Nozzle 120883 Retaining Cap 120898 Shielded Retaining Cap 120884 Shield
Shield
120884
Shielded Retaining Cap
120898
Nozzle
120882
Electrode
120881
Swirl Ring
120880
Retaining Cap
120883
Nozzle
120882
Electrode
120881
Swirl Ring
120880
Shielded Consumables
Unshielded Consumables
For CE compliance, do not use the unshielded consumables.
MAINTENANCE/PARTS
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powermax19 0 c Operator Manual 5-7
PAC105 Torch Assembly and 20 ft (6.1 m) Torch Lead – 128833
Item Part Number Description
1 001288 ...............................Handle
2 027254 ...............................Spring
3 002244 ...............................Safety Trigger Assembly
4 120874 ...............................Torch Main Body with Switch, PAC105
5 058503 ...............................O-Ring: VITON .625 X .070
6 075339 ...............................Screws (5), P/S, # 4 X 1/2, PH, RND, S/B
7 128478 ...............................Torch Lead Replacement Kit, 20 ft (6.1 m)
8 005202 ...............................Switch, Torch Pushbutton
120880*..............................Swirl Ring
120881*..............................Electrode
120882*..............................Nozzle
120898*..............................Shielded Retaining Cap
120884*..............................Shield
* See page 5-6 for consumable parts.
235678411
MAINTENANCE/PARTS
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Powermax190c Labels
Optional Parts
Part Number Description
011088 Filter, air compressor inlet 060133 Work lead with clamp 060138 Power cord, Pmx190c, 120V 060145 Power cord, Pmx190c, 230V
110124
110253
110290
120V Data label
110291
230V Data label
110458
120V Data label
110459
230V Data label
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