Plasma Arc
Cutting System
Operator Manual
803650 Revision 3
powermax190c
®
Operator Manual
(P/N 803650)
© Copyright 2004 Hypertherm, Inc.
All Rights Reserved
Hypertherm and Powermax are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
Hypertherm, Inc.
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
0
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
0
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
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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
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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.
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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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5-2 powermax19 0 c Operator Manual
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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5-8 powermax19 0 c Operator Manual
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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