Hypertherm Powermax600 Operator Manual

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Plasma Arc Cutting System

Operator Manual 803390 Revision 3

powermax

600

Plasma Arc Cutting System

Operator Manual

IM-339

(P/N 803390)

Hypertherm and Powermax are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries.

Revision 3 November 2013

Hypertherm, Inc.

Hanover, NH USA

http://www.hypertherm.com

email:info@hypertherm.com

powermax600

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

800-643-9878 Tel (Technical Service)

800-737-2978 Tel (Customer Service)

Hypertherm Automation, LLC

5 Technology Drive

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)

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 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 596908 Tel

31 165 596901 Fax

Technical Service:

00 800 49 73 7843 – toll-free in Europe

31 165 596900 Tel

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

3/27/03

ELECTROMAGNETIC COMPATIBILITY (EMC)

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.

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

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 components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Hypertherm Plasma Systems i

WARRANTY

ii Hypertherm Plasma Systems

9-01

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.

NATIONAL AND LOCAL CODES

National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

TRANSFER OF RIGHTS

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.

powermax600

Operator Manual iii

ELECTROMAGNETIC COMPATIBILITY ......................................................................................................................i

WARRANTY.................................................................................................................................................................ii

Section 1 Safety

Recoginize 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

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 exploded if damaged...................................................................................................................1-5

Noise can damage hearing.......................................................................................................................................1-5

Pacemaker and hearing aid operation......................................................................................................................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

Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2

Les chocs électriques peuvent être fatals...............................................................................................................1a-3

Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3

L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4

Mise à la masse et à la terre...................................................................................................................................1a-4

Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................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 prothéses auditives........................................................................................................................1a-5

Étiquette de sécurité ...............................................................................................................................................1a-6

Section 2 Specifications

Specifications, power supply ....................................................................................................................................2-2

Specifications, PAC123 torches................................................................................................................................2-3

Symbols and markings .............................................................................................................................................2-4

Section 3 Setup

Lifting power supply ..................................................................................................................................................3-2

Power hookup...........................................................................................................................................................3-3

Torch hookup (208-240/480 volt only) ......................................................................................................................3-5

Gas hookup ..............................................................................................................................................................3-6

PAC123 machine torch hookup ................................................................................................................................3-7

iv powermax600 Operator Manual

TABLE OF CONTENTS

Section 4 Operation

Controls and Indicators.............................................................................................................................................4-2

Confirm torch consumables ......................................................................................................................................4-3

Installing torch consumables ....................................................................................................................................4-4

Pilot arc control switch (208-240/480 volt only) ........................................................................................................4-5

Turn on power...........................................................................................................................................................4-5

Check indicator lights................................................................................................................................................4-5

Adjust gas pressure and current setting ...................................................................................................................4-6

Hand torch operation ................................................................................................................................................4-7

Machine torch operation .........................................................................................................................................4-12

Cut chart .................................................................................................................................................................4-12

Section 5 Maintenance/Parts

Routine maintenance................................................................................................................................................5-2

Inspect consumables ................................................................................................................................................5-3

Torch lead replacement ............................................................................................................................................5-5

Work cable replacement ...........................................................................................................................................5-6

Power cord replacement...........................................................................................................................................5-7

Air filter element replacment .....................................................................................................................................5-8

Basic Troubleshooting ............................................................................................................................................5-10

Technical Questions................................................................................................................................................5-10

Parts .......................................................................................................................................................................5-14

Torch consumables.........................................................................................................................See Section 4

PAC123T hand torch assembly (No Q-disc.) .................................................................................................5-14

PAC123T hand torch assembly (With Q-disc.)...............................................................................................5-16

PAC123M machine torch assembly (No Q-disc.)...........................................................................................5-18

PAC123M machine torch assembly (With Q-disc.) ........................................................................................5-20

Power supply - filter regulator ........................................................................................................................5-22

Power supply - work cable .............................................................................................................................5-22

Power max600 labels.....................................................................................................................................5-23

Power,max600 field upgrade kits and optional parts......................................................................................5-23

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. NFPAStandard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210

9. NFPAStandard 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.

1102 12

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

100-200 A N

10 No11-12

200-400 A N

12 No13

Plus de 400 A N

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

2/12/01

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.

110212

powermax600

Operator Manual 2-1

Section 2

SPECIFICATIONS

In this section:

Specifications, Power Supply ..................................................................................................................................2-2

Specifications, PAC123 Torches ..............................................................................................................................2-3

Symbols and Markings .............................................................................................................................................2-4

2-2 powermax600 Operator Manual

SPECIFICATIONS

Specifications, Power Supply

Rated Open Circuit Voltage (U0) 300 VDC Rated Output Current (I2) 20 A – 40 A Rated Output Voltage (U2) 140 VDC Duty Cycle at 40°C 50 % (I2=40 A, U2=140 V)

(See data tag on power supply for 100 % (I2=28 A, U2=140 V more information on duty cycle.)

Operating temperature -10° to +40°C (+14° to 104° F) Apparent Input Power (S1) 230/400 V = 6.7 kVA

208-240/480 V = 9.5 kVA

Input Voltage (U1)/ Input Current (I1) at 230 V/17 A – 3-phase, 50/60 Hz CE

5.6 kW Output 400 V/9,7 A – 3-phase, 50/60 Hz CE 208-240 V/40-46 A – 1-phase, 50/60 Hz CSA/NRTL

480 V/12 A – 3-phase, 50/60 Hz CSA/NRTL Gas Type Air Nitrogen Gas Quality Clean, dry, oil-free 99.995 % pure Gas Inlet Pressure and Flow See Section 3, Setup

PMX600.14

Powermax600 Power Supply Dimensions and Weight

20 in

510 mm

9.5 in

240 mm

17 in

430 mm

Weight with hand torch

and 15 ft / 4.5 m lead.

47 lb

21 kg

SPECIFICATIONS

powermax600

Operator Manual 2-3

Specifications PAC123 Torches

Maximum Cutting Capacity

40A PAC123T 5/8 inch / 16 mm @ 50 % duty cycle 40A PAC123M 1/4 inch / 6 mm @ 50 % duty cycle 28A PAC123M 1/8 inch / 3 mm @ 100 % duty cycle

Gouging Capability 5.6 pounds / 2.5 kg (metal removal rate) hour

Weight

3.5 pounds / 1.6 kg with 15 ft / 4.5 m lead

PAC123T 4.5 pounds / 2 kg with 25 ft / 7.5 m lead

7 pounds / 3.2 kg with 50 ft / 15 m lead 6 pounds / 2.7 kg with 15 ft / 4.5 m lead

PAC123M 7 pounds / 3.2 kg with 25 ft / 7.5 m lead

9.5 pounds / 4.3 kg with 50 ft / 15 m lead

PAC123T Hand Torch Dimensions

PAC123M Machine Torch Dimensions

PAC123T

PAC123T.04

PAC123M.07

8.72" / 221 mm

8.5" / 216 mm

15.06"

383 mm

3.10"

79 mm

1.58"

40 mm

1.00"

25 mm

1.38"

35 mm

1.00" 25 mm

2-4 powermax600 Operator Manual

SPECIFICATIONS

Symbols and Markings

MARK (230/400 Volt only)

The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. The hand torches must have shielded consumable parts to maintain S mark compliance.

IEC Symbols Used

The following symbols may appear on the power supply data plate, control labels and switches.

Direct Current (DC)

The terminal for the external protective (earth) conductor

AC input power connection

Plasma torch cutting and gouging

Alternating current (AC)

An inverter-based power source

Volt/amp curve, "drooping" characteristic

Power is off

Power is on

Plasma torch in the TEST position (cooling and cutting gas exiting nozzle)

powermax600

Operator Manual 3-1

Section 3

SETUP

In this section:

Lifting Power Supply .................................................................................................................................................3-2

Power Hookup ..........................................................................................................................................................3-2

Torch Hookup (Quick Disconnect Only)....................................................................................................................3-5

Gas Hookup..............................................................................................................................................................3-5

PAC123M Machine Torch Setup...............................................................................................................................3-7

SETUP

3-2 powermax600 Operator Manual

Lifting Power Supply

WARNING

The power supply weighs up to 54 lb / 25 kg. Do not lift the power supply by ONE handle. The handle can break, resulting in injury and damage to the power supply.

Power Hookup

Check Required Input Voltage

Look at U1 on the data plate to check input voltage requirements. The data plate is on the back of the power supply.

54 lb

25 kg

Hoist

Cover in place

Approved

hoisting strap.

Keep as vertical

as possible

SETUP

powermax600

Operator Manual 3-3

Power Hookup (Continued)

Install Power Cord Plug

Use a power cord plug that is certified by national or local electrical codes. The plug should be connected to the power cord by a licensed electrician.

Extension Cord

Use a cord that is certified by national or local codes. The cord should be installed by a licensed electrician. Refer to the length requirements listed below.

< 10 ft 10-25 ft 25-50 ft 50-100 ft 100-150 ft

< 3 m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45 m InputVoltage Phase Recommended Cord Gauge Size (mm

)

208-240 VAC 1 10 10 10 16 16 230 VAC 3 4 6 6 10 10 400 VAC 3 2.5 2.5 4 6 6 480 VAC 3 4 4 4 4 6

Recommended Cord Gauge Size (AWG)

208-240 VAC 1 8 8 8 6 6 230 VAC 3 12 10 10 8 8 400 VAC 3 14 14 12 10 10 480 VAC 3 12 12 12 12 10

PMX600.02

SETUP

3-4 powermax600 Operator Manual

Line Voltage Disconnect Box

Use a line disconnect box for each power supply so that the operator can turn the power supply off quickly in an emergency situation. Locate the switch near the power supply so that it is easily accessible to the operator. The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses. Use slow-blow fuses as listed below.

Grounding Requirements

To ensure personal safety, proper operation and to reduce electromagnetic interference (EMI), the Powermax600 must be properly grounded:

• The power supply chassis is electrically conductive and can present a shock hazard if it is not properly

grounded through the line voltage disconnect box.

• The power supply must be properly grounded through the power cord according to national or local

electrical codes.

• Three-phase service must use a 4-wire cord that includes a protective earth ground.

• Also see Grounding Safety, in Section 1 of this manual.

Generator Power

When using a generator to power the Powermax600:

• Use a generator with a minimum auxiliary output of 8 kVA.

• The generator must be dedicated to powering the plasma cutting system.

• Generator Operation:

1. Set the generator output to AC.

2. Plug the Powermax600 power cord into the auxiliary power outlet.

3. Set the generator to the appropriate output range. If the Powermax600 circuit breaker will not

stay on, reduce the generator output.

• Use unshielded consumables if you experience difficulty with thicker material cutting (non-CE systems only).

Input Input Current Recommended Voltage Phase @ 5.6 kw Output Slow-Blow Fuse Size

208-240 VAC 1 46-40 A 100 A 230 VAC 3 17 A 40 A 400 VAC 3 9.7 A 25 A 480 VAC 3 12 A 25 A

PMX600.03

X600.04

SETUP

powermax600

Operator Manual 3-5

Minimum Gas Inlet Pressure 90 psi / 6.2 bar Gas Flow 6 scfm @ 90 psi / 170 l/min @ 6.2 bar

Gas Hookup

Gas Requirements

Air must be filtered to remove all dirt, water and oil. Contaminants can damage the power supply, torch and consummables.

The power supply will not power-up if the gas inlet pressure is below minimum.

CAUTION: Do not exceed 120 psi / 8.3 bar pressure at the power supply gas inlet.

Damage to system may result from higher pressures.

Torch Hookup (For models with quick disconnect)

Install torch lead to power supply.

PMX600.06

Key-way

Before tightening, align threads by turning one turn counterclockwise.

3-6

SETUP

powermax600 Operator Manual

Gas Supply Connection

•

Use an inert gas hose to connect the gas supply (air or nitrogen) to the power supply gas inlet.

• Apply liquid pipe sealant to the threads to ensure a leak-free installation.

CAUTION: Do not use PTFE tape on pipe threads. Pieces of tape

can enter the air line and damage the system.

Shipped with these parts installed.

10-99

208-240/480V

90 psi / 6.2 bar

230/400V

90 psi / 6.2 bar

PMX600.11

SETUP

powermax600

Operator Manual 3-7

123M

.06

Pigtail from Machine Torch Lead

On/Off Pendant

PAC123M ON/OFF Pendant Connection

PAC123M Torch Alignment

Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0° and 90°.

PAC123M Machine Torch Setup

Socket A White Wire Socket B Not Used Socket C Black Wire

Torch

0°

90°

SETUP

3-8 powermax600 Operator Manual

powermax600

Operator Manual 4-1

10-99

Section 4

OPERATION

In this section:

Controls and Indicators.............................................................................................................................................4-2

Confirm Torch Consumables.....................................................................................................................................4-3

installing Torch Consumables ...................................................................................................................................4-4

Pilot Arc ControlSswitch (208-240/480 Volt Only).....................................................................................................4-5

Turn On Power..........................................................................................................................................................4-5

Check Indicator Lights ..............................................................................................................................................4-5

Adjust Gas Pressure and Current Setting.................................................................................................................4-6

Hand Torch Operation...............................................................................................................................................4-7

Machine Torch Operation........................................................................................................................................4-12

Cut Chart ................................................................................................................................................................4-12

OPERATION

10-99

4-2 powermax600 Operator Manual

PMX600.05

OFF

Controls and Indicators

Current (Amps)

Adjustment

Knob

Indicator Lamps

Pressure Gauge

Power Lamp

See Section 5

Ready Lamp

ON (I)/OFF (0) Switch

Pressure Regulator

Pilot Arc

Control Switch

(208-240,480 V)

OPERATION

10-99

powermax600

Operator Manual 4-3

Confirm Torch Consumables

Machine

Cutting

Unshielded *

120827 120600 120826

Deflector

120574

120303 120600 120606

Hand

Cutting

Gouging

120828 120600 120826

Shield Retaining Cap Nozzle

120573

120576

Electrode Swirl Ring

120608 120600 120831

* In CE countries, unshielded consumables may only be used in machine-torch applications.

OPERATION

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4-4 powermax600 Operator Manual

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.

Installing Torch Consumables



 



Hand tighten only.

OPERATION

10-99

powermax600

Operator Manual 4-5

Turn On Power

Position the power switch to ON.

Check that the POWER ON lamp is illuminated.

Check Indicator Lights



Check that the remaining indicator lamps are NOT illuminated.

See Section 5 for details.





PMX600.07A

Pilot Arc Control Switch (208-240/480 Volt Only)

Use to cut expanded metal. Automatically reinitiates pilot.

Use to cut plate/sheet metal. Optimum consumable life.

Check that the OK lamp is illuminated.

OPERATION

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4-6 powermax600 Operator Manual

Turn the current adjustment knob to the gas test setting.





Push the knob down to lock the regulator.



• Look at the pressure gauge and check that the correct gas pressure is set.

• If the correct gas pressure is set, proceed to .

• If the gas pressure requires adjustment, proceed to .



Adjust Gas Pressure and Current Setting

Pull the regulator knob up to unlock.

Turn the regulator knob to obtain the correct pressure.

Turn the current adjustment knob to the desired amps setting.

15 ft

4.5 m

50 ft

15 m

25 ft

7.5 m

72 psi

5.0 BAR

72 psi

5.0 BAR

78 psi

5.4 BAR

60 psi

4.2 BAR

55 psi

3.8 BAR

50 psi

3.4 BAR

PMX600.18

Lead Length

OPERATION

10-99

powermax600

Operator Manual 4-7

Hand Torch Operation

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.

Safety Trigger Operation

Avoid firing the torch when it is not in contact with the workpiece.







OPERATION

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4-8 powermax600 Operator Manual

Hand Torch Cutting Technique

Firing the torch unnecessarily reduces nozzle and electrode life.

When cutting, make sure that sparks are exiting from the bottom of the workpiece.

If sparks are spraying up from the workpiece, you are moving the torch too fast, or without sufficient power.

Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line.

Shielded Consumables. 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.

• To cut thin material, reduce the amps until you get the best

quality cut.

• For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment.

Unshielded Consumables. Maintain an approximate 1/16 inch / 1.5 mm torch-to-work distance.

OPERATION

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powermax600

Operator Manual 4-9

Attach the work clamp securely to the workpiece. Remove rust, paint or other coatings to ensure good electrical contact.

Attach the work clamp as close as possible to the area being cut, to reduce exposure to electromagnetic fields (EMF).

Do not attach it to the portion that will fall away.

Starting a Cut from the Edge of the Workpiece

Hold the torch nozzle vertical at the edge of the workpiece.

Start cutting from the edge of the workpiece.

Pause at the edge until the arc has completely cut through the workpiece.

Then, proceed with the cut.

Attach the Work Clamp

OPERATION

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4-10 powermax600 Operator Manual

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.

Piercing

Hold the torch so that the nozzle is within 1/16 inch / 1.5 mm from the workpiece before firing the torch.

Fire the torch at an angle to the workpiece, then slowly rotate it to an upright position.

When sparks are exiting from the bottom of the workpiece, the arc has pierced through the material.

When the pierce is complete, proceed with the cut.

OPERATION

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powermax600

Operator Manual 4-11

Gouging

Hold the torch perpendicular to the workpiece.

Pull the trigger to transfer the arc.

Rotate the torch to 45° from the workpiece.

Feed into the gouge.

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.

Direction of travel

45°

OPERATION

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4-12 powermax600 Operator Manual

Machine Torch Operation

Cut Chart - 40 Amp Standard Consumables

• The following recommended settings are for mechanized cutting.

• Torch-to-work distance for the following cut chart is 1/16 inch / 1.5 mm for all cuts.

Shield

120827

Retaining Cap

120600

Nozzle

120826

Electrode

120573

Swirl Ring

120576

PAC123

Torch

Material Thickness Arc Arc Recommended Travel Speed Pierce

Material Current Voltage Delay

(ga. or in.) (mm) (A) (VDC) (ipm) (mm/min.) (Sec.)

26 ga. 0.5 Mild Steel 20 155 250 6850 0 16 ga. 1.5 Mild Steel 20 155 385 1780 0 16 ga. 1.5 Mild Steel 40 120 370 10150 0

1/8" 3 Mild Steel 40 120 140 4950 0.5

1/4" 6 Mild Steel 40 130 55 1680 1.0 3/8" 10 Mild Steel 40 140 27 640 † 1/2" 13 Mild Steel 40 140 19 460 † 5/8" 16 Mild Steel 40 150 10 250 †

0.020" 1 Aluminum 20 170 175 4150 0

0.060" 1.5 Aluminum 20 170 125 3330 0 16 ga. 1.5 Aluminum 40 130 420 10900 0

1/8" 3 Aluminum 40 135 140 4450 0.5

1/4" 6 Aluminum 40 140 53 1620 1.0 3/8" 10 Aluminum 40 150 25 510 † 1/2" 13 Aluminum 40 150 17 410 † 5/8" 16 Aluminum 40 160 8 200 †

26 ga. 0.5 Stainless Steel 20 160 235 5970 0 16 ga. 1.5 Stainless Steel 20 160 50 1270 0 16 ga. 1.5 Stainless Steel 40 130 400 10150 0

1/8" 3 Stainless Steel 40 140 105 4060 0.5

1/4" 6 Stainless Steel 40 140 44 1320 1,0 3/8" 10 Stainless Steel 40 140 21 510 † 1/2" 13 Stainless Steel 40 150 14 330 † 5/8" 16 Stainless Steel 40 160 7 180 †

† To cut material above 6 mm, start torch at edge of material.

powermax600

Operator Manual 5-1

10-99

Section 5

MAINTENANCE AND PARTS

In this section:

Routine Maintenance................................................................................................................................................5-2

Inspect Consumables ...............................................................................................................................................5-3

Torch Lead Replacement..........................................................................................................................................5-5

Work Cable Replacement.........................................................................................................................................5-6

Power Cord Replacement.........................................................................................................................................5-7

Air Filter Element Replacement ................................................................................................................................5-8

Basic Troubleshooting ............................................................................................................................................5-10

Technical Questions................................................................................................................................................5-10

Parts .......................................................................................................................................................................5-14

Torch Consumables ........................................................................................................................See Section 4

PAC123T Hand Torch Assembly (No Quick Disconnect) ...............................................................................5-14

PAC123T Hand Torch Assembly (With Quick Disconnect).............................................................................5-16

PAC123M Machine Torch Assembly (No Quick Disconnect) .........................................................................5-18

PAC123M Machine Torch Assembly (With Quick Disconnect).......................................................................5-20

Power Supply - Filter Regulator .....................................................................................................................5-22

Power Supply - Work Cable ...........................................................................................................................5-22

Powermax600 Labels.....................................................................................................................................5-23

Powermax600 Field Upgrade Kits and Optional Parts...................................................................................5-23

MAINTENANCE AND PARTS

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5-2 powermax600 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.

Each Use

Check gas pressure.

Replace damaged power cord or plug.

Replace damaged torch lead.

Check pressure hose and connections for leaks.

Clean the inside of the power supply with air pressure or vacuum.

Replace damaged labels.

Check torch cap-on safety switch: listen for "click" when the retaining cap is loosened.

Check consumables for proper installation and wear.

Check trigger for damage. Check torch body for cracks and exposed conductors.

Each Week

6 Months

3 Months

MAINTENANCE AND PARTS

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powermax600

Operator Manual 5-3

Inspect Consumables

Missing Castellation

Shield

Wear of castellations Castellations must not be

worn off.

Replace

Edge gas holes Blocked holes None Clear by pushing a pin

through blocked hole from the inside

Center hole Round Hole must be round Replace

Signs of arcing None Replace

Nozzle tip

Nozzle

Even wear or erosion

1/32 inch / 1 mm minimum remaining

Replace

Side wear or erosion None Replace

Center hole Round

(View from inside)

Hole must be round Replace

Center surface

Electrode

Wear Pit not more than

1/16 inch / 1.6 mm deep

Replace

o o

Max. 1.6 mm

External surfaces

Part Check For Limit Action

MAINTENANCE AND PARTS

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5-4 powermax600 Operator Manual

Inspect Consumables (Continued)

External surfaces

Damage or debris Clean and no damage Replace

Edge gas holes Blocked holes None Replace

External surfaces

Damage or wear None Replace

Lubricated Not dry Apply a thin film of silicone

lubricant.

Part Check For Limit Action

Swirl Ring

Torch O-ring

MAINTENANCE AND PARTS

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powermax600

Operator Manual 5-5

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 Replacement (For Models Without Quick Disconnect)

Disconnect electrical power and gas supply before removing the old torch lead.

Installation

CAUTION: Do not tighten the strain relief collar (4) onto the torch lead until

the gas fitting (3) is tight, or the gas connection may leak.

1. Install the strain relief (1) and secure with nut (2).

2. Connect and tighten the gas fitting (3).

3. Tighten the strain relief collar (4) onto the lead.

4. Connect the electrical connections (5), (6) and (7). Tighten the terminal block screws to 10 in-lb / 12 kg cm of torque.

5. Install the power supply cover.

6. Reconnect electrical power and gas supply.

















 



CAUTION: This is a high current connection.

Proper torque is critical.

MAINTENANCE AND PARTS

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5-6 powermax600 Operator Manual

Disconnect electrical power and gas supply before removing the old work cable.

Installation

1. Install the strain relief (1) to the power supply and secure with nut (2).

2. Install the work cable (3) through the strain relief.

3. Tie a knot (4) in the end of the work cable.

4. Tighten the strain relief collar (5) onto the cable.

5. Connect the work cable to the terminal block (6). Tighten the terminal block screw to 10 in-lb / 12 kg cm of torque.

6. Install the power supply cover. Reconnect electrical power and gas supply.

Work Cable Replacement

CAUTION: This is a high current connection.

Proper torque is critical.











PMX600.15



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.

MAINTENANCE AND PARTS

10-99

powermax600

Operator Manual 5-7

Power Cord Replacement

Disconnect electrical power and gas supply before removing the old power cord.

Installation

1. Insert the new power cord through the strain relief.

2. Pass all 4 wires through the toroid, as shown (230 and 400 volt only).

3. Install the power cord connections where shown.

4. Tighten the strain relief onto the power cord.

5. Install the power supply cover.

6. Reconnect electrical power and gas supply.

208V - 240V

230V and 400V

PMX600.12

480V

230V 400V

YELLOW GREEN

GREEN

BROWN BLUE BLACK

BLACK WHITE

GREEN

BLACK WHITE RED

Pass all 4 wires through the toroid 2 times.

Pass all 4 wires through the toroid 3 times.

NOTE: Toroid must be installed for

power supply to be in compliance with EMC standard EN50199.

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.

MAINTENANCE AND PARTS

10-99

5-8 powermax600 Operator Manual

Air Filter Element Replacement









Compress the hose fitting collar and pull the gas hose from the hose fitting.



Pull the drain hose from the grommet in the floor of the power supply.



Unscrew the filter bowl. Do not discard the O-ring.



Remove the filter element from the filter housing.

NOTE: Do not allow the filter element to turn

when loosening the screw.

Removal

• Disconnect electrical power.

• Disconnect gas supply.

• Remove the power supply cover.

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.

MAINTENANCE AND PARTS

10-99

powermax600

Operator Manual 5-9

Air Filter Element Replacement (continued)



Push the pressure line fully into the hose fitting.







Install the drain hose into the grommet.

• Install the power supply cover.

• Reconnect electrical power and gas supply.



Install the new filter element into the filter housing. Secure with screw and retainer.



Install the filter bowl and O-ring into the filter housing.





Installation

MAINTENANCE AND PARTS

10-99

5-10 powermax600 Operator Manual

Basic Troubleshooting

PMX600.05

OFF

Controls and Indicator Lamps

Green POWER IS ON

When illuminated, indicates that AC voltage is supplied to the power supply and that the ON/OFF switch is in the ON position.

Pressure

Gauge

Current

Adjustment

Knob

ON (I)/OFF (0)

Switch

Pressure

Regulator

Green SYSTEM READY

When illuminated, indicates that circuits are activated and that all fault conditions are clear (none of the yellow lamps are illuminated).

Yellow LOW LINE VOLTAGE

When illuminated, indicates that the AC line voltage is: 1) below operating limits, or 2) is missing 1 phase (230V and 400V systems only).

Yellow LOW GAS PRESSURE

When illuminated, indicates that the incoming gas pressure is below operating limits.

Yellow TORCH PARTS ARE LOOSE OR REMOVED

When illuminated, indicates that the torch consumables are loose or not installed.

Yellow HIGH TEMPERATURE

When illuminated, indicates that the power supply temperature has exceeded operating limits.

Pilot Arc Control Switch (208-240,480 V)

MAINTENANCE AND PARTS

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powermax600

Operator Manual 5-11

Problem Cause / Solution

1. The ON/OFF power switch is set to I (ON), but the fan does not operate and the POWER ON lamp is not illuminated.

1.1 The power cord is not plugged into the power receptacle.

Plug the power cord into the receptacle.

1.2 The disconnect power switch is not set to ON or there is no power available to the disconnect power switch box.

Turn on the power at the main power panel or at the disconnect power switch box.

2. The POWER ON lamp is illuminated and the LOW GAS PRESSURE lamp is illuminated.

2.1 The gas supply is turned OFF or not connected to the power supply.

Check that the gas is turned on and is connected to the power supply.

2.2 The incoming gas pressure is too low.

Set incoming gas pressure to 90-120 psi / 6.2-8.3 bar. Check that there are no leaks in the gas supply line.

3. The POWER ON lamp is illuminated and the LOW LINE VOLTAGE lamp is illuminated.

3.1 Line voltage is too low or a phase is missing.

The following table lists the operating range of the Powermax600 power supplies. Have an electrical technician check incoming power.

5. The POWER ON lamp is illuminated and the HIGH TEMPerature lamp is illuminated.

5.1 One of the internal thermostat switches has opened due to overheating.

Leave the power supply on to allow the fan to cool the power supply.

4. The power supply shuts off after you turn it on (208-240 or 230 volt unit only).

4.1 The line voltage is too high.

See table above. Have an electrical technician check incoming power.

Note: To avoid performance deterioration, input

voltage should be within 10% of the specified system line voltage.

208 Low Line Conditions: Symptoms include difficulty maintaining pilot arc or cutting thicker material. System performance can be improved by reducing output setting or by using nonshielded consumables.

System

Lower Limit Line Voltage Upper Limit

180 VAC 208-240 VAC 276 VAC 189 VAC 230 VAC 270 VAC 328 VAC 400 VAC 470 VAC 408 VAC 480 VAC 552 VAC

MAINTENANCE AND PARTS

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5-12 powermax600 Operator Manual

Problem Cause / Solution

6. The POWER ON lamp is illuminated and the SYSTEM READY lamp is not illuminated.

6.1 The Start Lock-out is activated.

If the power supply is turned on while the torch trigger is pressed, the system ready lamp will not illuminate and the torch will be disabled. To clear fault, release the torch trigger and turn off the power supply and then turn it on.

6.2 Torch consumables are loose or removed from the torch.

If the torch consumables become loose or are removed while the power supply is on, the system ready lamp will not illuminate and the torch will be disabled. To clear fault, turn off power supply and tighten or install torch consumables. See Installing Torch Consumables, Section 4.

7. The POWER ON lamp is illuminated and the TORCH PARTS LOOSE OR REMOVED lamp is illuminated.

7.1 Torch consumables are loose or removed from the torch.

Turn off power supply and tighten or install torch consumables. See Installing Torch Consumables, Section 4.

If the torch consumables become loose or were removed while the power supply is on, turn off the power supply, correct the problem and then turn on the power supply to clear this fault.

8. The arc does not transfer to the workpiece. 8.1 The work clamp is not connected to the workpiece,

or the work clamp is broken.

Connect or repair the work clamp.

8.2 The work clamp is not making good metal-to-metal contact.

Clean the area where the clamp contacts the workpiece.

8.3 The torch is too far away from the workpiece.

Move the torch head closer to the workpiece and start the torch again. See Torch Operation, Section 4.

MAINTENANCE AND PARTS

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powermax600

Operator Manual 5-13

Problem Cause / Solution

9. The arc blows out, but re-ignites when the torch switch is depressed again.

9.1 The consumable parts are worn or damaged.

Inspect and change the consumable parts, if necessary. See Inspect Consumables, in this section. See Torch Operation, Section 4.

9.2 The gas pressure is incorrect.

Adjust the operating gas pressure. See Check and Adjust Gas Pressure, Section 4. Check that the gas

pressure to the power supply is not less than 90 psi /

6.2 bar at a flow of 6 scfm / 170 l/m.

9.3 The gas filter element inside the power supply is contaminated.

Replace element - See Air Filter Element Replacement, in this section.

10. The arc sputters and hisses. 10.1 The gas filter element inside the power supply is contaminated.

Replace element - See Air Filter Element Replacement, in this section.

10.2 There is water in the air line.

Install or repair air filteration to power supply - See Gas Requirements, Section 3.

11. Cut quality is not good. 11.1 Consumables are worn or the torch is being used incorrectly .

See Inspect Consumables, in this section. See Hand Torch Operation, Section 4.

Technical Questions

If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance:

1. Call your Hypertherm distributor or authorized Hypertherm repair facility.

2. Call nearest Hypertherm office listed in the front of this manual.

3. See the Powermax600 Service Manual for wiring diagrams, higher-level troubleshooting and more parts list information.

MAINTENANCE AND PARTS

10-99

5-14 powermax600 Operator Manual

Parts

PAC123T Hand Torch Assembly (No Quick Disconnect)

Item Part Number Description Quantity

086001* PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect) 086002* PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)

086003* PAC123T Hand Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect) 1 001288 Handle, 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch (switch and wire splices) 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring, Gutcha 1 6 075339 Screws, P/S, # 4 X 1/2, PH, RND, S/B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O-Ring: BUNA 90 Duro .614X.070 1 9 129475 Replacement Torch Lead, 15 ft / 4.5 m 1 9 129476 Replacement Torch Lead, 25 ft / 7.5 m 1 9 129477 Replacement Torch Lead, 50 ft / 15 m 1

* Top assembly includes the following consumables (See page 4-3 for details of consumable parts):

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120828 Shield 1

MAINTENANCE AND PARTS

10-99

powermax600

Operator Manual 5-15

PAC123T.01

* Included with replacement

assembly.



*















PAC123T Hand Torch and Lead Assembly - No Quick Disconnect

MAINTENANCE AND PARTS

10-99

5-16 powermax600 Operator Manual

PAC123T Hand Torch Assembly (With Quick Disconnect)

Item Part Number Description Quantity

086023* PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead and Quick Disconnect

086024* PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead and Quick Disconnect

086025* PAC123T Hand Torch Assembly with 50 ft / 15 m Lead and Quick Disconnect 1 001288 Handle, 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch (switch and wire splices) 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring, Gutcha 1 6 075339 Screws, P/S, # 4 X 1/2, PH, RND, S/B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O-Ring: BUNA 90 Duro .614X.070 1 9 129599 Replacement Torch Lead, 15 ft / 4.5 m 1 9 129600 Replacement Torch Lead, 25 ft / 7.5 m 1 9 129601 Replacement Torch Lead, 50 ft / 15 m 1

* Top assembly includes the following consumables (See page 4-3 for details of consumable parts):

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120828 Shield 1

MAINTENANCE AND PARTS

10-99

powermax600

Operator Manual 5-17

PAC123T.02

* Included with replacement

lead assembly.



*















PAC123T Hand Torch and Lead Assembly - With Quick Disconnect

MAINTENANCE AND PARTS

10-99

5-18 powermax600 Operator Manual

PAC123M Machine Torch Assembly (No Quick Disconnect)

Item Part Number Description Quantity

086004* PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect)

086005* PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)

086006* PAC123M Machine Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect) 1 120613 Sleeve, Machine Torch 1 2 020620 Sleeve, Torch Position 1 3 128374 Replacement Torch Lead, 15 ft / 4.5 m 1 3 128375 Replacement Torch Lead, 25 ft / 7.5 m 1 3 128376 Replacement Torch Lead, 50 ft / 15 m 1 4 027599 Snap Ring 1 5 120583 Torch Main Body with Safety Switch 1 6 044016 O-Ring: BUNA 90 Duro 0.614 X 0.070 inch 1

* Top assembly includes the following consumables (See page 4-3 for details of consumable parts):

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120827 Shield 1

MAINTENANCE AND PARTS

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powermax600

Operator Manual 5-19

PAC123M.03

On/Off Pendant (not part of machine torch assembly See Powermax600 Field Upgrade Kits and Optional Parts on page 5-23 for part numbers).

PAC123M Machine Torch and Lead Assembly - No Quick Disconnect













* Included with replacement

lead assembly.

MAINTENANCE AND PARTS

10-99

5-20 powermax600 Operator Manual

PAC123M Machine Torch Assembly (With Quick Disconnect)

Item Part Number Description Quantity

086026* PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead and Quick Disconnect

086027* PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead and Quick Disconnect

086029* PAC123M Machine Torch Assembly with 50 ft / 15 m Lead and Quick Disconnect 1 120613 Sleeve, Machine Torch 1 2 020620 Sleeve, Torch Position 1 3 128572 Replacement Torch Lead w/Quick Disconnect, 15 ft / 4.5 m 1 3 128573 Replacement Torch Lead w/Quick Disconnect, 25 ft / 7.5 m 1 3 128574 Replacement Torch Lead w/Quick Disconnect, 50 ft / 15 m 1 4 027599 Snap Ring 1 5 120583 Torch Main Body with Safety Switch 1 6 044016 O-Ring: BUNA 90 Duro 0.614 X 0.070 inch 1

* Top assembly includes the following consumables (See page 4-3 for details of consumable parts):

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120827 Shield 1

MAINTENANCE AND PARTS

10-99

powermax600

Operator Manual 5-21

M.04

PAC

123

On/Off Pendant (not part of machine torch assembly See Powermax600 Field Upgrade Kits and Optional Parts on page 5-23 for part numbers).

PAC123M Machine Torch and Lead Assembly - With Quick Disconnect













* Included with replacement

lead assembly.

MAINTENANCE AND PARTS

10-99

5-22 powermax600 Operator Manual

Part

Item Number Description Qty.

1 011086 Air filter element 1 2 011087 O-ring 1

Power Supply – Work Cable

Part

Item Number Description Qty.

1 123375 Work Cable with clamp, 15 ft / 4.6 m 1







Power Supply – Filter Regulator

MAINTENANCE AND PARTS

10-99

powermax600

Operator Manual 5-23

Powermax600 Labels

Powermax600 Field Upgrade Kits and Optional Parts

Part Number Description

028714 On/Off Pendant with Lead, 25 ft / 7.5 m (Also comes standard with most

machine torch system configurations. See note below.) 128061 On/Off Pendant with Lead, 50 ft / 15 m 128062 On/Off Pendant with Lead, 75 ft / 23 m 128379 Work Cable Kit, 50 ft / 15 m 128378 Wheel Kit 027112 Circle Cutting Guide 027113 Stabilizer, Circle Cutting Guide 027114 Magnetic Pivot Radius Guide 024548 Leather Cable Covers, 25 ft / 7.5 m

Note: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations.

110996

110258 .........230V, 400V

110276 .........208-240V, 480V

110261 .........230V, 400V

010287 .........208-240V, 480V

MAINTENANCE AND PARTS

10-99

5-24 powermax600 Operator Manual

Hypertherm Powermax600 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ELECTROMAGNETIC COMPATIBILITY (EMC)

WARRANTY

TABLE OF CONTENTS