Hypertherm Powermax600 Service Manual

powermax600

Plasma Arc
Cutting System

Service Manual
803400 Revision 2

®

.

powermax600

Plasma Arc Cutting System

Service Manual

IM-340

(P/N 803400)

Revision 2 - NOVEMBER 1999

Hypertherm, Inc.

Hanover, NH USA
http://www.hypertherm.com
email:[e-mail]

© Copyright 1999 Hypertherm, Inc.

All Rights Reserved

Hypertherm and Powermax are trademarks of Hypertherm, Inc.

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

Hypertherm Offices Worldwide

Hypertherm, Inc.

Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
Tel.: [phone] (Main Office)
Fax: [phone] (All Departments)
Tel.: [phone] (Technical Service)
Tel.: [phone] (Customer Service)
email: [e-mail] (General Information)
email: [e-mail] (Technical/Customer Services)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau
Rodenbacher Chaussee 6
D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]

European Technical Support Organization (ETSO)

Technologiepark Hanau
Rodenbacher Chaussee 6
D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]

:

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
Tel.: [phone]
Fax: [phone]

Hypertherm U.K.

9 Berkeley Court • Manor Park
Runcorn, Cheshire, England WA7 1TQ
Tel.: [phone]
Fax: [phone]

France

10, Allée de I’lsara
F-95000 Cergy-Pontoise, France
Tel.: [phone]
Fax: [phone]

Italy

Via Torino 2
20123 Milan, Italy
Tel.: [phone]
Fax: [phone]

The Netherlands

Burg, Haverkampstraat 13
7091 CN Dinxperlo, Holland
Tel.: [phone]
Fax: [phone]

ELECTROMAGNETIC COMPATIBILITY

EMC INTRODUCTION

The CE power supplies have been built in
compliance with standard EN50199. To
ensure that the equipment works in a
compatible manner with other radio and
electronic systems, 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 should be used
only in an industrial environment. It may
be difficult to ensure electromagnetic
compatibility in a domestic 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

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.

. In other cases

e. Health of the people around, for
example the use of pacemakers and
hearing aids.
f. Equipment used for calibration or
measurement.
g. Immunity of other equipment in the
environment. User shall ensure that
other equipment being used in the
environment is compatible. This may
require additional protection measures.
h. Time of day that cutting or other
activities are to be carried out.

The size of the surrounding area to be
considered will depend on the structure of
the building and other activities that are
taking place. The surrounding area may
extend beyond the boundaries of the
premises.

METHODS OF REDUCING
EMISSIONS

Mains Supply

Cutting equipment should 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 should 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.

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.

powermax600 Service Manual

i

WARRANTY

WARNING

Genuine Hypertherm parts are the factory­recommended 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.

GENERAL

Hypertherm, Inc. warrants that products shall be free from
defects in materials and workmanship, under proper and
normal use for which such equipment is recommended, for
a period of two (2) years, except only with respect to the
torch, for which the warranty period shall be one (1) year,
from the date of its delivery to you.

Hypertherm, at its sole option, shall repair, replace, or
adjust, free of charge, any 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, all costs, insurance and freight prepaid,
and which examination proves not to be free from defects in
materials and workmanship. Hypertherm shall not be liable
for any repairs, replacements, or adjustments of Products
covered by this warranty, except those made pursuant to
this paragraph or with Hypertherm's written consent. This
warranty shall not apply to any Product which has been
mishandled, incorrectly installed, modified or assembled by
you or any other person. Hypertherm shall be liable for
breach of this warranty only if it receives written notice of
such breach within the applicable warranty period specified
herein above. THE FOREGOING SHALL CONSTITUTE
THE SOLE REMEDY TO DISTRIBUTORS OR THEIR
CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF
ITS WARRANTY.

any patent or other right. Distributors shall notify Hyper­therm promptly upon learning of any action or threatened
action in connection with any such alleged infringement,
and each party may appoint its own counsel for any such
action or threatened action.

DISCLAIMER OF OTHER WARRANTIES

HYPERTHERM MAKES NO WARRANTIES REGARDING
PRODUCTS MANUFACTURED BY IT OR OTHERS (IN­CLUDING WITHOUT IMPLIED LIMITATION WARRAN­TIES AS TO MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE), EITHER EXPRESS OR IM­PLIED, EXCEPT AS PROVIDED HEREIN. This warranty is
in lieu of any and all warranties, express or implied, by law
or otherwise; and Distributors are not authorized to give any
other warranty purporting to be binding upon Hypertherm
upon resale of Products to their customers. IN NO EVENT
shall Hypertherm be liable for incidental or consequential
damages or injury to the person or property of anyone by
reason of any defect in any Equipment sold hereunder.

UPON RECEIPT

1. Verify that all parts and items on your order have been
received. Alert your distributor if any parts or items are
damaged or missing.

2. Inspect the power supply for any physical damage that
may have occurred during shipping. If there is evidence
of damage, refer to the
communications regarding this equipment must in­clude the model number and serial number located on
the back of the Powermax600.

3. Before setting up and operating the Powermax600,
read the Safety section of this manual.

Claims

section below. All

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 agrees to indemnify, protect
and hold harmless Distributors and their customers against
any and all liability or claims in any manner imposed upon
or accruing against Distributors and their customers be­cause of the use in or about the construction or operation of
equipment or any design, system, formula, combination,
article or material which infringes or alleges to infringe on

ii

CLAIMS

Claims for damage during shipment — If your unit was

damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of
lading upon request. If you need additional assistance, call
Customer Service listed in the front of this manual, or your
authorized Hypertherm distributor.

Claims for defective or missing merchandise — If any of
the merchandise is defective or missing, call your
authorized Hypertherm distributor. If you need additional
assistance, call Customer Service listed in the front of this
manual.

powermax600 Service Manual

TABLE OF CONTENTS

Electromagnetic Compatibility .................................................................................................................................. i

Warranty ............................................................................................................................................................ ii

SECTION 1 - SAFETY

RECOGNIZE SAFETY INFORMATION ...............................................................................................................1-2

FOLLOW SAFETY INSTRUCTIONS ...................................................................................................................1-2

CUTTING CAN CAUSE FIRE OR EXPLOSION .................................................................................................. 1-2

ELECTRIC SHOCK CAN KILL.............................................................................................................................1-3

CUTTING CAN PRODUCE TOXIC FUMES ........................................................................................................1-3

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

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

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU..........................................................1a-4

MISE À LA MASSE ET À LA TERRE ................................................................................................................. 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

ÉTIQUETTE DE SÉCURITÉ .............................................................................................................................. 1a-6

SECTION 2 SPECIFICATIONS

SPECIFICATIONS, POWER SUPPLY.................................................................................................................. 2-2

SPECIFICATIONS, PAC123 TORCHES ............................................................................................................... 2-3

SETUP SPECIFICATIONS ................................................................................................................................... 2-4

INSTALL POWER CORD PLUG ........................................................................................................................... 2-4

CHECK REQUIRED INPUT VOLTAGE ................................................................................................................ 2-4

S MARK (230/400 VOLT ONLY) ....................................................................................................................... 2-4

GROUNDING REQUIREMENTS .......................................................................................................................... 2-5

POWER CORD / EXTENSION CORD.................................................................................................................. 2-5

GAS REQUIREMENTS......................................................................................................................................... 2-6

LINE VOLTAGE DISCONNECT BOX ................................................................................................................... 2-6

powermax600 Service Manual

iii

TABLE OF CONTENTS

SECTION 3 MAINTENANCE

CONTROLS AND INDICATORS ........................................................................................................................... 3-2

INDICATOR LAMPS ............................................................................................................................................. 3-2

CONTROLS. ......................................................................................................................................................... 3-2

THEORY OF OPERATION ................................................................................................................................... 3-3

GENERAL ............................................................................................................................................................. 3-3

230/400 VOLT FUNCTIONAL DESCRIPTION...................................................................................................... 3-4

208-240/480 VOLT FUNCTIONAL DESCRIPTION .............................................................................................. 3-6

SEQUENCE OF OPERATION .............................................................................................................................. 3-8

TROUBLESHOOTING .......................................................................................................................................... 3-9

TEST EQUIPMENT............................................................................................................................................... 3-9

TROUBLESHOOTING PROCEDURES AND SEQUENCE .................................................................................. 3-9

VISUAL INSPECTION - EXTERNAL .................................................................................................................... 3-9

VISUAL INSPECTION - INTERNAL ................................................................................................................... 3-10

RESISTANCE CHECKS ......................................................................................................................................3-11

TROUBLESHOOTING GUIDE............................................................................................................................ 3-14

VOLTAGE CHECKS............................................................................................................................................ 3-21

COMPONENT REPLACEMENT ......................................................................................................................... 3-26

POWER CORD REPLACEMENT ....................................................................................................................... 3-26

TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT) ............................................... 3-27

AIR FILTER ELEMENT REPLACEMENT ........................................................................................................... 3-28

WORK CABLE REPLACEMENT ........................................................................................................................ 3-30

CAPACITOR REPLACEMENT ........................................................................................................................... 3-31

HEAT SINK COMPONENT REPLACEMENT ..................................................................................................... 3-32

SECTION 4 PARTS LIST - 400/230V CE

POWER SUPPLY – EXTERIOR ........................................................................................................................... 4-2

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE.......................................................................................... 4-3

POWER SUPPLY – BACK INTERIOR RIGHT SIDE ............................................................................................ 4-4

POWER SUPPLY – INTERIOR FAN SIDE ........................................................................................................... 4-5

POWER SUPPLY – HEAT SINK ASSEMBLY ....................................................................................................... 4-6

RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V ....................................................................... 4-7

SECTION 5 PARTS LIST - 208-240/480V

POWER SUPPLY – EXTERIOR ........................................................................................................................... 5-2

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE.......................................................................................... 5-3

POWER SUPPLY – BACK INTERIOR RIGHT SIDE ............................................................................................ 5-4

POWER SUPPLY – INTERIOR FAN SIDE ........................................................................................................... 5-5

POWER SUPPLY – HEAT SINK ASSEMBLY ....................................................................................................... 5-6

RECOMMENDED SPARE PARTS - POWERMAX600- 208-240/480V ................................................................ 5-7

SECTION 6 PARTS LIST - TORCH AND CONSUMABLES

PAC123T HAND TORCH ASSEMBLY (NO QUICK DISCONNECT) .................................................................... 6-2

PAC123T HAND TORCH ASSEMBLY (WITH QUICK DISCONNECT) ................................................................ 6-4

PAC123M MACHINE TORCH ASSEMBLY (NO QUICK DISCONNECT) ............................................................. 6-6

PAC123M MACHINE TORCH ASSEMBLY (WITH QUICK DISCONNECT) ......................................................... 6-8

TORCH CONSUMABLES ................................................................................................................................... 6-10

RECOMMENDED SPARE PARTS - PAC123 TORCH ........................................................................................6-11

SECTION 7 WIRING DIAGRAMS

iv

powermax600 Service Manual

S

AFETY

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

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

Additional Safety Information .................................................................................1-5

Warning Label ........................................................................................................1-6

Hypertherm Plasma Systems

1-1

S

AFETY

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.

CUTTING CAN CAUSE FIRE OR EXPLOSION

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.

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.

1-2

11-98

Hypertherm Plasma Systems

ELECTRIC SHOCK CAN KILL

S

AFETY

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.

• 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

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

Hypertherm Plasma Systems

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.

1-3

8-99

S

AFETY

PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches

Plasma arc comes on immediately when the torch
switch is activated.

ARC RAYS CAN BURN EYES AND SKIN

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, or 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

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.

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.

GROUNDING SAFETY

Work Cable Attach the work cable securely to the

workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall away
when the cut is complete.

Work Table Connect the work table to an earth
ground, in accordance with appropriate national or local
electrical codes.

1-4

4-99

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 connect-

ing 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.

Hypertherm Plasma Systems

S

AFETY

COMPRESSED GAS EQUIPMENT SAFETY

• Never lubricate cylinder valves or regulators with oil
or grease.

• Use only correct gas cylinders, regulators, hoses and
fittings designed for the specific application.

• Maintain all compressed gas equipment and associ­ated parts in good condition.

• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national
or local codes.

NOISE CAN DAMAGE HEARING

GAS CYLINDERS CAN EXPLODE
IF DAMAGED

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.

PACEMAKER AND HEARING
AID OPERATION

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.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1,
American Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2,

Welding Processes

1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1,

Educational Eye and Face Protection

Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1,

Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

Recommended Safe Practices for the Preparation for

Safety in Welding and Cutting

Fire Prevention in the Use of Cutting and

, American National Standards Institute

Safe Practices for Occupation and

, American National

, American Welding Society

,

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.

5. AWS F5.2,

Cutting

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1,

Cylinders

1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B,
Fire Protection Association
470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978,
Protection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA,
U.S. Government Printing Office, Washington, D.C. 20402

Recommended Safe Practices for Plasma Arc

, American Welding Society

, Compressed Gas Association

Safety and Health Standards

Safe Handling of Compressed Gases in

Code for Safety in Welding and Cutting

Cutting and Welding Processes

National Electrical Code

, 29FR 1910

, National

, National Fire

,

Hypertherm Plasma Systems

1-5

11-98

S

AFETY

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.

1-6

8-99

Hypertherm Plasma Systems

S

ÉCURITÉ

Section 1a

SÉCURITÉ

Cette section comprend:

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

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU........1a-4

MISE À LA MASSE ET À LA TERRE ...............................................................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

ÉTIQUETTE DE SÉCURITÉ ............................................................................1a-6

HYPERTHERM Systèmes plasma 1a-1

08/99

S

ÉCURITÉ

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.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

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.

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.

1a-2

08/99

HYPERTHERM Systèmes plasma

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

S

ÉCURITÉ

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.

• 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 ensuite
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 TOXIQUES

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 béryllum, à moins que la zone de travail
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.

HYPERTHERM Systèmes plasma 1a-3

08/99

S

ÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané

L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

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 ou 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 No 10 No 11-12
200-400 A No 12 No 13
Plus de 400 A No 14 No 14

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 :

o

8N

o

11

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.

• 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.

MISE À LA MASSE ET À LA TERRE

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.

1a-4

08/99

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.

HYPERTHERM Systèmes plasma

S

ÉCURITÉ

SÉCURITÉ DES BOUTEILLES DE GAZ
COMPRIMÉ

• 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.

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES

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.

PACEMAKERS ET
PROTHÈSES AUDITIVES

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 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.

HYPERTHERM Systèmes plasma 1a-5

08/99

S

ÉCURITÉ

Étiquette de sécurité

Cette étiquette est apposée sur certaines sources de courant. Il est
important que l’utilisateur et le technicien de maintenance comprenne
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.

1a-6

08/99

HYPERTHERM Systèmes plasma

SPECIFICATIONS

Section 2

SPECIFICATIONS

In this section:

SPECIFICATIONS, POWER SUPPLY ...................................................................... 2-2

SPECIFICATIONS, PAC123 TORCHES ................................................................... 2-3

SETUP SPECIFICATIONS........................................................................................ 2-4

INSTALL POWER CORD PLUG ............................................................................... 2-4

CHECK REQUIRED INPUT VOLTAGE .................................................................... 2-4

S MARK (230/400 VOLT ONLY) ........................................................................... 2-4

GROUNDING REQUIREMENTS .............................................................................. 2-5

POWER CORD / EXTENSION CORD...................................................................... 2-5

GAS REQUIREMENTS............................................................................................. 2-6

LINE VOLTAGE DISCONNECT BOX ....................................................................... 2-6

powermax600 Service Manual

2-1

10-99

PECIFICATIONS

PMX600.14

U(egatloVtiucriCnepOdetaR

0

)CDV003

I(tnerruCtuptuOdetaR

2

)A04–A02

U(egatloVtuptuOdetaR

2

)CDV041

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rofylppusrewopnogatatadeeS(

)elcycytudnonoitamrofnierom

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U,A82=

2

)V041=

erutarepmetgnitarepO°04+ot°01-°401ot°41+(C)F

S(rewoPtupnItnerappA

1

)

AVk7.6=V004/032

AVk5.9=V084/042-802

U(egatloVtupnI

1

I(tnerruCtupnI/)

1

ta)

tuptuOwk6.5

ECzH06/05,esahp3-A71/V032

ECzH06/05,esahp3-A7.9/V004

LTRN/ASCzH06/05,esahp1-A04-64/V042-802

LTRN/ASCzH06/05,esahp3-A21/V084

epyTsaGriAnegortiN

ytilauQsaGeerf-lio,yrd,naelCerup%599.99

wolFdnaerusserPtelnIsaG snoitacificepSputeSeeS

S

Section 2 SPECIFICATIONS

SPECIFICATIONS, POWER SUPPLY

Powermax600 Power Supply Dimensions and Weight

20 in

510 mm

47 lb

21 kg

Weight with hand torch

and 15 ft / 4.5 m lead.

9.5 in

240 mm

17 in

430 mm

2-2

Figure 2-1 Powermax600 Power Supply Dimensions

powermax600 Service Manual

11-99

SPECIFICATIONS, PAC123 TORCHES

yticapaCgnittuCmumixaM

T321CAPA04elcycytud%05@mm61/hcni8/5
M321CAPA04elcycytud%05@mm6/hcni4/1
M321CAPA82elcycytud%001@mm3/hcni8/1

ytilibapaCgniguoG

)etarlavomerlatem(

gk5.2/sdnuop6.5

thgieW

T321CAP

daelm5.4/tf51htiwgk6.1/sdnuop5.3

daelm5.7/tf52htiwgk2/sdnuop5.4

daelm51/tf05htiwgk2.3/sdnuop7

M321CAP

daelm5.4/tf51htiwgk7.2/sdnuop6

daelm5.7/tf52htiwgk2.3/sdnuop7

daelm51/tf05htiwgk3.4/sdnuop5.9

PAC123T

PAC123T.04

PAC123M.07

SPECIFICATIONS

Dimensions

8.72" / 221 mm

8.5" / 216 mm

1.58"
40 mm

3.10"
79 mm

1.00"
25 mm

Figure 2-2 PAC123T Hand Torch Dimensions

1.00"
25 mm

15.06"
383 mm

1.38"
35 mm

Figure 2-3 PAC123M Machine Torch Dimensions

powermax600 Service Manual

2-3

10-99

PECIFICATIONS

COMP.01

S

S 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.

SETUP SPECIFICATIONS

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. See Figure 2-4.

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.

Figure 2-4 Data Plate Input Voltage

2-4

10-99

powermax600 Service Manual

SPECIFICATIONS

A

PMX600.02

Power Cord / 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

Input
Voltage Phase Recommended Cord Gauge Size (mm2)

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

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.

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PECIFICATIONS

PMX600.03

PMX600.04

S

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.

Input Input Current Recommended

Voltage Phase @ 5.6 kw Output Slow-Blow Fuse Size

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

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.

Minimum Gas Inlet Pressure 90 psi / 6.2 bar

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

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powermax600 Service Manual

MAINTENANCE

Section 3

MAINTENANCE

In this section:

CONTROLS AND INDICATORS ............................................................................... 3-2

INDICATOR LAMPS.................................................................................................. 3-2

CONTROLS. ............................................................................................................. 3-2

THEORY OF OPERATION ....................................................................................... 3-3

GENERAL ................................................................................................................. 3-3

230/400 VOLT FUNCTIONAL DESCRIPTION.......................................................... 3-4

208-240/480 VOLT FUNCTIONAL DESCRIPTION .................................................. 3-6

SEQUENCE OF OPERATION .................................................................................. 3-8

TROUBLESHOOTING .............................................................................................. 3-9

TEST EQUIPMENT................................................................................................... 3-9

TROUBLESHOOTING PROCEDURES AND SEQUENCE ...................................... 3-9

VISUAL INSPECTION - EXTERNAL ........................................................................ 3-9

VISUAL INSPECTION - INTERNAL.......................................................................... 3-10

RESISTANCE CHECKS ........................................................................................... 3-11

TROUBLESHOOTING GUIDE.................................................................................. 3-14

VOLTAGE CHECKS .................................................................................................. 3-21

COMPONENT REPLACEMENT ............................................................................... 3-26

POWER CORD REPLACEMENT ............................................................................. 3-26

TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT)...... 3-27

AIR FILTER ELEMENT REPLACEMENT ................................................................. 3-28

WORK CABLE REPLACEMENT .............................................................................. 3-30

CAPACITOR REPLACEMENT.................................................................................. 3-31

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