Hypertherm powermax600 Operator's Manual
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Hypertherm powermax600 Operator's Manual

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Plasma Arc
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Operator Manual
803390 Revision 3

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  • Page 1 powermax ® Plasma Arc Cutting System Operator Manual 803390 Revision 3...
  • Page 2 (P/N 803390) Revision 3 November 2013 Hypertherm, Inc. Hanover, NH USA http://www.hypertherm.com email:info@hypertherm.com © Copyright 2013 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.
  • Page 3 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...
  • Page 4 The size of the surrounding area to be Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety, nor connected to earth ing place.

  • Page 5: Warranty

    Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS 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...
  • Page 7 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...
  • Page 8 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 Hypertherm Plasma Systems...

  • Page 9: Recoginize Safety Information

    • Do not cut pressurized cylinders, pipes, or any table to eliminate the possibility of hydrogen closed container. detonation. Refer to the Appendix section of this • Do not cut containers that have held combustible manual for aeration manifold details. materials. Hypertherm Plasma Systems 11-98...

  • Page 10: Electric Shock Can Kill

    • Provide a disconnect switch close to the power • Each Hypertherm plasma system is designed to be supply with properly sized fuses. This switch allows used only with specific Hypertherm torches. Do not the operator to turn off the power supply quickly in substitute other torches which could overheat and an emergency situation.

  • Page 11: Plasma Arc Can Cause Injury And Burns

    Work Table Connect the work table to an earth the power cord ground. Fasten the retaining nut ground, in accordance with appropriate national or tightly. local electrical codes. • Tighten all electrical connections to avoid excessive heating. Hypertherm Plasma Systems 5/6/02...

  • Page 12: Compressed Gas Equipment Safety

    Hazardous Substances, American Welding Society Protection Association, 470 Atlantic Avenue, Boston, MA 02210 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98...

  • Page 13: Warning Label

    Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or cutting. 110212 Do not remove or paint over (cover) warning labels. Hypertherm Plasma Systems 8-01...
  • Page 14 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 Hypertherm Systèmes plasma 1a-1 2/12/01...

  • Page 15: Identifier Les Consignes De Sécurité

    • Ne pas couper de bouteilles, de tuyaux ou autres Se référer à l’annexe du manuel pour plus de récipients fermés et pressurisés. renseignements sur les collecteurs d’aération. • Ne pas couper de récipients contenant des matières combustibles. 1a-2 Hypertherm Systèmes plasma 2/12/01...

  • Page 16: Les Chocs Électriques Peuvent Être Fatals

    • Chaque système plasma Hypertherm est conçu pour être • En cas d’utilisation d’une table à eau, s’assurer que cette utilisé uniquement avec des torches Hypertherm dernière est correctement mise à...

  • Page 17: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures

    Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 5/6/02...

  • Page 18: Sécurité Des Bouteilles De Gaz Comprimé

    Les tuyaux gelés peuvent être endommagés ou éclater si • Se tenir le plus loin possible de la source de courant. l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01...

  • Page 19: Étiquette De Sécurité

    Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 Hypertherm Systèmes plasma 2/12/01...

  • Page 20: Section 2 Specifications

    Section 2 SPECIFICATIONS In this section: Specifications, Power Supply ..........................2-2 Specifications, PAC123 Torches ..........................2-3 Symbols and Markings .............................2-4 powermax Operator Manual...

  • Page 21: Specifications, Power Supply

    Gas Type Nitrogen Gas Quality Clean, dry, oil-free 99.995 % pure Gas Inlet Pressure and Flow See Section 3, Setup Powermax600 Power Supply Dimensions and Weight 9.5 in 20 in 240 mm 510 mm 47 lb 21 kg 17 in...

  • Page 22: Specifications Pac123 Torches

    SPECIFICATIONS 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)

  • Page 23: Symbols And Markings

    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.
  • Page 24 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 powermax Operator Manual...

  • Page 25: Section 3 Setup

    SETUP 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. Hoist Approved hoisting strap.
  • Page 26 SETUP 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.
  • Page 27 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.

  • Page 28: Gas Hookup

    SETUP Torch Hookup (For models with quick disconnect) Install torch lead to power supply. Key-way Before tightening, align threads by turning one turn counterclockwise. PMX600.06 Gas Hookup Gas Requirements Air must be filtered to remove all dirt, water and oil. Contaminants can damage the power supply, torch and consummables.

  • Page 29: Powermax600 Operator Manual

    Do not use PTFE tape on pipe threads. Pieces of tape can enter the air line and damage the system. 208-240/480V 90 psi / 6.2 bar 230/400V Shipped with these parts installed. 90 psi / 6.2 bar PMX600.11 powermax600 Operator Manual 10-99...
  • Page 30 SETUP PAC123M Machine Torch Setup PAC123M ON/OFF Pendant Connection Pigtail from Machine On/Off Pendant Torch Lead Socket A White Wire Socket B Not Used Socket C Black Wire PAC123M Torch Alignment Mount the machine torch perpendicular to the workpiece in order to get a vertical cut.
  • Page 31 SETUP powermax Operator Manual...
  • Page 32 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 powermax Operator Manual...

  • Page 33: Section 4 Operation

    OPERATION Controls and Indicators Current (Amps) Adjustment Knob Indicator Lamps Power Lamp Ready Lamp Pressure Gauge Section 5 PMX600.05 Pilot Arc Control Switch (208-240,480 V) Pressure Regulator ON (I)/OFF (0) Switch powermax Operator Manual 10-99...

  • Page 34: Confirm Torch Consumables

    OPERATION Confirm Torch Consumables Shield Retaining Cap Nozzle Electrode Swirl Ring 120828 120600 120826 Hand Cutting 120573 120608 120600 120831 Gouging 120576 120827 120600 120826 Machine Cutting Deflector 120303 120600 120606 120574 Unshielded * * In CE countries, unshielded consumables may only be used in machine-torch applications. powermax Operator Manual 10-99...

  • Page 35: Installing Torch Consumables

    OPERATION Installing Torch Consumables 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. Hand tighten only.

  • Page 36: Pilot Arc Control Switch (208-240/480 Volt Only)

    OPERATION Pilot Arc Control Switch (208-240/480 Volt Only) Use to cut plate/sheet metal. Use to cut expanded metal. Automatically reinitiates pilot. Optimum consumable life. PMX600.07A Turn On Power Position the power switch to ON. Check Indicator Lights Check that the POWER ON lamp is illuminated. Check that the OK lamp is illuminated.

  • Page 37: Adjust Gas Pressure And Current Setting

    OPERATION Adjust Gas Pressure and Current Setting Turn the current adjustment knob to the gas test setting. • Look at the pressure gauge Lead Length and check that the correct gas 15 ft 25 ft 50 ft pressure is set. 4.5 m 7.5 m 15 m...

  • Page 38: Hand Torch Operation

    OPERATION 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. •...

  • Page 39: Hand Torch Cutting Technique

    OPERATION 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.
  • Page 40 OPERATION Attach the Work Clamp 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).
  • Page 41 OPERATION Piercing WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. Hold the torch so that the nozzle is within 1/16 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.
  • Page 42 OPERATION Gouging WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. Hold the torch perpendicular to the workpiece. Pull the trigger to transfer the arc.

  • Page 43: Machine Torch Operation

    OPERATION 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 Retaining Cap Nozzle Electrode Swirl Ring...
  • Page 44 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 powermax Operator Manual 10-99...

  • Page 45: Routine Maintenance

    MAINTENANCE AND PARTS 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 consumables for proper Check gas pressure. installation and wear.

  • Page 46: Inspect Consumables

    MAINTENANCE AND PARTS Inspect Consumables Part Check For Limit Action Missing Castellation Shield External surfaces Wear of castellations Castellations must not be Replace worn off. Edge gas holes Blocked holes None Clear by pushing a pin through blocked hole from the inside Center hole Round...
  • Page 47 MAINTENANCE AND PARTS Inspect Consumables (Continued) Part Check For Limit Action Swirl Ring External surfaces Damage or debris Clean and no damage Replace Edge gas holes Blocked holes None Replace Torch O-ring External surfaces Damage or wear None Replace Lubricated Not dry Apply a thin film of silicone lubricant.

  • Page 48: Torch Lead Replacement

    MAINTENANCE AND PARTS Torch Lead Replacement (For Models Without Quick Disconnect) 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. 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.

  • Page 49: Work Cable Replacement

    MAINTENANCE AND PARTS Work Cable Replacement WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. Disconnect electrical power and gas supply before removing the old work cable. Installation 1.

  • Page 50: Power Cord Replacement

    MAINTENANCE AND PARTS Power Cord Replacement WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. Disconnect electrical power and gas supply before removing the old power cord. Installation 1.

  • Page 51: Air Filter Element Replacement

    MAINTENANCE AND PARTS Air Filter Element Replacement WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. Removal • Disconnect electrical power. •...
  • Page 52 MAINTENANCE AND PARTS Air Filter Element Replacement (continued) Installation 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. Push the pressure line fully into the hose fitting. Install the drain hose into the grommet.

  • Page 53: Basic Troubleshooting

    MAINTENANCE AND PARTS Basic Troubleshooting Controls and Indicator Lamps Pressure Regulator Current Adjustment Knob Pressure Gauge ON (I)/OFF (0) Switch Pilot Arc PMX600.05 Control Switch (208-240,480 V) 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.
  • Page 54 3.1 Line voltage is too low or a phase is missing. and the LOW LINE VOLTAGE lamp is The following table lists the operating range illuminated. of the Powermax600 power supplies. Have an electrical technician check incoming power. Note: To avoid performance deterioration, input System...
  • Page 55 MAINTENANCE AND PARTS Problem Cause / Solution 6. The POWER ON lamp is illuminated 6.1 The Start Lock-out is activated. If the power supply is turned on while the torch trigger is and the SYSTEM READY lamp is not pressed, the system ready lamp will not illuminate and illuminated.

  • Page 56: 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. powermax...

  • Page 57: Parts

    MAINTENANCE AND PARTS 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) 001288...
  • Page 58 MAINTENANCE AND PARTS * Included with replacement assembly. PAC123T Hand Torch and Lead Assembly - No Quick Disconnect powermax Operator Manual 5-15 10-99...

  • Page 59: Pac123T Hand Torch Assembly (With Quick Disconnect)

    MAINTENANCE AND PARTS 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 001288...
  • Page 60 MAINTENANCE AND PARTS * Included with replacement lead assembly. PAC123T Hand Torch and Lead Assembly - With Quick Disconnect powermax Operator Manual 5-17 10-99...

  • Page 61: Pac123M Machine Torch Assembly (No Quick Disconnect)

    MAINTENANCE AND PARTS 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) 120613...
  • Page 62 * Included with replacement lead assembly. 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 powermax...

  • Page 63: Pac123M Machine Torch Assembly (With Quick Disconnect)

    MAINTENANCE AND PARTS 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 120613...
  • Page 64 * Included with replacement lead assembly. 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 powermax...

  • Page 65: Power Supply - Filter Regulator

    MAINTENANCE AND PARTS Power Supply – Filter Regulator Part Item Number Description Qty. 011086 Air filter element 011087 O-ring Power Supply – Work Cable Part Item Number Description Qty. 123375 Work Cable with clamp, 15 ft / 4.6 m powermax 5-22 Operator Manual 10-99...

  • Page 66: Powermax600 Labels

    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. powermax Operator Manual 5-23 10-99...
  • Page 67 MAINTENANCE AND PARTS powermax 5-24 Operator Manual 10-99...

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