290-Index

EN50199

EN50192

Plasma Arc

Cutting System

Operator Manual

802900 Rev. 0

Plasma Arc Cutting System

Operator Manual

IM-290

(P/N 802900)

Hypertherm, Inc.

P.O. Box 5010

Hanover, New Hampshire 03755-5010

Tel.: 603 643-3441

Fax: 603 643-5352

http://www.hypertherm.com

HYPERTHERM and POWERMAX are trademarks of Hypertherm, Inc. and may be

registered in the United States and/or other countries.

Revision 0 July, 1997

Hypertherm Offices Worldwide

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

Tel.: (603) 643-3441 (Main Office)

Fax: (603) 643-5352 (All Departments)

Tel.: (800) 643-9878 (Technical Service)

Tel.: (800) 737-2978 (Customer Service)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D–63457 Hanau-Wolfgang, Germany

Tel.: 49 6181 58 2100

Fax: 49 6181 58 2134

European Technical Support Organization (ETSO)

Technologiepark Hanau

Rodenbacher Chaussee 6

D–63457 Hanau-Wolfgang, Germany

Tel.: 49 6181 58 2100

Fax: 49 6181 58 2134

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2

K.B. Warehouse Complex

Singapore 417847, Republic of Singapore

Tel.: 65 841 2489

Fax: 65 841 2490

Hypertherm U.K.

9 Berkeley Court • Manor Park

Runcorn, Cheshire, England WA7 1TQ

Tel.: 44 1928 579 074

Fax: 44 1928 579 604

Hypertherm France

10, Allée de I’lsara

F-95000 Cergy-Pontoise, France

Tel.: 33 1 34 24 03 05

Fax: 33 1 34 25 09 64

Hypertherm Italy

Via Torino 2

20123 Milan, Italy

Tel.: 39 02 725 46 312

Fax: 39 02 725 46 400

Operator Manual

LECTROMAGNETIC

OMPATIBILITY

EMC INTRODUCTION

The 115/230V CE power supply has 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

. In other cases

it could involve constructing an

electromagnetic screen enclosing the

power source and the work complete with

associated input filters. In all cases

electromagnetic disturbances must be

reduced to the point where they are no

longer troublesome.

ASSESSMENT OF AREA

Before installing the equipment the user

shall make an assessment of potential

electromagnetic problems in the

surrounding area. The following shall be

taken into account:

a. Other supply cables, control cables,

signalling and telephone cables; above,

below and adjacent to the cutting

equipment.

b. Radio and television transmitters and

receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example

guarding of industrial equipment.

e. Health of the people around, for

example the use of pacemakers and

hearing aids.

f. Equipment used for calibration or

measurement.

g. Immunity of other equipment in the

environment. User shall ensure that

other equipment being used in the

environment is compatible. This may

require additional protection measures.

h. Time of day that cutting or other

activities are to be carried out.

The size of the surrounding area to be

considered will depend on the structure of

the building and other activities that are

taking place. The surrounding area may

extend beyond the boundaries of the

premises.

METHODS OF REDUCING

EMISSIONS

Mains Supply

Cutting equipment 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.

Operator Manual

ARRANTY

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, replace-

ments, or adjustments of Products covered by this warranty, except those made pursuant to this para-

graph 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. HYPER-

THERM 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 HYPER-

THERM OF ITS WARRANTY.

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 HYPER-

THERM, HYPERTHERM agrees to indemnify, protect and hold harmless Distributors and their custom-

ers 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 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.

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.

TABLE OF CONTENTS

Operator Manual

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

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

SECTION 1 SAFETY .................................................................................................................... 1-1

About Notes, Cautions & Warnings .................................................................................................... 1-1

Safety Instructions.............................................................................................................................. 1-2

Eye Protection .............................................................................................................................. 1-2

Skin Protection ............................................................................................................................. 1-2

Toxic Fume Protection.................................................................................................................. 1-2

Fire Prevention ............................................................................................................................. 1-2

Electric Shock Prevention ............................................................................................................ 1-2

Explosion Prevention ................................................................................................................... 1-3

Noise Protection ........................................................................................................................... 1-4

Grounding .................................................................................................................................... 1-4

Safety Reminders......................................................................................................................... 1-4

Electronic Health Support Equipment .......................................................................................... 1-4

SECTION 1A SÉCURITÉ ............................................................................................................. 1a-1

Au sujet des Notes, Attention et avertissement................................................................................ 1a-1

Consignes de sécurité...................................................................................................................... 1a-2

Protection des yeux.................................................................................................................... 1a-2

Protection de la peau ................................................................................................................. 1a-2

Prévention des vapeurs toxiques ............................................................................................... 1a-2

Prévention des incendies ........................................................................................................... 1a-2

Prévention des chocs électriques .............................................................................................. 1a-2

Prévention des explosions ......................................................................................................... 1a-3

Protection contre le bruit ............................................................................................................ 1a-4

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

Rappels de sécurité ................................................................................................................... 1a-4

Prothèses électroniques............................................................................................................. 1a-4

SECTION 2 SPECIFICATIONS ...................................................................................................... 2-1

Introduction ........................................................................................................................................ 2-2

Specifications ..................................................................................................................................... 2-2

Power Supply ............................................................................................................................... 2-2

PAC110 Torch.............................................................................................................................. 2-3

S Mark ............................................................................................................................................. 2-4

IEC Symbols Used ............................................................................................................................. 2-4

SECTION 3 SETUP........................................................................................................................ 3-1

Upon Receipt ..................................................................................................................................... 3-2

Claims ................................................................................................................................................ 3-2

Locating Power Supply ...................................................................................................................... 3-2

115/215 Voltage Configurations ......................................................................................................... 3-2

Input Voltage Selector Switch ...................................................................................................... 3-2

Power Cord Plugs ........................................................................................................................ 3-2

Grounding .......................................................................................................................................... 3-4

Work Cable and Clamp ...................................................................................................................... 3-4

Plasma Air Supply .............................................................................................................................. 3-4

iii

TABLE OF CONTENTS

Operator Manual

Additional Air Filtration ................................................................................................................. 3-5

Air Hose Connection .......................................................................................................................... 3-5

SECTION 4 OPERATION ............................................................................................................. 4-1

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

Operating Instructions ........................................................................................................................ 4-3

Operating Tips.................................................................................................................................... 4-4

Changing Consumable Parts ....................................................................................................... 4-4

Cutting .......................................................................................................................................... 4-5

Piercing ........................................................................................................................................ 4-6

Operating Data - 25A Consumables .................................................................................................. 4-7

Common Cutting Faults ..................................................................................................................... 4-8

Duty Cycle and Overheating .............................................................................................................. 4-8

SECTION 5 MAINTENANCE/PARTS........................................................................................... 5-1

Introduction ........................................................................................................................................ 5-2

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

Trouble LED Indicators ...................................................................................................................... 5-3

Pressure ....................................................................................................................................... 5-3

Torch Cap .................................................................................................................................... 5-3

Over-Temp ................................................................................................................................... 5-3

PAC110 Torch Repair ........................................................................................................................ 5-4

Parts and Required Tools ............................................................................................................ 5-4

Remove Torch Main Body ............................................................................................................ 5-4

Install New Torch Main Body ....................................................................................................... 5-4

Basic Troubleshooting........................................................................................................................ 5-6

Technical Questions........................................................................................................................... 5-8

Parts ................................................................................................................................................... 5-8

Powermax350 Hand Systems ...................................................................................................... 5-8

Consumable Parts........................................................................................................................ 5-8

PAC110 Torch Assembly and 15 Ft (4.5 M) Torch Lead, 25A ..................................................... 5-9

PAC110 Torch Assembly and 25 Ft (7.6 M) Torch Lead, 25A ..................................................... 5-9

ILLUSTRATIONS

Figure 2-1 Powermax350 Hand Plasma Cutting System............................................................. 2-3

Figure 2-2 PAC110 Torch with Dimensions .................................................................................. 2-3

Figure 3-1 Repositioning Input Voltage Selector Switch .............................................................. 3-3

Figure 3-2 Changing Power Cord Plugs ...................................................................................... 3-3

Figure 3-3 Proper Work Clamp Connection ................................................................................. 3-4

Figure 3-4 Recommended Three-Stage Air Filtration System ..................................................... 3-5

Figure 3-5 Air Supply Connection ................................................................................................ 3-5

Figure 4-1 Powermax350 Controls and Indicators....................................................................... 4-2

Figure 4-2 Proper Work Clamp Connection ................................................................................. 4-3

Figure 4-3 Consumables Parts .................................................................................................... 4-4

Figure 4-4 Starting a Cut.............................................................................................................. 4-5

Figure 4-5 Dragging the Torch ..................................................................................................... 4-5

Figure 4-6 Cutting a Circle ........................................................................................................... 4-6

Figure 4-7 Piercing....................................................................................................................... 4-6

Figure 5-1 Trouble LED Indicators ............................................................................................... 5-3

Figure 5-2 PAC110 Torch Repair ................................................................................................. 5-5

Figure 5-3 Consumable Parts ...................................................................................................... 5-8

Figure 5-4 PAC110 Assembly and Lead...................................................................................... 5-9

SAFETY

HYPERTHERM Plasma Systems

1-1

5-98

About Notes, Cautions and Warnings

Notes: Throughout this manual, useful information for operating the plasma system is presented in “notes”,

such as shown in this paragraph.

Cautions: Information in bold type and surrounded by a box describes a situation that may cause

damage to the plasma system.

Before using this plasma arc system. . . .

Each person who will operate this equipment, perform

service or maintenance, or supervise its use must read

the safety instructions and warnings in this manual and

the labels on the equipment.

WARNINGS

Warnings describe situations that present a physical danger to the operator, and advice to avoid or

correct the situation. Each type of warning includes applicable danger symbols, such as a hand burn,

electrical shock, fire, explosion, etc.

WARNING — Electric Shock

• Never touch the torch body, workpiece or the water in

a water table when operating the plasma system.

• When using a water table, be sure that it is correctly

connected to earth ground.

• Operating the plasma system completes an electrical

circuit between the torch and the workpiece and

anything touching the workpiece. The workpiece is part

of the electrical circuit.

WARNING — Instant-On

Torches

Instant-on torches produce a plasma

arc immediately after the torch switch

pushed.

Always hold a hand torch away from

your body as a precaution against

accidental torch firing. Be aware of

this hazard, which has potential for

serious bodily injury.

In this section:

About Notes, Cautions and Warnings ..................... 1-1

Safety Instructions................................................... 1-2

Eye Protection .................................................. 1-2

Skin Protection ................................................. 1-2

Toxic Fume Prevention..................................... 1-2

Fire Prevention ................................................. 1-2

Electric Shock Prevention................................. 1-2

Explosion Prevention ........................................ 1-3

Compressed Gas Cylinders .......................... 1-3

Section 1 SAFETY

Pressure Regulators...................................... 1-3

Hoses ............................................................ 1-3

Noise Protection .................................................. 1-4

Grounding ............................................................ 1-4

Input Power ................................................... 1-4

Work Cable.................................................... 1-4

Work Table .................................................... 1-4

Safety Reminders ................................................ 1-4

Electronic Health Support Equipment .................. 1-4

HYPERTHERM Plasma Systems

SAFETY

1-2

Eye Protection

• Wear dark safety glasses or goggles with side

shields, or a welding helmet, in accordance with

applicable national or local codes, to protect eyes

against the plasma 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

• Replace the glasses, goggles or helmet when the lens

becomes pitted or broken.

• Warn other people in the area not to look directly at

the arc unless they are wearing glasses, goggles or a

helmet.

• Prepare the cutting area in a manner that reduces the

reflection and transmission of ultraviolet light:

– Paint walls and other surfaces with dark colors to

reduce reflection.

– Install protective screens or curtains to reduce

ultraviolet transmission.

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 which covers all

exposed areas.

– Cuffless trousers to prevent entry of sparks and

slag.

Toxic Fume Prevention

• Keep the cutting area well ventilated.

• Remove all chlorinated solvents from the cutting area

before cutting. Certain chlorinated solvents

decompose when exposed to ultraviolet radiation to

form phosgene gas.

• Wear proper breathing mask and use proper

ventilation when cutting galvanized metal.

• Do not cut containers with toxic materials inside.

Clean containers that have held toxic materials

thoroughly before cutting.

WARNING — Toxic Fumes

Do not cut metal or painted metals

containing zinc, lead, cadmium or beryllium

unless the operator, or anyone else subjected

to the fumes, wears respiratory equipment or

an air-supplied helmet.

5-98

Fire Prevention

• Make fire extinguishers available in the

cutting area.

• Remove all combustible materials from the immediate

cutting area to a distance of at least 35 feet (10 m).

• Quench freshly cut metal or allow metal to cool

before handling it or bringing it into contact with

combustible materials.

• Never use a plasma system to cut containers with

potentially flammable materials inside. Such

containers must be thoroughly cleaned prior to

cutting.

• Ventilate potentially flammable atmospheres before

cutting with a plasma system. When cutting with

oxygen as the plasma gas, an exhaust ventilation

system is required.

• Never operate the plasma system in an atmosphere

which contains heavy concentrations of dust,

flammable gas or combustible liquid vapors unless

properly vented.

Electric Shock Prevention

All Hypertherm plasma systems use high

voltage (up to 300 VDC) to initiate the plasma

arc. Take the following precautions when

operating the plasma system:

• Wear insulated gloves and boots, and keep body and

clothing dry.

• Do not stand, sit or lie on—or touch—any wet surface

when using the plasma system.

• Maintain proper insulation against electrical shock. If

you must work in or near a damp area, use extreme

caution.

• Provide a wall-mounted disconnect switch with

properly sized fuses close to the power supply. This

switch allows the operator to turn the power supply off

quickly in an emergency situation.

• Conform to all local electrical codes for primary wiring

sizes and types.

• Inspect the primary power cord frequently for damage

or cracking of the cover. Bare wiring can kill. Do not

use a system with a damaged power cord. Replace a

damaged power cord immediately.

• Inspect the torch leads. Replace if frayed or

damaged.

• 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.

SAFETY

HYPERTHERM Plasma Systems

1-3

• Never use a cylinder that is not upright and secured

in place.

• Never move or transport a cylinder without its

protective valve cover in place.

• Never use a gas cylinder or its contents for any

purpose other than that for which it is intended.

• Never lubricate cylinder valves with oil or grease.

• Never allow electrical contact between the plasma arc

and a cylinder.

• Never expose cylinders to excessive heat, sparks,

slag or open flame.

• Never use hammers, wrenches or other tools to open

stuck cylinder valves.

Pressure Regulators

• Be certain that all pressure regulators are in proper

working condition.

• Never use a regulator for any gas other than that for

which it is intended.

• Never use a regulator that leaks, creeps excessively

or is physically damaged in any way.

• Never attempt to lubricate a regulator with oil or

grease.

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.

Installing an aeration manifold on the floor of the

water table is an effective way to eliminate the

possibility of hydrogen detonation when cutting

aluminum. Refer to the Appendix section of this

manual for instructions on how to fabricate an

aeration manifold.

Hoses

• Label and color-code all gas hoses in order to clearly

identify the type of gas in each hose. Consult

applicable national or local codes.

• Never use the oxygen hose for any gas other than

oxygen.

• Examine hoses at regular intervals for leaks, wear,

loose connections or other hazard.

• Replace hose that is damaged in any way.

Electric Shock Prevention (continued)

• Before changing the torch parts, disconnect the main

power or unplug the power supply. After changing

torch parts and replacing the retaining cap, plug in the

power supply again.

• Never bypass or shortcut the safety interlocks.

• Before removing a power supply cover for

maintenance, disconnect the main power at the wall

disconnect switch or unplug the power supply. To

avoid exposure to severe electrical hazard, wait five

minutes after disconnecting the main power to allow

capacitors to discharge.

• Never operate the plasma system unless the power

supply unit covers are in place. Exposed power

supply connections present a severe electrical

hazard.

Explosion Prevention

WARNING — Compressed Gas

The plasma system uses compressed gas.

Observe proper precautions when handling and

using compressed gas equipment and cylinders.

• Do not use the plasma system if explosive dust or

vapors may be present.

• Do not cut pressurized cylinders or any closed

container.

WARNING —

Hydrogen Explosion Hazard

If your system uses hydrogen, remember that this

is a flammable gas that presents an explosion

hazard. Keep flames away from cylinders

containing hydrogen mixtures and hoses that

carry hydrogen mixtures. Also, keep flames and

sparks away from the torch when using argon-

hydrogen as the plasma gas.

Compressed Gas Cylinders

Handle and use compressed gas cylinders in accor-

dance with safety standards published by the U.S.

Compressed Gas Association (CGA), American Weld-

ing Society (AWS), Canadian Standards Association

(CSA) or applicable national or local codes.

• Never use a cylinder that leaks or is physically

damaged.

5-98

HYPERTHERM Plasma Systems

SAFETY

1-4

5-98

Safety Reminders

• Never bypass or shortcut the safety interlocks on any

of the plasma system units.

• Except in Hypertherm’s largest mechanized systems,

all Hypertherm torches are designed with a safety

interlock that prevents firing of the plasma arc when

the retaining cap is loosened.

• 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 potentially dangerous situation to the

operator and any personnel in the area. Hypertherm’s

warranty does not cover problems caused by the use

of torches not made by Hypertherm.

• Use only consumable parts and replacement parts

made by Hypertherm. Hypertherm’s warranty does

not cover problems caused by the use of parts not

made by Hypertherm.

• Never operate the plasma system with any of its

covers not in place. This would be hazardous to the

operator and other people in the area, and prevents

the proper cooling of the equipment.

Electronic Health Support Equipment

Plasma arc cutting and gouging systems create electric

and magnetic fields that may interfere with the correct

operation of electronic health support equipment, such

as pacemakers or hearing aids. Any person who wears

a pacemaker or hearing aid should consult a doctor

before operating or being near any plasma system

when it is in use. To minimize exposure to EMF:

• Keep both the work cable and the torch lead on one

side of your body. Keep your body from coming in

between the torch lead and the work cable.

• Route torch leads as close as possible to work cable.

• Do not wrap the torch lead or work cable around your

body.

• Stay as far away from the power supply as possible.

Hoses (continued)

• Keep hose lengths to a minimum to prevent damage,

reduce pressure drop and to prevent possible flow

restrictions.

• Prevent kinking by laying out hoses as straight as

possible between termination points.

• Coil any excess hose and place it out of the way to

prevent damage and to eliminate the danger of

tripping.

Noise Protection

The plasma cutting process can generate high

levels of noise. Depending on the arc current,

material being cut, acoustics and size of the

cutting room, distance from the torch and other factors,

acceptable noise levels as defined by national or local

codes may be exceeded by your plasma system.

• Always wear proper ear protection when cutting or

gouging with the plasma system.

Grounding

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 properly connect the power cord ground wire.

Conform to Canadian Standards Association (CSA)

standards by placing the power cord 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.

Work Cable

• Attach the work cable securely to the workpiece or

the work table by making 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.

SÉCURITÉ

HYPERTHERM Systèmes plasma 1a-1

10/6/98

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 AVERTISSE-

MENT 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.

Section 1a SÉCURITÉ

SÉCURITÉ

1a-2

10/6/98

HYPERTHERM Systèmes plasma

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 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 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.

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

• 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.

5/27/99

SÉCURITÉ

HYPERTHERM Systèmes plasma 1a-3

10/6/98

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

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

• 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.

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 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 N

10 N

11-12

200-400 A N

12 N

Plus de 400 A N

14 N

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 :

personnes.

4/9/99

SÉCURITÉ

1a-4

10/6/98

HYPERTHERM Systèmes plasma

• 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.

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

PACEMAKERS ET

PROTHÈSES AUDITIVES

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.

10/16/98

PECIFICATIONS

2-1

Operator Manual

In this section:

Introduction ......................................................................................................2-2

Specifications ................................................................................................... 2-2

Power Supply ..............................................................................................2-2

PAC110 Torch ..............................................................................................2-3

S Mark.............................................................................................................2-4

IEC Symbols Used ...........................................................................................2-4

Section 2

SPECIFICATIONS

2-2

PECIFICATIONS

Operator Manual

INTRODUCTION

The Powermax350 plasma cutting system uses a chopper power supply to cut mild steel, stainless

steel, aluminum and other metals. Cylinder air or shop air is used as the plasma gas. Air used for

plasma cutting must be clean, dry and oil-free.

This instruction manual provides information for the user to set up and operate the system and perform

limited maintenance on the torch and power supply. This manual also provides a detailed list of safety

practices so that the system can be safely operated and maintained. READ THE SAFETY SECTION

(Section 1) FIRST!

The Powermax350 service manual provides higher-level troubleshooting and a more complete parts

list.

SPECIFICATIONS

Power Supply

Rated Open Circuit Voltage (OCV) (U

) ........................255 VDC

Rated Output Current (I

) ..............................................17–27 amps

Full Rated Output ..........................................................27 amps at 91 VDC at 104° F (40° C)

Duty Cycle (X) at 40° C, at rated output

voltage (U

), and at rated output current (I

) .................35% (I

=27A, U

=91V)

60% (I

=21A, U

=88V)

100% (I

=17A, U

=87V) See power supply data

tag for more information on duty cycle.

Ambient Temperature and Duty Cycle ..........................Power supplies will operate between +14° and

104° F (-10° and +40° C). Power supplies

operated in an ambient temperature above

86° F (30° C) may show some decrease in

duty cycle.

Apparent Input Power (S

) ............................................3.8 kVA

) both non CE and CE power

supplies

Input Voltage (U

)/Input Current (I

)

at 2.25 kw Output ..........................................................115/230V/33.3/17.8A 1-Phase, 60 Hz (Non CE)

115/230V/33.3/17.8A 1-Phase, 50 Hz (CE)

Dimensions ...................................................................See Figure 2-1.

Weight ...........................................................................44 pounds (20 kg)

47 pounds (21.4 kg) with torch

Gas Requirements:

Gas Type.......................................................................Air - clean, dry, oil-free

Supplied Air Pressure and Flowrate..............................70 -120 psi (4.8 - 8.3 bar) @ 270 scfh/4.5 scfm

(127 l/min) supplied to power supply pressure

regulator.

Power Supply Pressure Regulator Setting ....................60 psi (4.1 bar) flowing

1-99

PECIFICATIONS

2-3

Operator Manual

Work

Lead

PAC110

Torch

Power

Cord

Powermax350

Figure 2-1 Powermax350 Plasma Cutting System

PAC110 Torch

Recommended Cutting Capacity ..................................1/4 inch (6 mm) @ 25A (35% duty cycle)

Maximum Cutting Capacity ...........................................3/8 inch (10 mm) @ 25A (35% duty cycle)

Severance Cutting Capacity..........................................1/2 inch (12 mm) @ 25A (35% duty cycle)

Gas Flow .......................................................................270 scfh/4.5 scfm at 60 psi (127 l/min at

4.1 bar)

Weight ...........................................................................3 pounds (1.4 kg)

Figure 2-2 PAC110 Torch with Dimensions

2-4

PECIFICATIONS

Operator Manual

S MARK

The Powermax350 conforms to standard EN50192. The S mark indicates that the power

supply and torch are suitable for use in environments with increased hazard of electrical shock.

Direct Current (DC).

Alternating current (AC).

Plasma cutting torch.

AC input power connection.

The terminal for the external protective (earthed) conductor.

A chopper-based power source.

Anode (+) work clamp.

Temperature switch.

Pressure switch.

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

The power is on.

The power is off.

Volt/amp curve.

IEC SYMBOLS USED

3-1

ETUP

Operator Manual

Section 3 SETUP

In this section:

Upon Receipt ...................................................................................................3-2

Claims ..............................................................................................................3-2

Locating Power Supply ....................................................................................3-2

115/230 Voltage Configurations ....................................................................... 3-2

Input Voltage Selector Switch...................................................................... 3-2

Power Cord Plugs........................................................................................3-2

Grounding ........................................................................................................3-4

Work Cable and Clamp ....................................................................................3-4

Plasma Air Supply ............................................................................................ 3-4

Additional Air Filtration .................................................................................3-5

Air Hose Connection ........................................................................................3-5

3-2

ETUP

Operator Manual

UPON RECEIPT

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

items are damaged or missing.

2. Inspect the power supply for any physical damage that may have occurred during shipping. If there

is evidence of damage, refer to the

Claims

section below.

All communications regarding this equipment must include the model number and serial number

located on the back of the Powermax350.

3. Before setting up and operating the Powermax350, read the Safety section of this manual.

CLAIMS

Claims for damage during shipment — If your unit was damaged during shipment, you must file a

claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you

need additional assistance, call Customer Service at 1 800 643 0030 in the U.S. and Canada, or your

authorized Hypertherm distributor.

Claims for defective or missing merchandise — All units shipped from Hypertherm undergo rigorous

quality control inspections for defects. If any of the merchandise is defective or missing, call your

authorized Hypertherm distributor. If you need additional assistance, call Customer Service at

1 800 643 0030 in the U.S. and Canada, or your authorized Hypertherm distributor.

LOCATING POWER SUPPLY

Locate the Powermax350 power supply near the 115V or 230V wall receptacle. Allow at least 10

inches (0.25 m) of space at the front and back of the power supply for proper ventilation.

115/230 VOLTAGE CONFIGURATIONS

The 115/230V Powermax350 power supplies are shipped to operate at the following voltages: the 60

Hz units at 115 volts and the 50 Hz units at 230 volts.

Input Voltage Selector Switch

The Input Voltage Selector switch allows either 115V or 230V to be used as the Powermax350 input

voltage. To set the required voltage, refer to the procedure on the following page (see Fig. 3-1).

Power Cord Plugs

The 115/230V Powermax350 power supplies are shipped with the following power cord configurations:

the 60 Hz units are shipped with a 115V plug on the power cord; the 50 Hz units are shipped without a

plug on the power cord. To operate at 230V, obtain a plug that meets national or local electrical codes.

The plug should be connected to the power cord by a licensed electrician. Also, note that some 115V

receptacles may require a plug that is different from the plug on the power cord. To install the required

plug, refer to the procedure on the following page (see Fig. 3-2). The installed 115V plug and cords

must conform to national or local electrical codes.

8-97

3-3

ETUP

Operator Manual

1 Power Cord plug (115V shown)

• Cut cord close to plug.

2 230V plug

3 To load 1 (brass) terminal

4 To load 2 (brass) terminal

5 To ground (green) terminal

6 Outer shell

7 Cord grip

Strip cord insulation back in order to

separate conductors. Strip conductor

insulation back in order to make good

contact with plug terminals. Make

connections, reinstall outer shell and

cord grip and secure with screws.

Do not overtighten.

This procedure is required if the power supply is to be

connected to a 230V receptacle, or to a 115V receptacle

that requires a plug that is different from the plug on the

power cord.

This procedure is necessary if 230V input power is required.

See the procedure in Fig. 3-2 for installing a power cord plug.

1 Input Voltage Selector switch

2 Retaining screw

• Remove screw and position

switch to select required

voltage.

• Reinstall retaining screw

and tighten to secure switch

in place.

3 Power Cord plug (115V shown)

• If plug does not match

voltage at receptacle or type

of receptacle, install suitable

plug as shown below.

4 115 or 230V receptacle (115V

shown)

• To use rated output (see

specifications in section 2), an

individual branch circuit capable

of carrying 33A, 115V at 35%

duty cycle; or 18A, 230V at 35

duty cycle and protected by fuses

or circuit breakers is required.

Cut cord

here

Figure 3-1 Repositioning Input Voltage Selector Switch

Figure 3-2 Changing Power Cord Plugs

3-4

ETUP

Operator Manual

Figure 3-3 Proper Work Clamp

Connection

GROUNDING

To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the

Powermax350 must be properly grounded:

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

electrical codes. Single-phase service must be of the 3-wire type with a green or green/yellow wire for

protective earth ground and must comply with national or local electrical requirements. Do not use a

2-wire service! Refer to

Grounding

, in the Safety section.

WORK CABLE AND CLAMP

The work clamp must be attached to the workpiece while cutting. Ensure that the work clamp and the

workpiece make good metal-to-metal contact. Attach the work clamp as close as possible to the area

being cut to reduce exposure to electric and magnetic fields (EMF). Do not attach the work clamp to

the portion of the workpiece to be cut away.

PLASMA AIR SUPPLY

The air supply for the Powermax350 can be supplied as shop compressed air or cylinder compressed

air. A high-pressure regulator on either type of supply must be used and must be capable of delivering

air at 270 scfh/4.5 scfm (127 l/min) at a pressure of 70 psi (4.8 bar) to the filter on the power supply. If

air supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness capability

decreases, and parts life shortens.

WARNING

Do not allow the air inlet pressure to the filter on the power supply to exceed 120 psi

(8.3 bar). The filter bowl may explode if this pressure is exceeded.

3-5

ETUP

Operator Manual

Additional Air Filtration

Use a three-stage coalescing filtration system as shown when site conditions introduce moisture, oil or

other contaminants into the air line.

AIR HOSE CONNECTION

Connect the air hose as follows:

From air

supply

Powermax350

Water/particle filter Oil filter Oil vapor filter

Figure 3-4 Recommended Three-Stage Air Filtration System

To Air Supply

Rear Panel

1 Air fitting

• Install 1/4 NPT quick-disconnect

nipple on to air fitting using a liquid

pipe sealant.

CAUTION: Never use Teflon tape when

installing the nipple or adapters. Bits of

tape can break off and enter the air line

and harm the pressure regulator,

pressure switch and valve.

• Nipple is found in the consumables

box, located in the left side of the power

supply cover.

2 Air hose

• Use a 3/8 inch (9.5 mm) ID inert gas

hose with a 1/4 NPT quick-disconnect

coupler.Connect it to the nipple installed

in step 1.

Adjust the air pressure according to the

procedure in Section 4.

Figure 3-5 Air Supply Connection

PERATION

4-1

Operator Manual

Section 4 OPERATION

In this section:

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

Operating Instructions ..................................................................................... 4-3

Operating Tips ................................................................................................. 4-4

Changing Consumable Parts...................................................................... 4-4

Cutting ........................................................................................................ 4-5

Piercing....................................................................................................... 4-6

Operating Data - 25A Consumables ............................................................... 4-7

Common Cutting Faults .................................................................................. 4-8

Duty Cycle and Overheating ........................................................................... 4-8

4-2

PERATION

Operator Manual

CONTROLS AND INDICATORS

• Green POWER ON LED

When illuminated, indicates that the Power Switch has been set at I (On).

• Green READY LED

When illuminated, indicates that the safety interlocks are satisfied.

• Yellow PRESSURE LED

When illuminated, indicates that the air pressure is below 40 psi (2.8 bar).

• Yellow TORCH CAP LED

When illuminated, indicates that the torch retaining cap is loose.

• Yellow OVER-TEMP LED

When illuminated, indicates that the power supply has overheated.

• AMPS-GAS TEST/SET Adjustment Knob

Adjusts output current between 16 and 25 amps. The GAS TEST/SET position allows adjustment

of the air pressure.

• Pressure Regulator Adjustment Knob

Regulates input gas pressure to the power supply.

• Pressure Gauge

Indicates gas pressure at the power supply.

• ON (I)/OFF (0) Power Switch

Activates the power supply and its control circuits.

Figure 4-1 Powermax350 Controls and Indicators

Green

Yellow

ON (I)/OFF (0)

Power Switch

Pressure

Gauge

Pressure Regulator

Adjustment Knob

Rear

Front

PERATION

4-3

Operator Manual

OPERATING INSTRUCTIONS

1. Ensure that the work environment and your clothing meet the safety requirements outlined in

the Safety section. Follow the instructions in the Setup section.

2. Verify that the air supply pressure is set between 70 and 120 psi (4.8 - 8.3 bar).

3. At the rear of the power supply, move the power switch to the ON (I) position. The POWER ON

and READY LEDs should illuminate. The PRESSURE, TORCH CAP and OVER-TEMP LEDs

should remain extinguished.

4. Adjust the pressure regulator to 60 psi (4.1 bar) on the pressure gauge:

• Set the knob to GAS TEST/SET position.

• Pull up on the adjustment knob and turn it to adjust the pressure to 60 psi (4.1 bar).

• Push down the knob to lock it.

5. Adjust the AMPS knob to the desired setting. See

Cut Chart

later in this section.

6. Attach work clamp securely to the workpiece. Do not attach it to the portion that will fall

away.

7. The Powermax350 is now ready to operate. When you are ready to cut, place the tip of the

torch on the workpiece. Press the torch switch to start the arc.

8. The arc will transfer from the torch to the workpiece. Move the torch in the desired direction, at

a speed which will ensure good cut quality. See

Cut Chart

later in this section.

9. When the cut is finished, release the torch switch. Postflow will continue for approximately 10

seconds. The arc can be instantly restarted during postflow by pressing the torch switch.

WARNING

Before operating this system, read the Safety section of this manual thoroughly!

WARNING

The PAC110 torch is an instant-on torch which

produces a plasma arc immediately after the

torch start switch closes. Always hold the hand

torch away from your body as a precaution

against accidental torch firing. Be aware of this

hazardous potential. Failure to do so can result

in serious bodily injury.

Figure 4-2

Proper Work Clamp

Connection

10-97

4-4

PERATION

Operator Manual

OPERATING TIPS

Changing Consumable Parts

Changing the consumable parts requires no tools:

1. Unscrew the retaining cap and the remaining parts will come apart easily. When you unscrew

the retaining cap, you will hear a click. This click is a microswitch (cap-on sensor switch) that

disables the power supply if it is plugged in.

2. Inspect the nozzle for damage or wear. If the hole is worn or oval-shaped, replace it.

3. Inspect the electrode. If the center has a pit more than 1/16 inch (1.6 mm) deep, replace it.

4. Inspect the swirl ring. It should be clean, and the holes along the side should not be plugged. If

it is damaged, replace it.

5. Inspect the O-ring on the torch. It should be lubricated and undamaged. If it is dry, lubricate it

with a thin film of the lubricant provided in the consumable parts kit. If it is damaged, replace it.

6. Replace the parts as shown in Fig. 4-3. Each part fits in only one direction, so you cannot put

the parts in backwards. Also, the torch will not fire if the parts are improperly installed.

7. When the nozzle, electrode and swirl ring are properly in place, replace the retaining cap.

When the retaining cap is tightened, the microswitch will click, indicating that the torch is again

ready for operation. Plug the power supply back in.

The consumable parts are found in a box, located in the left side of the power supply cover.

Swirl Ring

020239

Extended

Electrode

020382

Extended

Nozzle

120504

Retaining Cap

020218

Figure 4-3 Consumable Parts

WARNING

SHOCK HAZARD: Always turn off the power and unplug the cord before changing consum-

able parts. Do not rely on the cap-on sensor switch to remove power. It is provided strictly

for safety backup. In the U.S., use a "lock-out / tag-out" procedure until the service or mainte-

nance work is complete. In other countries, follow appropriate national or local safety proce-

dures.

PERATION

4-5

Operator Manual

Cutting

• Do not fire the pilot arc into the air needlessly—doing so causes a significant reduction of the

nozzle and electrode life.

• If arc transfer to the workpiece does not occur within 5 seconds, the pilot arc will shut off. Re-

lease the torch start switch and press it again to reset the pilot arc timer.

• Start cutting from the edge of the workpiece (Fig. 4-4).

• When cutting, make sure that the sparks are coming out of the bottom of the workpiece. If they

are spraying on top of the workpiece, you are moving the torch too fast, or you do not have

sufficient power to fully penetrate the workpiece.

• Hold the torch lightly on the metal or just above the metal. Holding the torch firmly to the work-

piece causes the shield or nozzle to stick and makes smooth cutting difficult. The arc transfers

to the workpiece once the torch is within 1/8 inch (3 mm) of the workpiece.

• Pulling the torch through the cut is easier than pushing it.

• Hold the torch nozzle at a vertical position and watch the arc as it cuts along the line (Fig. 4-5).

By lightly dragging the nozzle on the workpiece, you can maintain a steady cut. For straight-line

cuts, use any straight edge as a guide.

• When cutting thin material, reduce the amps until you get the best quality cut.

• To cut circles, use a template or a radius cutter attachment (Fig. 4-6).

Figure 4-4 Starting a Cut Figure 4-5 Dragging the Torch

8-97

4-6

PERATION

Operator Manual

Figure 4-6

Cutting a Circle

Piercing

• Hold the torch so that the nozzle is approximately 1/16 inch (1.6 mm) away from the workpiece

before firing the torch. This method maximizes the life of the nozzle.

• Hold the torch at an angle to the workpiece away from yourself, then slowly rotate it to an

upright position. This is particularly important when cutting thicker material. Make sure that the

torch is pointed away from you and the people near you to avoid any danger from sparks and

hot metal (Fig. 4-7).

• When the pierce is complete, bring the torch to a perpendicular position and proceed with the

cut.

• Start the cut at an angle rather than in an upright position. This method permits the hot metal to

escape to one side rather than splashing back against the nozzle. This will protect the operator

from the sparks and extend the life of the nozzle.

1. Tilt the torch and press the start button. 2. Rotate the torch to an upright position.

Figure 4-7 Piercing

PERATION

4-7

Operator Manual

OPERATING DATA - 25A CONSUMABLES

The following recommended settings are for hand-held cutting at 25 amps. Torch-to-work distance for

the following cut charts is 1/16 inch (1.6 mm) for all cuts. The settings are optimized to provide the best

cut angle, least dross and best cut surface finish. Remember that these settings are intended to

provide a good starting point for each different cutting assignment. Every cutting system

requires "fine-tuning" for each cutting application to the materials on site in order to obtain

optimum cut quality.

Swirl Ring

020239

Extended

Electrode

020382

Extended

Nozzle

120504

Retaining Cap

020218

Material Thickness Arc Current Approximate Travel Speed*

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

Mild Steel 18 GA 1.3 25 70 1775

12 GA 2.8 25 52 1320

1/8 3.6 25 47 1190

3/16 4.8 25 33 825

1/4 6.0 25 17 430

3/8 9.0 25 9 225

Stainless 18 GA 1.3 25 65 1650

Steel 12 GA 2.8 25 48 1215

1/8 3.6 25 41 1040

3/16 4.8 25 27 685

1/4 6.0 25 14 355

3/8 9.0 25 7 175

Aluminum 18 GA 1.3 25 81 2055

12 GA 2.8 25 55 1395

1/8 3.6 25 44 1115

3/16 4.8 25 29 735

1/4 6.0 25 9 225

3/8 9.0 25 5 125

* Recommended travel speeds are 10–20% slower than maximum. These slower speeds will produce optimum

cut quality.

4-8

PERATION

Operator Manual

COMMON CUTTING FAULTS

• The workpiece is not totally penetrated. Causes can be:

- The current is too low.

- The cut speed is too high.

- The torch parts are worn.

- The metal being cut is too thick.

- The work clamp is not properly attached to the workpiece.

• Dross forms on the bottom of the cut. Causes can be:

- The cutting speed is too slow.

- The torch parts are worn.

- The metal being cut is too thick.

- The current is too low.

DUTY CYCLE AND OVERHEATING

• The duty cycle is the amount of time, in minutes, that a pilot or plasma arc can remain "on" within a

10-minute period when operating at 104° F (40° C).

- At the 25-amp setting, the arc can remain on 3.5 minutes out of every 10 minutes without

causing the temperature sensors to disable the unit.

- At 20 amps, the duty cycle is 60%, or 6 minutes out of every 10 minutes.

- At 17 amps, the duty cycle increases to 100%.

• If the power supply overheats, the OVER-TEMP LED will illuminate, the arc will shut off and the

cooling fan will continue to run.

• To resume cutting, wait for the OVER-TEMP LED to extinguish (usually 15 minutes or less) and

reduce amperage or duty cycle.

1-99

AINTENANCE

ARTS

5-1

Operator Manual

Section 5 MAINTENANCE/PARTS

Introduction ..................................................................................................... 5-2

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

Trouble LED Indicators.................................................................................... 5-3

Pressure ..................................................................................................... 5-3

Torch Cap ................................................................................................... 5-3

Over-Temp.................................................................................................. 5-3

PAC110 Torch Repair ...................................................................................... 5-4

Parts and Required Tools ........................................................................... 5-4

Remove Torch Main Body .......................................................................... 5-4

Install New Torch Main Body ...................................................................... 5-4

Basic Troubleshooting ..................................................................................... 5-6

Technical Questions ........................................................................................ 5-8

Parts................................................................................................................ 5-8

Powermax350 Hand Systems .................................................................... 5-8

Consumable Parts ...................................................................................... 5-8

PAC110 Torch Assembly and 15 Ft (4.5 M) Torch Lead, 25A ..................... 5-9

PAC110 Torch Assembly and 25 Ft (7.6 M) Torch Lead, 25A ..................... 5-9

In this section:

Operator Manual

5-2

AINTENANCE

ARTS

INTRODUCTION

This section contains information for simple maintenance and troubleshooting. A brief parts list is also

included. For higher-level troubleshooting, see

Technical Questions

later in this section.

ROUTINE MAINTENANCE

WARNING

SHOCK HAZARD: Always turn off the power and unplug the cord before changing consum-

able parts. Do not rely on the cap-on sensor switch to remove power. It is provided strictly

for safety backup. In the U.S., use a "lock-out / tag-out" procedure until the service or main-

tenance work is complete. In other countries, follow appropriate national or local safety

procedures.

Under severe conditions, routine maintenance should be performed more frequently.

Before Each Use

• Check the air pressure.

• Check the torch and consumables.

Every Week

• Check the torch cap -on sensor system by listening for the micro-switch to "click" when the

retaining cap is loosened. See Changing Consumable Parts in the Operation section.

3 Months

• Replace damaged or unreadable labels.

• Service the filter and pressure regulator.

• Check the air supply hose.

• Replace any cracked parts.

• Check the torch body and torch lead.

• Replace the torch lead if the insulation is broken.

6 Months

• Blow out or vacuum inside of power supply.

AINTENANCE

ARTS

5-3

Operator Manual

Figure 5-1 Trouble LED Indicators

TROUBLE LED INDICATORS

If certain problems occur, the READY LED extinguishes, a trouble LED illuminates and the torch stops

firing.

• PRESSURE LED - Illuminates if air pressure is below 40 psi (2.8 bar).

Turn power Off (O) and check for proper air pressure (see Section 4, Operating Instructions)

• TORCH CAP LED - Illuminates if the retaining cap is loose.

Turn power Off (O) and check that the retaining cap is tight. Whenever the torch cap shut-

down system has been activated, turn the power Off (O) and then On (I) to reset the

system. Check the torch cap shutdown system once a week as follows:

Turn power On (I) and loosen the torch cap.

If shutdown system works properly, READY LED extinguishes and TORCH CAP LED illumi-

nates.

If the shutdown system does not work properly, turn power Off (O) and check for proper air

pressure (see Section 4, Operating Instructions), blocked or leaking hose or loose torch cap.

Check the system by retightening the retaining cap and resetting the power as described above.

• OVER-TEMP LED - Illuminates if power supply overheats. See Duty Cycle and Overheating in

the Operation section.

Operator Manual

5-4

AINTENANCE

ARTS

PAC110 TORCH REPAIR

Parts and Required Tools

The PAC110 torch can be repaired in the field by removing the torch main body from the torch assem-

bly and installing a new torch main body and a plastic cinch strap (Tyrap). To perform the repair, the

following customer-supplied tools are required:

• #1 Phillips-head screwdriver

• 7/16" open-end wrench

• Wire cutters

• Crimping tool

WARNING

SHOCK HAZARD: Always turn off power, unplug cord from wall before working on the

torch. In the U.S., use a "lock-out/tag-out" procedure until the service or maintenance

work is complete. In other countries, follow appropriate local or national safety proce-

dures.

Remove Torch Main Body

To disassemble and repair the torch, refer to Figure 5-2 and perform the following procedure:

1. Remove the five screws which secure the handle halves together.

2. Remove the torch main body and torch switch from the handle halves.

3. Disconnect the cinch strap (Tyrap).

4. Cut the four white wires connecting the torch lead to the plunger. Cut the wires at the butt splice.

5. Cut the two blue wires connecting the torch lead to the microswitch. Cut the wires at the butt

splices.

6. Cut the two red wire connecting the torch lead to the pilot arc lead. Cut the wire at the butt splice.

7. Disconnect the torch main body and torch lead gas fitting using the 7/16" open-end wrench.

Install New Torch Main Body

To install the new torch, reverse the removal procedure:

1. While holding the torch main body to keep the wires from twisting, connect the body assembly and

the torch lead gas fitting using the 7/16" open-end wrench.

AINTENANCE

ARTS

5-5

Operator Manual

2. Connect the two red wire from the torch lead to the butt splice connecting the red wire to the pilot

arc fitting using the crimping tool.

3. Connect the two blue wires from the torch lead to the butt splices connecting the white wires to the

microswitch using the crimping tool.

4. Connect the four white wires from the torch lead to the butt splice connecting the black plunger wire

to the torch main body using the crimping tool.

5. Connect the cinch strap (Tyrap) as shown.

6. Install the torch main body assembly and torch switch into one of the handle halves. While position-

ing the handle halves together, be careful not to pinch any wires. Be especially careful around

the torch switch retainers.

7. Replace the five screws to secure the handle halves together. If the seams do not fit together

tightly, remove the screws and check for pinched wires.

Figure 5-2 PAC110 Torch Repair

Operator Manual

5-6

AINTENANCE

ARTS

BASIC TROUBLESHOOTING

Problem Cause/Solution

1. No pilot arc; difficulty in establishing an arc.

2. No cutting output; POWER ON, READY,

PRESSURE, TORCH CAP and OVER-TEMP

LEDs extinguished; fan not running.

3. No cutting output; POWER ON and READY

LEDs illuminated; PRESSURE, TORCH CAP and

OVER-TEMP LEDs extinguished; fan running.

4. No cutting output; POWER ON LED

illuminated; READY, PRESSURE, TORCH CAP

and OVER-TEMP LEDs extinguished; fan

running.

5. No control of cutting output.

6. No air flow; POWER ON and READY LEDs

illuminated; PRESSURE, TORCH CAP and

OVER-TEMP LEDs extinguished; fan running.

7. PRESSURE LED illuminated; READY LED

extinguished.

1.1 Clean or replace worn consumables as

necessary.

1.2 Check for proper installation of swirl ring.

1.3 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

2.1 Place the Power switch to On(I)

2.2 Plug in the power cord.

2.3 Check line disconnect fuses and replace if

needed or reset circuit breakers.

2.4 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

3.1 Check that the work clamp is connected.

3.2 Clean or replace worn consumables as

necessary.

3.3 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

4.1 Reset the power switch.

4.2 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

5.1 Check position of input voltage selector

switch S2.

5.2 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

6.1 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

7.1 Check for correct air pressure (see Section

4, Operation Instructions).

7.2 Check for sufficient air supply pressure (see

Section 2, Specifications).

AINTENANCE

ARTS

5-7

Operator Manual

Problem Cause/Solution

8. TORCH CAP LED illuminated; READY LED

extinguished.

9. OVER-TEMP LED illuminated; READY LED

extinguished.

10. Fan not running; POWER ON and READY

LEDs illuminated.

11. PRESSURE, TORCH CAP and OVER-TEMP

LEDs not working.

7.3 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

8.1 Check torch retaining cap to ensure it is tight.

8.2 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

9.1 Thermostat in power supply is open

(overheating). Allow the fan to run; the

thermostat closes when the unit has cooled

(see Section 4, Duty Cycle and

Overheating).

9.2 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

10.1 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

11.1 Refer to Service Manual IM-292 (802920) for

more detailed troubleshooting.

Operator Manual

5-8

AINTENANCE

ARTS

TECHNICAL QUESTIONS

If you are unable to fix the problem with your Powermax350 by following this basic troubleshooting

guide or if you need further assistance:

1. Call your distributor. He/she will be able to help you, or refer you to an authorized Hypertherm

repair facility.

2. Call Hypertherm's Technical Service group at 1 800 643 9878 or the nearest Hypertherm office,

listed in the front of this manual.

3. See the Powermax350 Service Manual IM-292 (802920) for wiring diagrams, higher level

troubleshooting and more parts list information.

PARTS

Powermax350 Hand Systems

070052 115/230 VAC, 1 Phase, 60 Hz 15 ft (4.5 M)

070053 115/230 VAC, 1 Phase, 60 Hz 25 ft (7.6 M)

070055 CE 115/230 VAC, 1 Phase, 50 Hz 15 ft (4.5 M)

070056 CE 115/230 VAC, 1 Phase, 50 Hz 25 ft (7.6 M)

Consumable Parts

The consumable parts are found in a box, located in the left side of the power supply cover.

Part Number Description

020239................................................................Ring, Swirl

020382.................................................Electrode, Extended

120504............................................ Nozzle, Extended, 25A

020218......................................................... Cap, Retaining

Swirl Ring

020239

Extended

Electrode

020382

Extended

Nozzle

120504

Retaining Cap

020218

Figure 5-3 Consumable Parts

5-98

AINTENANCE

ARTS

5-9

Operator Manual

PAC110 Torch Assembly and 15 ft (4.5 m) Torch Lead, 25A - 070057

PAC110 Torch Assembly and 25 ft (7.6 m) Torch Lead, 25A - 070058

Part Number Description

001192 ................................. Handle, PAC110

075339 ................................. Screws (3), P/S, # 4 X 1/2, PH, RND, S/B

075341 ................................. Screws (2), P/S, # 4 X 3/4, PH, RND, S/B

005094 ................................. Switch, Torch Pushbutton

020239* ................................ Ring, Swirl

020382* ................................ Electrode, Extended

120504* ................................ Nozzle, Extended, 25A

020218* ................................ Cap, Retaining

020588 ................................. Torch Main Body with Switch, PAC110

044016 ....................................... O-Ring: BUNA 90 Duro .614X.070

029241 ................................. Torch Lead, 15 ft (4.5 m)

029257 ................................. Torch Lead, 25 ft (7.6 m)

* See Fig. 5-3 for consumable parts.

Handle

001192

Torch Lead

029241, 15 ft (4.5 m)

029257, 25 ft (7.6 m)

Torch

Pushbutton

Switch

005094

Handle

001192

O-Ring

044016

Screw

075339

Screw (2)

075341

Screw (2)

075339

Figure 5-4 PAC110 Torch Assembly and Torch Lead

Torch Main

Body with Switch

020588