MAXPRO200® - Powermax 105

MAXPRO200® - Powermax 105
MAXPRO200
Instruction Manual
807700 – Revision 1
®
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MXAXPRO200, Sensor THC, Sensor PHC, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United
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© 2013 Hypertherm, Inc.
MAXPRO200
Instruction Manual
807700 – Revision 1
English
March 2013
Hypertherm, Inc.
Hanover, NH 03755 USA
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[email protected] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 Fax
07/18/12
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax
Contents
Safety ..........................................................................................................................................................9
Recognize safety information ............................................................................................................................................................. 9
Follow safety instructions .................................................................................................................................................................... 9
Electrical hazards .................................................................................................................................................................................. 9
Electric shock can kill ....................................................................................................................................................................... 10
Cutting can cause fire or explosion ............................................................................................................................................... 11
Fire prevention ............................................................................................................................................................................ 11
Explosion prevention ................................................................................................................................................................. 11
Toxic fumes can cause injury or death .......................................................................................................................................... 12
Grounding safety ............................................................................................................................................................................... 13
Static electricity can damage circuit boards ............................................................................................................................... 13
Compressed gas equipment safety .............................................................................................................................................. 14
Gas cylinders can explode if damaged ........................................................................................................................................ 14
A plasma arc can cause injury and burns .................................................................................................................................... 14
Arc rays can burn eyes and skin .................................................................................................................................................... 15
Pacemaker and hearing aid operation .......................................................................................................................................... 16
Noise can damage hearing .............................................................................................................................................................. 16
A plasma arc can damage frozen pipes ....................................................................................................................................... 16
Dry dust collection information ....................................................................................................................................................... 17
Laser radiation .................................................................................................................................................................................... 18
Symbols and marks ........................................................................................................................................................................... 19
Additional safety information ........................................................................................................................................................... 20
Warning labels ................................................................................................................................................................................... 20
Electromagnetic Compatibility (EMC) .............................................................................................23
Introduction ......................................................................................................................................................................................... 23
Installation and use ............................................................................................................................................................................ 23
Assessment of area ........................................................................................................................................................................... 23
Methods of reducing emissions ..................................................................................................................................................... 23
Mains supply ............................................................................................................................................................................... 23
MAXPRO200 Instruction Manual 807700 Revision 1
1
Contents
Maintenance of cutting equipment .................................................................................................................................................24
Cutting cables .....................................................................................................................................................................................24
Equipotential bonding ................................................................................................................................................................24
Earthing of the workpiece .........................................................................................................................................................24
Screening and shielding ...................................................................................................................................................................24
Warranty .................................................................................................................................................. 25
Attention ...............................................................................................................................................................................................25
General .................................................................................................................................................................................................25
Patent indemnity .................................................................................................................................................................................26
Limitation of liability ............................................................................................................................................................................26
National and local codes ..................................................................................................................................................................26
Liability cap ..........................................................................................................................................................................................26
Insurance ..............................................................................................................................................................................................26
Transfer of rights .................................................................................................................................................................................26
Product Stewardship ........................................................................................................................... 27
Introduction ..........................................................................................................................................................................................27
National and local safety regulations .............................................................................................................................................27
Certification test marks .....................................................................................................................................................................27
Differences in national standards ...................................................................................................................................................27
Safe installation and use of shape cutting equipment ...............................................................................................................28
Procedures for periodic inspection and testing ..........................................................................................................................28
Qualification of test personnel .........................................................................................................................................................28
Residual current devices (RCDs) ...................................................................................................................................................28
Higher-level systems .........................................................................................................................................................................29
Environmental Stewardship .............................................................................................................. 31
Introduction ..........................................................................................................................................................................................31
National and local environmental regulations ...............................................................................................................................31
The RoHS directive ............................................................................................................................................................................31
Proper disposal of Hypertherm products .....................................................................................................................................31
The WEEE directive ...........................................................................................................................................................................31
The REACH regulation ......................................................................................................................................................................32
Proper handling and safe use of chemicals .................................................................................................................................32
Fumes emission and air quality .......................................................................................................................................................32
Specifications ........................................................................................................................................ 33
System description ............................................................................................................................................................................33
General .........................................................................................................................................................................................33
Power supply ...............................................................................................................................................................................33
Ignition console ...........................................................................................................................................................................33
Torch ..............................................................................................................................................................................................33
Gas system ..................................................................................................................................................................................33
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MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Cooling system ........................................................................................................................................................................... 35
System gas requirements ................................................................................................................................................................ 35
Power supply ...................................................................................................................................................................................... 36
Mechanized torches .......................................................................................................................................................................... 37
Straight torch – 428024 .......................................................................................................................................................... 37
Quick-disconnect torch – 428027 or 428028 .................................................................................................................. 38
Hand torches ...................................................................................................................................................................................... 39
90 degree hand torch – 420108 ........................................................................................................................................... 39
65 degree hand torch – 420107 ........................................................................................................................................... 40
Installation .............................................................................................................................................. 41
Upon receipt ....................................................................................................................................................................................... 41
Claims .................................................................................................................................................................................................. 41
Installation requirements .................................................................................................................................................................. 41
Noise levels ......................................................................................................................................................................................... 41
Placement of system components ................................................................................................................................................. 42
Recommended grounding and shielding practices ................................................................................................................... 44
Introduction ................................................................................................................................................................................. 44
Types of grounding .................................................................................................................................................................... 44
Grounding practices ................................................................................................................................................................. 44
Placement of the power supply ...................................................................................................................................................... 48
Torch lead connections .................................................................................................................................................................. 49
Work lead connections .................................................................................................................................................................. 52
Torch connections ........................................................................................................................................................................... 53
Connect the torch to the quick-disconnect receptacle ............................................................................................................ 54
Torch mounting and alignment ....................................................................................................................................................... 55
Mounting the torch .................................................................................................................................................................... 55
Torch alignment .......................................................................................................................................................................... 55
CNC interface cable ....................................................................................................................................................................... 56
Notes to CNC interface cable run list ................................................................................................................................... 56
Remote ON/OFF switch (provided by customer) ...................................................................................................................... 58
Power requirements .......................................................................................................................................................................... 60
General ......................................................................................................................................................................................... 60
Line disconnect switch ............................................................................................................................................................. 61
Main power cable .................................................................................................................................................................... 61
Connect the power ........................................................................................................................................................................... 62
Torch coolant requirements ............................................................................................................................................................ 63
Premixed coolant for standard operating temperatures ................................................................................................... 63
Custom Coolant mix for cold operating temperatures (below -12° C / 10° F) ........................................................... 64
Custom Coolant mix for hot operating temperatures (above 38° C / 100° F) ............................................................ 65
Water purity requirements ....................................................................................................................................................... 65
MAXPRO200 Instruction Manual 807700 Revision 1
3
Contents
Fill the power supply with coolant ..................................................................................................................................................66
Connect the supply gases ...............................................................................................................................................................67
Air/air cutting ...............................................................................................................................................................................67
N2/N2 supply gas connection ..................................................................................................................................................67
O2/Air Supply gas hook up ......................................................................................................................................................67
Gas requirements ...............................................................................................................................................................................71
Setting the supply gas regulators ...........................................................................................................................................71
Gas regulators .....................................................................................................................................................................................72
Supply gas plumbing .........................................................................................................................................................................73
Supply gas hoses ...............................................................................................................................................................................74
Air .................................................................................................................................................................................................74
Oxygen ........................................................................................................................................................................................74
Nitrogen ......................................................................................................................................................................................74
Operation ................................................................................................................................................ 75
Daily start-up .......................................................................................................................................................................................75
Controls and indicators .....................................................................................................................................................................76
Power supply operation ....................................................................................................................................................................77
General .........................................................................................................................................................................................77
3-digit display functions ............................................................................................................................................................78
Choosing a cutting process .....................................................................................................................................................79
Handheld cutting ................................................................................................................................................................................80
Specifications ..............................................................................................................................................................................80
Consumable selection and gas settings ...............................................................................................................................80
Starting a cut ...............................................................................................................................................................................80
Piercing .........................................................................................................................................................................................81
Gouging ................................................................................................................................................................................................82
Specifications ..............................................................................................................................................................................82
Gouging safety ............................................................................................................................................................................82
Gouge a workpiece ....................................................................................................................................................................82
Gouging techniques ..................................................................................................................................................................83
Straight gouging .................................................................................................................................................................83
Side gouging .......................................................................................................................................................................84
Gouge profiles and metal removal rates ...............................................................................................................................85
Varying the gouge profile ..........................................................................................................................................................86
Cutting parameters ............................................................................................................................................................................86
Mechanized consumables ................................................................................................................................................................86
Hand held torch consumables ........................................................................................................................................................86
Hand held cutting and gouging consumable selection .....................................................................................................87
Mild steel ...............................................................................................................................................................................87
Stainless steel .....................................................................................................................................................................88
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MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Aluminum ............................................................................................................................................................................. 89
Install and inspect consumables .................................................................................................................................................... 90
Install consumables ................................................................................................................................................................... 90
Inspect consumables ................................................................................................................................................................ 91
Torch maintenance ............................................................................................................................................................................ 92
Routine maintenance ................................................................................................................................................................ 92
Quick-disconnect maintenance .............................................................................................................................................. 92
Maintenance kit .......................................................................................................................................................................... 92
Torch connections ..................................................................................................................................................................... 93
Quick-disconnect torch .................................................................................................................................................... 93
Straight torch ...................................................................................................................................................................... 93
Replace the torch water tube ................................................................................................................................................. 94
Common cutting faults ..................................................................................................................................................................... 95
Machine torch ............................................................................................................................................................................. 95
Hand torch ................................................................................................................................................................................... 95
Optimizing cut quality ....................................................................................................................................................................... 96
Tips for table and torch ............................................................................................................................................................ 96
Plasma setup tips ...................................................................................................................................................................... 96
Maximize the life of consumable parts .................................................................................................................................. 96
Additional factors of cut quality .............................................................................................................................................. 97
Cut angle ............................................................................................................................................................................. 97
Dross .................................................................................................................................................................................... 98
Straightness of the cut surface ....................................................................................................................................... 98
How to increase cutting speed ...................................................................................................................................... 98
Estimated kerf-width compensation ...................................................................................................................................... 99
Metric .................................................................................................................................................................................... 99
English ................................................................................................................................................................................100
Cut charts ..........................................................................................................................................................................................101
Maintenance ........................................................................................................................................119
Introduction .......................................................................................................................................................................................119
Preventive maintenance .................................................................................................................................................................119
Power supply status ........................................................................................................................................................................120
Sequence of operation and power supply status ....................................................................................................................121
PCB block diagram .........................................................................................................................................................................126
Error codes .......................................................................................................................................................................................127
Diagnostic functions .......................................................................................................................................................................128
Troubleshooting table .....................................................................................................................................................................129
Initial checks .....................................................................................................................................................................................137
Power measurement .......................................................................................................................................................................138
MAXPRO200 Instruction Manual 807700 Revision 1
5
Contents
Power supply coolant system servicing ..................................................................................................................................... 139
Draining the coolant system .................................................................................................................................................. 139
Coolant flow test ...................................................................................................................................................................... 140
Coolant system filter replacement ....................................................................................................................................... 142
Air filter element replacement ....................................................................................................................................................... 143
Control board ................................................................................................................................................................................... 144
Control board LED list ............................................................................................................................................................ 144
Control board test points ....................................................................................................................................................... 144
Gas leak tests ................................................................................................................................................................................... 147
Start circuit ........................................................................................................................................................................................ 148
Operation ................................................................................................................................................................................... 148
Start circuit functional schematic ......................................................................................................................................... 148
Start circuit troubleshooting .................................................................................................................................................. 149
Pilot arc current levels .................................................................................................................................................................... 151
Transfer current ........................................................................................................................................................................ 151
Chopper tests .................................................................................................................................................................................. 152
Automatic chopper and current sensor tests during power-up .................................................................................... 152
Using a meter to measure open circuit voltage (OCV) ........................................................................................... 153
Phase loss detection .............................................................................................................................................................. 154
Torch lead test ......................................................................................................................................................................... 155
Preventive maintenance ................................................................................................................................................................. 156
Introduction ............................................................................................................................................................................... 156
Preventive maintenance protocol ......................................................................................................................................... 156
The power supply .................................................................................................................................................................... 156
Cooling system ........................................................................................................................................................................ 157
Torch main body ...................................................................................................................................................................... 157
Gas flows .................................................................................................................................................................................. 157
Cable connections .................................................................................................................................................................. 158
Ignition enclosure .................................................................................................................................................................... 158
System grounding ................................................................................................................................................................... 158
............................................................................................................................................................................................................. 158
Preventive Maintenance Master Schedule ................................................................................................................................ 159
Daily: ........................................................................................................................................................................................... 159
Weekly: ...................................................................................................................................................................................... 159
Semi-annually: .......................................................................................................................................................................... 159
Annually: .................................................................................................................................................................................... 159
Preventive Maintenance Protocol Checklist .............................................................................................................................. 160
Year 1 preventive maintenance (PM) kits .................................................................................................................................. 161
Maintenance kits parts list ..................................................................................................................................................... 161
Service parts replacement schedule .......................................................................................................................................... 161
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MAXPRO200 Instruction Manual 807700 Revision 1
Contents
Parts List ...............................................................................................................................................165
Control panel ....................................................................................................................................................................................165
Power supply ....................................................................................................................................................................................166
Ignition enclosure ............................................................................................................................................................................172
Height control connection kits ......................................................................................................................................................173
Sensor THC connection kit – 428023 ...............................................................................................................................173
Sensor PHC connection kit – 428022 ..............................................................................................................................173
Wire groups and harnesses ..........................................................................................................................................................173
USB cables for software updates ................................................................................................................................................173
Cable for USB update – 223291 ........................................................................................................................................173
Cable for USB update – 223273 ........................................................................................................................................173
Power supply gas hose kit – 228862 ......................................................................................................................................173
Machine torches ..............................................................................................................................................................................174
Straight torch ............................................................................................................................................................................174
Quick-disconnect torch ..........................................................................................................................................................174
Leads and cables ............................................................................................................................................................................175
Machine torch leads ................................................................................................................................................................175
CNC cables ..............................................................................................................................................................................175
Work leads ................................................................................................................................................................................175
Work clamp ...............................................................................................................................................................................175
Hand torch leads .....................................................................................................................................................................175
Inline valve kit ....................................................................................................................................................................................175
Hand torch heat shield – 127389 .............................................................................................................................................175
90 degree hand torch .....................................................................................................................................................................176
65 degree hand torch .....................................................................................................................................................................177
Consumable parts kits ....................................................................................................................................................................178
Mechanized torch consumable kit – 428013 ...................................................................................................................178
Hand torch consumable kit – 428014 ...............................................................................................................................179
Supply gas hoses ............................................................................................................................................................................180
Oxygen .......................................................................................................................................................................................180
Nitrogen .....................................................................................................................................................................................180
Air ................................................................................................................................................................................................180
Recommended spare parts ...........................................................................................................................................................181
Wiring Diagrams .................................................................................................................................183
Wiring diagram symbols ................................................................................................................................................................184
MAXPRO200 Instruction Manual 807700 Revision 1
7
Contents
Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture .............................197
1 - Identification of the substance/mixture and of the company undertaking ................................................................... 197
2 - Hazards identification ............................................................................................................................................................... 198
3 - Composition/information on ingredients ............................................................................................................................. 198
4 - First aid measures ..................................................................................................................................................................... 198
5 - Fire-fighting measures ............................................................................................................................................................. 198
6 - Accidental release measures ................................................................................................................................................. 199
7 - Handling and storage ............................................................................................................................................................... 199
8 - Exposure controls/personal protection ................................................................................................................................ 199
9 - Physical and chemical properties .......................................................................................................................................... 200
10 - Stability and reactivity ............................................................................................................................................................ 200
11 - Toxicological information ...................................................................................................................................................... 201
12 - Ecological information ........................................................................................................................................................... 201
13 - Disposal considerations ........................................................................................................................................................ 201
14 - Transport information ............................................................................................................................................................. 202
15 - Ecological information ........................................................................................................................................................... 202
16 - Other information .................................................................................................................................................................... 202
8
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
RECOGNIZE SAFETY
INFORMATION
The symbols shown in this section are used to identify
potential hazards. When you see a safety symbol in this
manual or on your machine, understand the potential
for personal injury, and follow the related instructions to
avoid the hazard.
FOLLOW SAFETY
INSTRUCTIONS
Read carefully all safety messages in this manual and
safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
DANGER
WARNING
CAUTION
Hypertherm uses American National Standards Institute
guidelines for safety signal words and symbols. A signal
word DANGER or WARNING is used with a safety
symbol. DANGER identifies the most serious hazards.
• DANGER and WARNING safety labels are located on
your machine near specific hazards.
• DANGER safety messages precede related
instructions in the manual that will result in serious
injury or death if not followed correctly.
• WARNING safety messages precede related
instructions in this manual that may result in injury or
death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in minor
injury or damage to equipment if not followed correctly.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.
ELECTRICAL HAZARDS
• Only trained and authorized personnel may open this
equipment.
• If the equipment is permanently connected, turn it off,
and lock out/tag out power before the enclosure is
opened.
• If power is supplied to the equipment with a cord,
unplug the unit before the enclosure is opened.
• Lockable disconnects or lockable plug covers must be
provided by others.
• Wait 5 minutes after removal of power before entering
the enclosure to allow stored energy to discharge.
MAXPRO200 Instruction Manual 807700 Revision 1
• If the equipment must have power when the enclosure
is open for servicing, arc flash explosion hazards may
exist. Follow ALL local requirements (NFPA 70E in the
USA) for safe work practices and for Personal
Protective Equipment when servicing energized
equipment.
• The enclosure shall be closed and the proper earth
ground continuity to the enclosure verified prior to
operating the equipment after moving, opening, or
servicing.
• Always follow these instructions for disconnecting
power before inspecting or changing torch
consumable parts.
9
Safety
ELECTRIC SHOCK CAN KILL
Touching live electrical parts can cause a fatal shock or
severe burn.
• Operating the plasma system completes an electrical
circuit between the torch and the workpiece. The
workpiece and anything touching the workpiece are
part of the electrical circuit.
• Never touch the torch body, workpiece or the water in
a water table when the plasma system is operating.
Electric shock prevention
All Hypertherm plasma systems use high voltage
in the cutting process (200 to 400 VDC are
common). Take the following precautions when
operating this system:
• Wear insulated gloves and boots, and keep your body
and clothing dry.
• Do not stand, sit or lie on – or touch – any wet surface
when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent any
physical contact with the work or ground. If you must
work in or near a damp area, use extreme caution.
• Provide a disconnect switch close to the power supply
with properly sized fuses. This switch allows the
operator to turn off the power supply quickly in an
emergency situation.
• When using a water table, be sure that it is correctly
connected to earth ground.
10
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage or
cracking of the cover. Replace a damaged power cord
immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place or
on the workbench with the work cable attached during
the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power to
allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
CUTTING CAN CAUSE FIRE OR EXPLOSION
Fire prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and properly
cleaned first.
• Ventilate potentially flammable atmospheres before
cutting.
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion prevention
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Explosion Hazard
Underwater Cutting with Fuel Gases
• Do not cut aluminum underwater or with water
touching the underside of the aluminum.
• Cutting aluminum underwater or with the water
touching the underside of the aluminum can result in
an explosive condition that can detonate during
plasma cutting operations.
WARNING
Hydrogen Detonation with
Aluminum Cutting
• Do not cut under water with fuel gases containing
hydrogen.
• Cutting under water with fuel gases containing
hydrogen can result in an explosive condition that
can detonate during plasma cutting operations.
MAXPRO200 Instruction Manual 807700 Revision 1
11
Safety
TOXIC FUMES CAN CAUSE INJURY OR DEATH
The plasma arc by itself is the heat source used for
cutting. Accordingly, although the plasma arc has not
been identified as a source of toxic fumes, the material
being cut can be a source of toxic fumes or gases that
deplete oxygen.
The air quality level in any relevant workplace depends
on site-specific variables such as:
Fumes produced vary depending on the metal that is
cut. Metals that may release toxic fumes include, but are
not limited to, stainless steel, carbon steel, zinc
(galvanized), and copper.
• Volume of material removed.
In some cases, the metal may be coated with a
substance that could release toxic fumes. Toxic coatings
include, but are not limited to, lead (in some paints),
cadmium (in some paints and fillers), and beryllium.
Gases produced by plasma cutting vary based on the
material to be cut and the method of cutting, but may
include ozone, oxides of nitrogen, hexavalent chromium,
hydrogen, and other substances if such are contained in
or released by the material being cut.
Caution should be taken to minimize exposure to fumes
produced by any industrial process. Depending upon
the chemical composition and concentration of the
fumes (as well as other factors, such as ventilation),
there may be a risk of physical illness, such as birth
defects or cancer.
It is the responsibility of the equipment and site owner
to test the air quality in the area where the equipment is
used and to ensure that the air quality in the workplace
meets all local and national standards and regulations.
• Table design (wet, dry, underwater).
• Material composition, surface finish, and composition
of coatings.
• Duration of cutting or gouging.
• Size, air volume, ventilation and filtration of the work
area.
• Personal protective equipment.
• Number of welding and cutting systems in operation.
• Other site processes that may produce fumes.
If the workplace must conform to national or local
regulations, only monitoring or testing done at the site
can determine whether the site is above or below
allowable levels.
To reduce the risk of exposure to fumes:
• Remove all coatings and solvents from the metal
before cutting.
• Use local exhaust ventilation to remove fumes from
the air.
• Do not inhale fumes. Wear an air-supplied respirator
when cutting any metal coated with, containing, or
suspected to contain toxic elements.
• Assure that those using welding or cutting
equipment, as well as air-supplied respiration
devices, are qualified and trained in the proper use of
such equipment.
• Never cut containers with potentially toxic materials
inside. Empty and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan
to ensure safe air quality.
12
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
GROUNDING SAFETY
Work cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall away
when the cut is complete.
Work table Connect the work table to an earth
ground, in accordance with appropriate national and
local electrical codes.
Input power
• Be sure to connect the power cord ground wire to
the ground in the disconnect box.
• If installation of the plasma system involves
connecting the power cord to the power supply, be
sure to connect the power cord ground wire properly.
• Place the power cord’s ground wire on the stud first,
then place any other ground wires on top of the
power cord ground. Fasten the retaining nut tightly.
• Tighten all electrical connections to avoid excessive
heating.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
Use proper precautions when handling printed circuit boards:
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling PC boards.
MAXPRO200 Instruction Manual 807700 Revision 1
13
Safety
COMPRESSED GAS EQUIPMENT
SAFETY
• Never lubricate cylinder valves or regulators with oil
or grease.
• Use only correct gas cylinders, regulators, hoses and
fittings designed for the specific application.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national
and local codes.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national and local codes.
• Never use a cylinder that is not upright and secured
in place.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma
arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to open a
stuck cylinder valve.
A PLASMA ARC CAN CAUSE INJURY AND BURNS
Instant-on torches
The plasma arc will cut quickly through gloves and skin.
Plasma arc comes on immediately when the torch
switch is activated.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
14
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
ARC RAYS CAN BURN EYES AND SKIN
Eye protection Plasma arc rays produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter
or matches, from your pockets before cutting.
• Use eye protection in accordance with applicable
national and local codes.
Cutting area Prepare the cutting area to reduce
reflection and transmission of ultraviolet light:
• Wear eye protection (safety glasses or goggles with
side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s
ultraviolet and infrared rays.
• Paint walls and other surfaces with dark colors to
reduce reflection.
• Use protective screens or barriers to protect others
from flash and glare.
Skin protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks, and hot
metal.
• Warn others not to watch the arc. Use placards or
signs.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
Minimum
protective shade
number
(ANSI Z49.1:2005)
Suggested shade
number for
comfort
(ANSI Z49.1:2005)
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
Less than 40 A
5
5
8
9
41 to 60 A
6
6
8
9
61 to 80 A
8
8
8
9
81 to 125 A
8
9
8
9
126 to 150 A
8
9
8
10
151 to 175 A
8
9
8
11
176 to 250 A
8
9
8
12
251 to 300 A
8
9
8
13
301 to 400 A
9
12
9
13
401 to 800 A
10
14
10
N/A
Arc current
(amps)
MAXPRO200 Instruction Manual 807700 Revision 1
15
Safety
PACEMAKER AND HEARING AID OPERATION
Pacemaker and hearing aid operation can be affected
by magnetic fields from high currents.
Pacemaker and hearing aid wearers should consult a
doctor before going near any plasma arc cutting and
gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one
side, away from your body.
• Route the torch leads as close as possible to the
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.
NOISE CAN DAMAGE HEARING
Cutting with a plasma arc can exceed acceptable noise
levels as defined by local codes in many applications.
Prolonged exposure to excessive noise can damage
hearing. Always wear proper ear protection when
cutting or gouging, unless sound pressure level
measurements taken at the installed site have verified
personal hearing protection is not necessary per
relevant international, regional, and local codes.
Use ear protectors if the noise is disruptive or if there is
a risk of hearing damage after all other engineering and
administrative controls have been implemented. If
hearing protection is required, wear only approved
personal protective devices such as ear muffs or ear
plugs with a noise reduction rating appropriate for the
situation. Warn others in the area of possible noise
hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
Significant noise reduction can be obtained by adding
simple engineering controls to cutting tables such as
barriers or curtains positioned between the plasma arc
and the workstation; and/or locating the workstation
away from the plasma arc. Implement administrative
controls in the workplace to restrict access, limit
operator exposure time, screen off noisy working areas
and/or take measures to reduce reverberation in
working areas by putting up noise absorbers.
A PLASMA ARC CAN DAMAGE FROZEN PIPES
Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.
16
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
DRY DUST COLLECTION INFORMATION
At some sites, dry dust can represent a potential
explosion hazard.
The U.S. National Fire Protection Association’s 2007
edition of NFPA standard 68, “Explosion Protection by
Deflagration Venting,” provides requirements for the
design, location, installation, maintenance, and use of
devices and systems to vent combustion gases and
pressures after any deflagration event. Consult with the
manufacturer or installer of any dry dust collection
system for applicable requirements before you install a
new dry dust collection system or make significant
changes in the process or materials used with an
existing dry dust collection system.
Consult your local “Authority Having Jurisdiction” (AHJ)
to determine whether any edition of NFPA 68 has been
“adopted by reference” in your local building codes.
Refer to NFPA68 for definitions and explanations of
regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other
terms.
MAXPRO200 Instruction Manual 807700 Revision 1
Note 1 – Hypertherm’s interpretation of these new
requirements is that unless a site-specific evaluation
has been completed to determine that all dust
generated is not combustible, the 2007 edition of
NFPA 68 requires the use of explosion vents designed
to the worst-case Kst value (see annex F) that could be
generated from dust so that the explosion vent size and
type can be designed. NFPA 68 does not specifically
identify plasma cutting or other thermal cutting
processes as requiring deflagration venting systems,
but it does apply these new requirements to all dry dust
collection systems.
Note 2 – Users of Hypertherm manuals should consult
and comply with all applicable federal, state, and local
laws and regulations. Hypertherm does not, by the
publication of any Hypertherm manual, intend to urge
action that is not in compliance with all applicable
regulations and standards, and this manual may never
be construed as doing so.
17
Safety
LASER RADIATION
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.
For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation labels
has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV),
wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.
Additional laser safety instructions:
• Modifying the laser or product in any way can
increase the risk of laser radiation.
• Consult with an expert on local laser regulations.
Laser safety training may be required.
• Use of adjustments or performance of procedures
other than those specified in this manual may result
in hazardous laser radiation exposure.
• Do not allow untrained persons to operate the laser.
Lasers can be dangerous in the hands of untrained
users.
• Do not look into the laser aperture or beam at any
time.
• Position the laser as instructed to avoid unintentional
eye contact.
• Do not use the laser on reflective workpieces.
• Do not use optical tools to view or reflect the laser
beam.
• Do not operate in explosive atmospheres, such as in
the presence of flammable liquids, gases, or dust.
• Use only laser parts and accessories that are
recommended or provided by the manufacturer for
your model.
• Repairs and servicing MUST be performed by
qualified personnel.
• Do not remove or deface the laser safety label.
• Do not disassemble or remove the laser or aperture
cover.
18
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
SYMBOLS AND MARKS
Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.
S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments
with increased hazard of electrical shock according to IEC 60674-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively, the product may have
a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and
standards. Only those versions of Hypertherm products with a CE marking located on or near the data plate
have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European
EMC Directive are incorporated within versions of the product with a CE marking.
GOST-TR mark
CE versions of Hypertherm products that include a GOST-TR mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.
c-Tick mark
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale in
Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
UkrSEPRO mark
The CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product
safety and EMC requirements for export to the Ukraine.
MAXPRO200 Instruction Manual 807700 Revision 1
19
Safety
ADDITIONAL SAFETY INFORMATION
1.
ANSI Standard Z49.1, Safety in Welding and Cutting,
American Welding Society, 550 LeJeune Road P.O. Box
351020, Miami, FL 33135
6.
CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202
2.
ANSI Standard Z49.2, Fire Prevention in the Use of Cutting
and Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
7.
CSA Standard W117.2, Code for Safety in Welding and
Cutting, Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
3.
ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National
Standards Institute, 1430 Broadway, New York, NY 10018
8.
NFPA Standard 51B, Cutting and Welding Processes,
National Fire Protection Association 470 Atlantic Avenue,
Boston, MA 02210
4.
AWS F4.1, Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers and Piping That Have
Held Hazardous Substances, American Welding Society 550
LeJeune Road, P.O. Box 351040, Miami, FL 33135
9.
NFPA Standard 70–1978, National Electrical Code, National
Fire Protection Association, 470 Atlantic Avenue, Boston, MA
02210
5.
AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society 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
11. AWS Safety and Health Fact Sheets, American Welding
Society 550 LeJeune Road, P.O. Box 351040, Miami, FL
33135 www.aws.org/technical/facts/
WARNING LABELS
This warning label is affixed to some power supplies. It is important that the operator and maintenance technician
understand the intent of these warning symbols as described.
Read and follow these instructions, employer safety
practices, and material safety data sheets. Refer to
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health
Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons
in the work area. Consult manual before operating. Failure
to follow all these safety instructions can result in death.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
1. Les étincelles de coupage peuvent provoquer une explosion
ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away
from yourself. Arc starts instantly when triggered.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Hazardous voltage. Risk of electric shock or burn.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Plasma fumes can be hazardous.
4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure skin.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect
head, eyes, ears, hands, and body. Button shirt collar. Protect ears
from noise. Use welding helmet with the correct shade of filter.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Become trained. Only qualified personnel should operate this
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
20
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
non respect des ces instructions de sécurité peut entraîner la mort.
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
MAXPRO200 Instruction Manual 807700 Revision 1
Safety
WARNING LABELS
1.
This warning label is affixed to some power supplies. It is important that the
operator and maintenance technician understand the intent of these
warning symbols as described. The numbered text corresponds to the
numbered boxes on the label.
1.1 Do not cut near flammables.
Cutting sparks can cause explosion
or fire.
1.2 Have a fire extinguisher nearby and
ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2.
Plasma arc can injure and burn; point
the nozzle away from yourself. Arc
starts instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3.
Hazardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace
gloves when wet or damaged.
3.2 Protect from shock by insulating
yourself from work and ground.
3.3 Disconnect power before servicing.
Do not touch live parts.
4.
Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust
to remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5.
Arc rays can burn eyes and injure
skin.
5.1 Wear correct and appropriate
protective equipment to protect head,
eyes, ears, hands, and body. Button
shirt collar. Protect ears from noise.
Use welding helmet with the correct
shade of filter.
MAXPRO200 Instruction Manual 807700 Revision 1
6.
Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in
the manual. Keep non-qualified
personnel and children away.
7.
Do not remove, destroy, or cover this
label. Replace if it is missing,
damaged, or worn.
21
Safety
22
MAXPRO200 Instruction Manual 807700 Revision 1
Electromagnetic Compatibility (EMC)
Introduction
Hypertherm’s CE-marked equipment is built in compliance
with standard EN60974-10. The equipment should be
installed and used in accordance with the information
below to achieve electromagnetic compatibility.
The limits required by EN60974-10 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.
a.
Other supply cables, control cables, signaling and
telephone cables; above, below and adjacent to the
cutting equipment.
b.
Radio and television transmitters and receivers.
c.
Computer and other control equip.
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.
This cutting equipment is designed for use only in an
industrial environment.
f.
Installation and use
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.
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 the work piece. 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.
h.
Time of day that cutting or other activities are to be
carried out.
Assessment of area
Mains supply
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:
Cutting equipment must be connected to the mains
supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take
additional precautions such as filtering of the mains
supply.
MAXPRO200 Instruction Manual 807700 Revision 1
23
The user is responsible for installing and using the plasma
equipment according to the manufacturer’s instructions.
Equipment used for calibration or measurement.
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
Electromagnetic Compatibility (EMC)
Consideration should be given to shielding the supply
cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding
should be connected to the cutting mains supply so that
good electrical contact is maintained between the conduit
and the cutting power source enclosure.
Maintenance of cutting equipment
The cutting equipment must be routinely maintained
according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
and properly fastened when the cutting equipment is in
operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with
the manufacturer’s written instructions. For example, 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.
Earthing of the 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 steel work, 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 in crease 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 provided in IEC 60974-9,
Arc Welding Equipment, Part 9: 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.
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 (nozzle for laser heads) at the same time.
The operator should be insulated from all such bonded
metallic components.
24
MAXPRO200 Instruction Manual 807700 Revision 1
Warranty
Attention
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any
damage or injury caused by the use of other than genuine
Hypertherm parts may not be covered by the Hypertherm
warranty, and will constitute misuse of the Hypertherm
Product.
You are solely responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the product in your
environment.
General
Hypertherm, Inc. warrants that its Products shall be free
from defects in materials and workmanship for the specific
periods of time set forth herein and as follows: if
Hypertherm is notified of a defect (i) with respect to the
plasma power supply within a period of two (2) years from
the date of its delivery to you, with the exception of
Powermax brand power supplies, which shall be within a
period of three (3) years from the date of delivery to you,
and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, and with
respect to torch lifter assemblies within a period of one (1)
year from its date of delivery to you, and with respect to
Automation products one (1) year from its date of delivery
to you, with the exception of the EDGE Pro CNC and
ArcGlide THC, which shall be within a period of two (2)
years from the date of delivery to you, and (iii) with respect
to HyIntensity fiber laser components within a period of
two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which
shall be within a period of one (1) year from its date of
delivery to you.
Hypertherm provides repair, replacement or adjustment of
the Product as the sole and exclusive remedy, if and only if
the warranty set forth herein properly is invoked and
applies. Hypertherm, at its sole option, shall repair,
replace, or adjust, free of charge, any defective Products
covered by this warranty which shall be returned with
Hypertherm’s prior authorization (which shall not be
unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance
and freight pre paid by the customer. Hypertherm shall not
be liable for any repairs, replacement, or adjustments of
Products covered by this warranty, except those made
pursuant to this paragraph and with Hypertherm’s prior
written consent.
The warranty set forth above is exclusive and is in lieu of all
other warranties, express, implied, statutory, or otherwise
with respect to the Products or as to the results which
may be obtained therefrom, and all implied warranties or
conditions of quality or of merchantability or fitness for a
particular purpose or against infringement. The foregoing
shall constitute the sole and exclusive remedy for any
breach by Hypertherm of its warranty.
Distributors/OEMs may offer different or additional
warranties, but Distributors/OEMs are not authorized to
give any additional warranty protection to you or make any
representation to you purporting to be binding upon
Hypertherm.
This warranty shall not apply to any Powermax brand
power supplies that have been used with phase
converters. In addition, Hypertherm does not warranty
systems that have been damaged as a result of poor
power quality, whether from phase converters or incoming
line power. This warranty shall not apply to any product
which has been incorrectly installed, modified, or
otherwise damaged.
MAXPRO200 Instruction Manual 807700 Revision 1
25
Warranty
Patent indemnity
Insurance
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to
be developed by Hypertherm, Hypertherm will have the
right to defend or settle, at its own expense, any suit or
proceeding brought against you alleging that the use of
the Hypertherm product, alone and not in combination
with any other product not supplied by Hypertherm,
infringes any patent of any third party. You shall notify
Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen
(14) days after learning of any action or threat of action),
and Hypertherm’s obligation to defend shall be
conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the
defense of the claim.
At all times you will have and maintain insurance in such
quantities and types, and with coverage sufficient and
appropriate to defend and to hold Hypertherm harmless in
the event of any cause of action arising from the use of the
products.
Transfer of rights
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or
substantially all of your assets or capital stock to a
successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30)
days before any such transfer occurs, you agree to notify
in writing Hypertherm, which reserves the right of
approval. Should you fail timely to notify Hypertherm and
seek its approval as set forth herein, the Warranty set forth
herein shall be null and void and you will have no further
recourse against Hypertherm under the Warranty or
otherwise.
Limitation of liability
In no event shall Hypertherm be liable to any
person or entity for any incidental, consequential
direct, indirect, punitive or exemplary damages
(including but not limited to lost profits) regardless
of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty,
failure of essential purpose, or otherwise, and even
if advised of the possibility of such damages.
National and local codes
National and local codes governing plumbing and
electrical installation shall take precedence over any
instructions contained in this manual. In no event shall
Hypertherm be liable for injury to persons or property
damage by reason of any code violation or poor work
practices.
Liability cap
In no event shall Hypertherm’s liability, if any,
whether such liability is based on breach of
contract, tort, strict liability, breach of warranties,
failure of essential purpose or otherwise, for any
claim, action, suit or proceeding (whether in court,
arbitration, regulatory proceeding or otherwise)
arising out of or relating to the use of the Products
exceed in the aggregate the amount paid for the
Products that gave rise to such claim.
26
MAXPRO200 Instruction Manual 807700 Revision 1
Product Stewardship
Introduction
Hypertherm maintains a global Regulatory Management
System to ensure that products comply with regulatory
and environmental requirements.
National and local safety regulations
National and Local safety regulations shall take
precedence over any instructions provided with the
product. The product shall be imported, installed,
operated and disposed of in accordance with national and
local regulations applicable to the installed site.
Certification test marks
Certified products are identified by one or more
certification test marks from accredited testing
laboratories. The certification test marks are located on or
near the data plate.
been tested for compliance with the European Low
Voltage Directive and the European EMC Directive. EMC
filters needed to comply with the European EMC Directive
are incorporated within versions of the power supply with
a CE Marking.
Certificates of compliance for Hypertherm products are
available from the Downloads Library on the Hypertherm
web site at https://www.hypertherm.com.
Differences in national standards
Nations may apply different performance, safety or other
standards. National differences in standards include, but
are not limited to:
•
Voltages
•
Plug and cord ratings
•
Language requirements
•
Electromagnetic compatibility requirements
Each certification test mark means that the product and its
safety-critical components conform to the relevant
national safety standards as reviewed and determined by
that testing laboratory. Hypertherm places a certification
test mark on its products only after that product is
manufactured with safety-critical components that have
been authorized by the accredited testing laboratory.
These differences in national or other standards may make
it impossible or impractical for all certification test marks to
be placed on the same version of a product. For example,
the CSA versions of Hypertherm’s products do not
comply with European EMC requirements, and therefore
do not have a CE marking on the data plate.
Once the product has left the Hypertherm factory, the
certification test marks are invalidated if any of the
following occurs:
Countries that require CE marking or have compulsory
EMC regulations must use CE versions of Hypertherm
products with the CE marking on the data plate. These
include, but are not limited to:
•
The product is modified in a manner that creates a
hazard or non-conformance with the applicable
standards.
•
Australia
•
New Zealand
•
Safety-critical components are replaced with
unauthorized spare parts.
•
Countries in the European Union
•
Russia
•
Any unauthorized assembly, or accessory that uses or
generates a hazardous voltage is added.
•
There is any tampering with a safety circuit or other
feature that is designed into the product as part of the
certification, or otherwise.
It is important that the product and its certification test
mark be suitable for the end-use installation site. When
Hypertherm products are shipped to one country for
export to another country; the product must be configured
and certified properly for the end-use site.
CE marking constitutes a manufacturer’s declaration of
conformity to applicable European directives and
standards. Only those versions of Hypertherm products
with a CE Marking located on or near the data plate have
MAXPRO200 Instruction Manual 807700 Revision 1
27
Product Stewardship
Safe installation and use of shape
cutting equipment
IEC 60974-9, titled Arc Welding Equipment – Installation
and use, provides guidance in the safe installation and use
of shape cutting equipment and the safe performance of
cutting operations. The requirements of national and local
regulations shall be taken into consideration during
installation, including, but not limited to, grounding or
protective earth connections, fuses, supply disconnecting
device, and type of supply circuit. Read these instructions
before installing the equipment. The first and most
important step is the safety assessment of the installation.
The safety assessment must be performed by an expert,
and determines what steps are necessary to create a safe
environment, and what precautions should be adopted
during the actual installation and operation.
Procedures for periodic inspection
and testing
Where required by local national regulations,
IEC 60974-4 specifies test procedures for periodic
inspection and after repair or maintenance, to ensure
electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the
continuity of the protective circuit and insulation
resistance tests in the factory as non-operating tests. The
tests are performed with the power and ground
connections removed.
Hypertherm also removes some protective devices that
would cause false test results. Where required by local
national regulations, a label shall be attached to the
equipment to indicate that it has passed the tests
prescribed by IEC60974-4. The repair report shall
indicate the results of all tests unless an indication is made
that a particular test has not been performed.
Qualification of test personnel
Electrical safety tests for shape cutting equipment can be
hazardous and shall be carried out by an expert in the field
of electrical repair, preferably someone also familiar with
welding, cutting, and allied processes. The safety risks to
personnel and equipment, when unqualified personnel are
performing these tests, may be much greater than the
benefit of periodic inspection and testing.
28
Hypertherm recommends that only visual inspection be
performed unless the electrical safety tests are specifically
required by local national regulations in the country where
the equipment is installed.
Residual current devices (RCDs)
In Australia and some other countries, local codes may
require the use of a Residual Current Devices (RCD)
when portable electrical equipment is used in the
workplace or at construction sites to protect operators
from electrical faults in the equipment. RCDs are
designed to safely disconnect the mains electrical supply
when an imbalance is detected between the supply and
return current (there is a leakage current to earth). RCDs
are available with both fixed and adjustable trip currents
between 6 to 40 milliamperes and a range of trip times up
to 300 milliseconds selected for the equipment
installation, application and intended use. Where RCDs
are used, the trip current and trip time on RCDs should be
selected or adjusted high enough to avoid nuisance
tripping during normal operation of the plasma cutting
equipment and low enough in the extremely unlikely event
of an electrical fault in the equipment to disconnect the
supply before the leakage current under a fault condition
can pose a life threatening electrical hazard to operators.
To verify that the RCDs continue to function properly over
time, both the trip current and the trip time should be
tested periodically. Portable electrical equipment and
RCDs used in commercial and industrial areas in Australia
and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma
cutting equipment to AS/NZS 3760, measure the
insulation resistance according to Appendix B of the
standard, at 250 VDC with the power switch in the ON
position to verify proper testing and to avoid the false
failure of the leakage current test. False failures are
possible because the metal oxide varistors (MOVs) and
electromagnetic compatibility (EMC) filters, used to
reduce emissions and protect the equipment from power
surges, may conduct up to 10 milliamperes leakage
current to earth under normal conditions.
If you have any questions regarding the application or
interpretation of any IEC standards described here, you
are required to consult with an appropriate legal or other
advisor familiar with the International Electrotechnical
standards, and shall not rely on Hypertherm in any respect
regarding the interpretation or application of such
standards.
MAXPRO200 Instruction Manual 807700 Revision 1
Product Stewardship
Higher-level systems
When a system integrator adds additional equipment;
such as cutting tables, motor drives, motion controllers or
robots; to a Hypertherm plasma cutting system, the
combined system may be considered a higher-level
system. A higher-level system with hazardous moving
parts may constitute industrial machinery or robotic
equipment, in which case the OEM or end-use customer
may be subject to additional regulations and standards
than those relevant to the plasma cutting system as
manufactured by Hypertherm.
It is the responsibility of the end-use customer and the
OEM to perform a risk assessment for the higher-level
system, and to provide protection against hazardous
moving parts. Unless the higher-level system is certified
when the OEM incorporates Hypertherm products into it,
the installation also may be subject to approval by local
authorities. Seek advice from legal counsel and local
regulatory experts if you are uncertain about compliance.
External interconnecting cables between component parts
of the higher level system must be suitable for
contaminants and movement as required by the final end
use installation site. When the external interconnecting
cables are subject to oil, dust, water, or other
contaminants, hard usage ratings may be required.
When external interconnecting cables are subject to
continuous movement, constant flexing ratings may be
required. It is the responsibility of the end-use customer or
the OEM to ensure the cables are suitable for the
application. Since there are differences in the ratings and
costs that can be required by local regulations for higher
level systems, it is necessary to verify that any external
interconnecting cables are suitable for the end-use
installation site.
MAXPRO200 Instruction Manual 807700 Revision 1
29
Product Stewardship
30
MAXPRO200 Instruction Manual 807700 Revision 1
Environmental Stewardship
Introduction
The Hypertherm Environmental Specification requires
RoHS, WEEE and REACH substance information to be
provided by Hypertherm’s suppliers.
Product environmental compliance does not address the
indoor air quality or environmental release of fumes by the
end user. Any materials that are cut by the end user are
not provided by Hypertherm with the product. The end
user is responsible for the materials being cut as well as
for safety and air quality in the workplace. The end user
must be aware of the potential health risks of the fumes
released from the materials being cut and comply with all
local regulations.
National and local environmental
regulations
National and local environmental regulations shall take
precedence over any instructions contained in this
manual.
The product shall be imported, installed, operated and
disposed of in accordance with all national and local
environmental regulations applicable to the installed site.
The European Environmental regulations are discussed
later in The WEEE Directive.
The RoHS directive
Hypertherm is committed to complying with all applicable
laws and regulations, including the European Union
Restriction of Hazardous Substances (RoHS) Directive
that restricts the use of hazardous materials in electronics
products. Hypertherm exceeds RoHS Directive
compliance obligations on a global basis.
Hypertherm continues to work toward the reduction of
RoHS materials in our products, which are subject to the
RoHS Directive, except where it is widely recognized that
there is no feasible alternative.
Declarations of RoHS Conformity have been prepared for
the current CE versions of Powermax plasma cutting
systems manufactured by Hypertherm. There is also a
“RoHS mark” on the Powermax CE versions below the
MAXPRO200 Instruction Manual 807700 Revision 1
“CE Marking” on the data plate of CE versions of
Powermax series units shipped since 2006. Parts
used in CSA versions of Powermax and other products
manufactured by Hypertherm that are either out of scope
or exempt from RoHS are continuously being converted to
RoHS compliance in anticipation of future requirements.
Proper disposal of Hypertherm
products
Hypertherm plasma cutting systems, like all electronic
products, may contain materials or components, such
as printed circuit boards, that cannot be discarded with
ordinary waste. It is your responsibility to dispose of any
Hypertherm product or component part in an
environmentally acceptable manner according to national
and local codes.
•
In the United States, check all federal, state, and local
laws.
•
In the European Union, check the EU directives,
national, and local laws. For more information, visit
www.hypertherm.com/weee.
•
In other countries, check national and local laws.
•
Consult with legal or other compliance experts when
appropriate.
The WEEE directive
On January 27, 2003, the European Parliament and
the Council of the European Union authorized Directive
2002/96/EC or WEEE (Waste Electrical and Electronic
Equipment).
As required by the legislation, any Hypertherm product
covered by the directive and sold in the EU after August
13, 2005 is marked with the WEEE symbol. This directive
encourages and sets specific criteria for the collection,
handling, and recycling of EEE waste. Consumer and
business-to-business wastes are treated differently
(all Hypertherm products are considered
business-to-business). Disposal instructions for the
CE versions of Powermax plasma systems can be found
at www.hypertherm.com/weee.
31
Environmental Stewardship
The URL is printed on the symbol-only warning label for
each of these CE version Powermax series units shipped
since 2006. The CSA versions of Powermax and other
products manufactured by Hypertherm are either out of
scope or exempt from WEEE.
The REACH regulation
The REACH regulation (1907/2006), in force since
June 1, 2007, has an impact on chemicals available to the
European market. The REACH regulation requirements for
component manufacturers states that the component shall
not contain more than 0.1% by weight of the Substances
of Very High Concern (SVHC).
Component manufacturers and other downstream users,
such as Hypertherm, are obligated to obtain assurances
from its suppliers that all chemicals used in or on
Hypertherm products will have a European Chemical
Agency (ECHA) registration number. To provide
chemical information as required by the REACH
regulation, Hypertherm requires suppliers to provide
REACH declarations and identify any known use of
REACH SVHC. Any use of SVHC in amounts exceeding
0.1% w/w of the parts has been eliminated. The MSDS
contains a full disclosure of all substances in the chemical
and can be used to verify REACH SVHC compliance.
The lubricants, sealants, coolants, adhesives, solvents,
coatings and other preparations or mixtures used by
Hypertherm in, on, for, or with its shape cutting equipment
are used in very small quantities (except the coolant) and
are commercially available with multiple sources that can
and will be replaced in the event of a supplier problem
associated with REACH Registration or REACH
Authorization (SVHCs).
Proper handling and safe use of
chemicals
Chemical Regulations in the USA, Europe, and other
locations require that Material Safety Data Sheets
(MSDS) be made available for all chemicals. The list of
chemicals is provided by Hypertherm. The MSDS are for
chemicals provided with the product and other chemicals
used in or on the product. MSDS can be downloaded
from the Downloads Library on the Hypertherm web site
at https://www.hypertherm.com. On the Search screen,
insert MSDS in the document title and click on Search.
Hypertherm does not manufacture or provide the materials
that are cut and has no knowledge whether the fumes
released from materials that are cut will pose a physical
hazard or health risk. Please consult with your supplier
or other technical advisor if you need guidance
concerning the properties of the material you will cut
using a Hypertherm product.
Fumes emission and air quality
Note: The following information on air quality is intended
for general information only and should not be used as
a substitute for reviewing and implementing applicable
government regulations or legal standards in the country
where the cutting equipment will be installed and
operated.
In the USA, the National Institute for Occupational Safety
and Health (NIOSH) Manual of Analytical Methods
(NMAM) is a collection of methods for sampling and
analyzing contaminants in workplace air. Methods
published by others, such as OSHA, MSHA, EPA, ASTM,
ISO or commercial suppliers of sampling and analytical
equipment, may have advantages over NIOSH methods.
For example, ASTM Practice D 4185 is a standard
practice for the collection, dissolution, and determination
of trace metals in workplace atmospheres. The sensitivity,
detection limit, and optimum working concentrations for
23 metals are listed in ASTM D 4185. An industrial
hygienist should be used to determine the optimum
sampling protocol, considering analytical accuracy, cost,
and optimum sample number. Hypertherm uses a third
party industrial hygienist to perform and interpret air
quality testing results taken by air sampling equipment
positioned at operator stations in Hypertherm buildings
where plasma cutting tables are installed and operated.
Where applicable, Hypertherm also uses a third party
industrial hygienist to obtain air and water permits.
If you are not fully aware and up to date on all applicable
government regulations and legal standards for the
installation site, you should consult a local expert prior
to purchasing, installing, and operating the equipment.
In the USA, OSHA does not require Material Safety
Data Sheets for articles such as electrodes, swirl rings,
retaining caps, nozzles, shields, deflectors and other solid
parts of the torch.
32
MAXPRO200 Instruction Manual 807700 Revision 1
Specifications
System description
General
The MAXPRO200 plasma system is designed to cut a wide range of thicknesses of mild steel, stainless steel, and
aluminum.
Power supply
The power supply is a 200 A, 165 VDC constant-current supply. It contains the circuitry to ignite a torch, plus a heat
exchanger and a pump to cool the chopper and torch. The power supply has a discrete machine interface to provide
communication with a CNC.
Ignition console
The ignition console is attached to the outside of the rear panel of the power supply enclosure. The ignition console uses
a spark-gap assembly. The ignition console converts 120 VAC control voltage from the power supply into high-frequency
and high-voltage pulses (9–10 kV) to initiate the pilot arc at the torch electrode-nozzle gap. The high-voltage,
high-frequency signal is coupled to the pilot arc lead.
Torch
•
The maximum production cutting capacity is the maximum thickness that can be cut with a 100% duty
cycle. The maximum production cutting capacity of the MAXPRO200 torch is 32 mm (1-1/4 inches)
for mild steel using the 200 amp O2/Air process, 22 mm (7/8 inch) for stainless steel, and 19 mm (5/8
inch) for aluminum using the 200 amp Air/Air process.
•
Maximum pierce capacity is 32 mm (1.25 inches) for mild steel, 25 mm (1 inch) for stainless steel, and
32 mm (1.25 inch) for aluminum.
•
The maximum severance capacity is the maximum thickness that can be severed without regard for
speed and cut quality. This thickness should only be cut occasionally and cannot be cut with a 100%
duty cycle. The maximum severance capacity of the MAXPRO200 torch is 75 mm (3 inches) for mild
steel, 63 mm (2-1/2 inches) for stainless steel, and 75 mm (3 inches) for aluminum.
Gas system
The gas system manages the pressure and timing of the gas supplied to the torch. It consists of a regulator, proportional
valves, pressure transducers, and an inline valve located in the torch lead.
MAXPRO200 Instruction Manual 807700 Revision 1
33
Specifications
34
MAXPRO200 Instruction Manual 807700 Revision 1
Specifications
Cooling system
The cooling system uses a liquid-to-air cooled heat exchanger and a pump to reduce the temperature of the coolant. The
coolant cools the chopper, torch lead and torch. The cooling system also contains flow and temperature sensors that
verify the cooling system is working properly.
System gas requirements
Gas quality and pressure requirements
Gases
Quality
Pressure +/- 10%
Flow rate
O2 oxygen
99.5% pure (liquid gas recommended)
Clean, dry, and oil free
621 kPa / 6.2 bar / 90 psi
3400 l/h 120 scfh
N2 nitrogen
99.9% pure (liquid gas recommended)
Clean, dry, and oil free
621 kPa / 6.2 bar / 90 psi
11330 l/h 400 scfh
Air
Clean, dry, and oil free (ISO 8573-1 class 1.4.2)
621 kPa / 6.2 bar / 90 psi
11330 l/h 400 scfh
Gases by process
Mild steel
Stainless steel
Aluminum
Plasma gas
Shield gas
Plasma gas
Shield gas
Plasma gas
Shield gas
Cutting 50 A
Air or O2
Air
Air
Air
Air
Air
Cutting 130 A
Air or O2
Air
Air
Air
Air
Air
N2
N2
N2
N2
Air or O2
Air
Air
Air
Air
Air
N2
N2
N2
N2
Amperage
Cutting 130 A
Cutting 200 A
Cutting 200 A
MAXPRO200 Instruction Manual 807700 Revision 1
35
Specifications
Power supply
Maximum Open Circuit Voltage (OCV) (U0)
360 VDC
Maximum output current (I2)
200 Amps
Output voltage (U2)
50 – 165 VDC
Duty cycle rating (X)
100% @ 33 kW, 40° C (104° F)
Ambient temperature/Duty cycle
Power supplies will operate between (-10°C – 40°C)
-10° C and +40° C (+14° and 104° F)
Power factor (cosϕ)
0.98 @ 33 kW output
Cooling
Forced air (Class F)
Insulation
Class H
Power supply
part numbers
AC
Voltage
(U1)
078610
200/208
078611
220
Regulatory
approval
Power kVA
(+/- 10%)
(U1 x l1 x 1.73)
108/104
CSA
37.4
98
CSA
37.4
Frequency
(Hz)
Amperage
l1
3
50
3
50-60
Phase
078612
240
3
60
90
CSA
37.4
078613
380
3
50
57
CCC
37.4
078614
400
3
50-60
54
CE/GOST-R
37.4
078615
415
3
50
52
CE/GOST-R
37.4
078616
440
3
50-60
49
CSA
37.4
078609
480
3
60
45
CSA
37.4
078617
600
3
60
36
CSA
37.4
1
2
1
63.5 mm (2.5 inches)
2
688 mm (27.1 inches)
3
133 mm (5.25 inches)
4
998 mm (39.3 inches)
5
927 mm (40.1 inches)
5
3
335.7 kg
(740 lb)
4
36
MAXPRO200 Instruction Manual 807700 Revision 1
Specifications
Mechanized torches
Straight torch – 428024
•
The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 inches)
•
The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)
1
2
7
4
3
6
5
1.02 kg
(2.25 lb)
1
397.15 mm (15.64 inches)
2
279.40 mm (11.00 inches)
3
117.75 mm (4.64 inches)
4
12.70 mm (0.50 inches)
5
44.20 mm (1.74 inches)
6
46 degrees
7
44.20 mm (1.74 inches)
MAXPRO200 Instruction Manual 807700 Revision 1
37
Specifications
Quick-disconnect torch – 428027 or 428028
•
The torch mounting sleeve for the quick-disconnect torch is available with an outside diameter of
50.8 mm (2.0 inches) or 44.45 mm (1.75 inches)
•
The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)
1
2
9
3
8
4
5
6
7
1.45 kg
(3.20 lb)
1
435.33 mm (17.14 inches)
2
279.40 mm (11.00 inches)
3
76.98 mm (3.03 inches)
4
78.95 mm (3.11 inches)
5
12.70 mm (0.50 inches)
6
44.20 mm (1.74 inches)
7
46 degrees
8
57.15 mm (2.25 inches)
9
44.20 mm (1.74 inches)
38
MAXPRO200 Instruction Manual 807700 Revision 1
Specifications
Hand torches
90 degree hand torch – 420108
•
The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)
1
5
2
3
4
0.91 kg
(2.0 lb)
1
310.40 mm (12.22 inches)
2
90 degrees
3
44.20 mm (1.74 inches)
4
305.05 mm (12.01 inches)
5
149.10 mm (5.87 inches)
MAXPRO200 Instruction Manual 807700 Revision 1
39
Specifications
65 degree hand torch – 420107
•
The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)
1
5
2
0.91 kg
(2.0 lb)
3
4
1
290.58 mm (11.44 inches)
2
65 degrees
3
44.20 mm (1.74 inches)
4
285.24 mm (11.23 inches)
5
238.51 mm (9.39 inches)
40
MAXPRO200 Instruction Manual 807700 Revision 1
Installation
Upon receipt
•
Verify that all system components on your order have been received. Contact your supplier if any items
are missing.
•
Inspect the system components for any physical damage that may have occurred during shipping. If
there is evidence of damage, refer to Claims. All communications regarding claims must include the
model number and serial number located on the rear of the power supply.
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance,
call customer service listed in the front of this manual, or your authorized Hypertherm distributor.
Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your
supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized
Hypertherm distributor.
Installation requirements
All installation and service of the electrical and plumbing systems must conform to national and local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.
Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual,
or your authorized Hypertherm distributor.
Noise levels
Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always wear
proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific
environment in which the system is used. See also Noise can damage hearing in the Safety section of this manual.
Specific information by product can be found in the Hypertherm downloads library at:
https://www.hypertherm.com/Xnet/library/DocumentLibrary.jsp
Select the product you are looking for from the Product Type drop down menu, choose “Regulatory” from the Category
drop down menu, and choose “Acoustical Noise Data Sheets” from the Sub Category drop down menu. Press Submit.
MAXPRO200 Instruction Manual 807700 Revision 1
41
Installation
Placement of system components
•
Place all system components in position prior to making electrical, gas, and interface connections.
Use the diagram in this section for component-placement guidelines.
•
Ground all system components to earth. See Recommended grounding and shielding practices on
page 44 for details.
•
To prevent leaks in the system, tighten all gas connections as shown below.
Torque specifications
42
Gas or water hose size
kgf-cm
lbf-in
lbf-ft
Up to 10 mm (3/8 in)
8.9–9.8
75–85
6.25–7
12 mm (1/2 in)
41.5–55
360–480
30–40
MAXPRO200 Instruction Manual 807700 Revision 1
Installation
System components
A
2
B
A
Power supply
Torch
Cable and lead
1
2
3
Torch lead
Work lead
CNC interface cable
Supply gas hoses
4
5
6
Air
N2
O2
Customer supplied power cable
7
Main power cable
7
1
2
6
5
B
4
3
MAXPRO200 Instruction Manual 807700 Revision 1
43
Installation
Recommended grounding and shielding practices
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. All work requiring the
removal of the plasma system cover must be performed by a qualified technician.
See the Safety section of your instruction manual for more safety precautions.
Introduction
This section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency
interference (RFI) and electromagnetic interference (EMI) (also called noise). It also describes the DC power ground and
the service ground. The diagram at the end of this section shows these types of grounds in a plasma cutting system.
Note: The grounding practices in this section have been used on many installations with excellent results, and
Hypertherm recommends that these practices be a routine part of the installation process. The actual methods
used to implement these practices may vary from system to system, but should remain as consistent as possible.
However, due to the variation in equipment and installations, these grounding practices may not succeed in every
case to eliminate RFI/EMI noise issues.
Types of grounding
Service ground (also called safety ground or potential earth (PE) ground) is the grounding system that applies to the
incoming line voltage. It prevents a shock hazard to any personnel from any of the equipment or the cutting
table. It includes the service ground coming into the plasma system and other systems such as the CNC
and the motor drives, as well as the supplemental ground rod connected to the cutting table. In the plasma
circuits, the ground is carried from the plasma system chassis to the chassis of each separate console
through the interconnecting cables.
DC power ground (also called cutting current ground) is the grounding system that completes the path of the cutting
current from the torch back to the plasma system. It requires that the positive lead from the plasma system
be firmly connected to the cutting table ground bus with a properly sized cables. It also requires that the
slats, on which the workpiece rests, make firm contact with the table and the workpiece.
RFI and EMI grounding and shielding is the grounding system that limits the amount of electrical noise emitted by
the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and
other control and measurement circuits. The grounding practices described in this section mainly target
RFI and EMI grounding and shielding.
Grounding practices
1. Unless noted, use only 16 mm2 (6 AWG) welding cable (047040) for the EMI ground cables shown on the diagram.
2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
each motor as possible. If there are motors at each end of the gantry, run a separate EMI ground cable from the
far motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable 21.2 mm2
(4 AWG; 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console must each
run separately to the table ground bus.
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3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the
cutting table. This is a PE ground and should be connected to the cutting table ground bus bar using 16 mm2
(6 AWG) green and yellow grounding cable (047121) or equivalent.
4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, between plasma systems in multi-drop connections, and for interconnections between all parts of the
Hypertherm system.
5. All hardware used in the ground system must be brass or copper. While you can use steel studs welded to the
cutting table for mounting the ground bus, no other aluminum or steel hardware can be used in the ground system.
6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.
7.
For a system with a remote high frequency console (RHF), the positive, negative, and pilot arc leads should be
bundled together for as long a distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be
run parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If possible, run power
and signal cables in separate cable tracks.
8. For a system with an RHF console, the ignition console should be mounted as closely as possible to the torch, and
must have a separate ground cable that connects directly to the cutting table ground bus bar.
9. Each Hypertherm component, as well as any other CNC or motor drive cabinet or enclosure, must have a separate
ground cable to the common (star) ground on the table. This includes the ignition console, whether if it is bolted to
the plasma system or to the cutting table.
10. The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch. It must
be electrically insulated from any metal and from any contact with the floor or building. The torch lead can be run in a
plastic cable tray or track, or covered with a plastic or leather sheath.
11. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted to the
torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (0.5 inches) wide. A
separate cable must run from the lifter to the gantry ground bus bar. The valve assembly should also have a separate
ground connection to the gantry ground bus bar.
12. If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground cable from
the end of the rail to the table. The rail ground cables connect directly to the table and do not need to connect to the
table ground bus bar.
13. If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is sampled.
One recommended location is inside the plasma system enclosure. If a Hypertherm voltage divider board is used, the
output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable
(Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield. connect the shield to the chassis of
the plasma system and leave it unconnected at the other end.
14. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable. Connectors
on these cables should have a metal housing. The shield, not the drain, should be connected to the metal housing of
the connector at each end of the cable. Never run the shield or the drain through the connector on any of the pins.
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Installation
The following picture shows an example of a cutting table ground bus. The components shown here may differ from your
system.
1
2
3
4
5
6
7
1
Gantry ground bus
2
Ground rod
3
Plasma system lead (+)
4
Remote high frequency (RHF) console
5
CNC enclosure
6
Torch holder
7
Plasma system chassis
The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to the motor. All of the
individual ground cables from the components mounted on the gantry go to the bus. A single heavy cable then goes from
the gantry ground bus to the table ground bus,
1
1
Cable to the cutting table ground bus
2
Ground cables from components on the gantry
2
The following diagram shows an example of grounding the components in a plasma cutting system.
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MAXPRO200 Instruction Manual 807700 Revision 1
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8
7
6
10
9
2
5
12
11
4
1
Chassis and RFI ground
3
AC earth and ground
1 Cutting table
2 Gantry
7
RHF console (not on all systems). Connect to table
ground bus bar.
8, 9 System-specific component such as metering
console, gas console, or selection console
3
Plasma system
4 Table ground bus bar
10 CNC chassis
11 Torch height control module
(ArcGlide, CommandTHC)
5
Gantry ground bus bar
12 System-specific component such as a cooler or
chiller
6 Torch height control lifter (ArcGlide, Sensor THC,
Sensor PHC, or other)
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Installation
A Placement of the power supply
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. All work requiring the
removal of the plasma system cover must be performed by a qualified technician.
See the Safety section of your instruction manual for more safety precautions.
The power supply can be moved by using the lifting eye or by forklift but the forks must be long enough to extend the
entire length of the base. Take care when lifting so that the underside of the power supply is not damaged. The forks must
also be centered front to back and side to side to prevent tipping while moving. Fork lift speeds should be kept to a
minimum, especially when making a turn or going around a corner.
•
Place the power supply in an area that is free of excessive moisture, has proper ventilation and is
relatively clean. Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service.
•
Cooling air is drawn in through the side panel and is exhausted through the rear of the unit by a cooling
fan. Do not place any filter device over the air intake locations, which reduces cooling efficiency and
VOIDS THE WARRANTY.
•
Do not place the power supply on an incline greater than 10° to prevent it from toppling.
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Installation
1 Torch lead connections
1. Insert the end of the torch lead through the opening of the ignition enclosure as shown below. Secure the collar on
the torch lead to the ignition enclosure by aligning the tabs on the collar with the corresponding openings in the
ignition enclosure, rotate the collar until it stops, and verify that the collar will not detach when released.
2. Connect the CPC connector to the CPC receptacle.
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Installation
Note: The plasma gas and coolant return hose connectors mentioned below are push-to-connect fittings.
•
To make a connection, push the hose fitting into the appropriate connector until it stops, 12 mm (0.472 in).
Connector-collar
•
To disconnect a fitting, push the connector-collar and hose toward the fitting, hold the collar in place and pull the
hose away from the fitting.
3. Connect the coolant return hose (red).
4. Connect the plasma gas hose (black).
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Note: The shield gas/pilot arc and coolant supply/negative lead hose connectors mentioned below are slightly
different push-to-connect fittings. Slide the hose fitting over the connector and press until it clicks into place. To
disconnect a fitting, pull the connector-collar toward the hose, and pull the hose away from the fitting.
5. Connect the pilot arc/shield gas hose (blue).
6. Connect the negative lead/coolant supply hose (blue with green tape).
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Installation
2 Work lead connections
Part number
Length
223335
7.5 m (25 ft)
223336
15 m (50 ft)
223337
23 m (75 feet)
223338
30 m (100 feet)
Remove the first nut and washer from the work lead terminal and use it to secure the work lead to the terminal.
Lower frame of work table (typical)
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B Torch connections
Note: The connections between the straight torch main body and the torch leads are identical to the connections
between the quick-disconnect receptacle and the torch leads.
Align the quick disconnect receptacle, or the straight torch main body, to the torch leads and secure using the
push-to-connect fittings.
Connect to torch lead
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Installation
Connect the torch to the quick-disconnect receptacle
Align the torch body to the quick disconnect receptacle and connect them by screwing completely together. Apply a thin
film of silicone lubricant to each o-ring. The o-rings should look shiny, but there should not be any excess or built-up
lubricant.
Be certain that there is no space between the torch body and the o-ring on the quick-disconnect.
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Torch mounting and alignment
Mounting the torch
1
1
Torch sleeve
2
Mounting bracket
3
Quick-disconnect receptacle
2
3
1. Install the torch (with torch leads attached) in the torch mounting bracket.
2. Position the torch below the mounting bracket, so that the bracket is around the lower portion of the torch sleeve but
not touching the torch quick-disconnect.
3. Tighten the securing screws.
Note: The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch.
Torch alignment
To align the torch at right angles to the workpiece, use a square as shown above.
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Installation
3 CNC interface cable
Part Number
Length
Part Number
Length
223327
1.3 m (5 feet)
223330
15 m (50 feet)
223328
3.0 m (10 feet)
223331
23 m (75 feet)
223329
7.5 m (25 feet)
223332
30 m (100 feet)
Power supply end
Wire
color
Pin
Input/
number Output Signal name
Orange
1
Input Start +
White
2
Input Start –
Brown
3
Input Hold +
White
4
input Hold –
CNC end
Input/
Output Notes
Function
The CNC initiates preflow, and if the hold input is not active,
Output
continues with the plasma arc. The system will stay in preflow if the Output
hold input remains active.
The CNC delays plasma arc initiation. This signal is normally used Output
in combination with the start signal to synchronize multiple torches. Output 1 and 3
Black
5
Output Motion +
White
6
Output Motion –
Notifies the CNC that an arc transfer has occurred and to begin
machine motion once the CNC’s pierce delay has timed out.
Notifies the CNC that an error has occurred.
Red
7
Output Error +
White
8
Output Error –
1
Input
Input
Input
Input
2
2
Notes to CNC interface cable run list
1. Inputs are optically isolated. They require 24 VDC at 12.5 mA, or dry-contact closure at 8 mA.
2. Outputs are optically isolated, open-collector, transistors. The maximum rating is 24 VDC at 10 mA.
3. Although the power supply has an output capability, it is normally used solely as an input.
4. There is no +24 VDC power available at the J6 CNC connector.
5. The wire clips on the center panel should be used to help route the CNC cable from the rear panel opening of the
power supply to J6 on the control board. Open the clips by depressing the release tab, and add the CNC cable to
the wires that are already present in the clip. See the figure on the next page.
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CNC cable routing and connection to control board
from the
CNC
To J6 on the control board
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Installation
Remote ON/OFF switch (provided by customer)
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. All work requiring the removal of
the plasma system cover must be performed by a qualified technician.
See Safety on page 9 of your instruction manual for more safety precautions.
1. Remove the 4 screws that secure the control panel to the power supply and locate terminal block J1.8 on the power
supply control board.
2. Remove the jumper wire between terminal 1 and terminal 2. Use a sturdy tool to depress the corresponding orange
release buttons on the spring clamp connector
1 2 3 4 5 6 7
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Installation
3. Connect the switch to terminals 1 and 2 as shown below. Use a sturdy tool to depress the corresponding orange
release buttons on the spring clamp connector.
1 2 3 4 5 6 7
Note: Use a switch, relay, or solid-state relay that is compatible with 24 VDC @ 100 mA.
Wires should be a twisted pair.
Note: The power switch on the power supply must be in the ON position for the remote switch to function and
the remote switch must be in the ON position (closed) for the power switch on the power supply to function.
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Installation
Power requirements
General
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to
5.61 MVA at the point between the user’s supply and the public system. It is the responsibility of the installer or user of
the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is
connected only to a supply with a short-circuit power Ssc greater than or equal to 5.61 MVA.
All switches, slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable
national and local electrical codes. Installation must be performed by a licensed electrician. Use a separate, primary, line
disconnect switch for the power supply. Recommendations on fuse and circuit breaker sizing are listed below, however
actual sizes required will vary based on individual site electrical line conditions (including but not limited to: source
impedance, line impedance, and line voltage fluctuation), product inrush characteristics, and regulatory requirements.
The main feed protection device (circuit breaker or fuse) must be sized to handle all branch-feed loads for both inrush and
steady-state current. The power supply must be wired into one of the branch-feed circuits. The power supply has a
steady-state current listed in the table below.
Use a motor-start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national
codes. Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the
rated input current (FLA) for 0.01 seconds and up to 12 times the rated input current (FLA) for 0.1 seconds.
Note: The table below is for reference only. All local and national electrical code must be followed.
Input voltage
Phase
Rated input
current @ “X” kW
output
200/208 VAC
3
108/104 amps
Recommended cable size for 15 m (50 feet)
maximum length
Recommended
time delay, high
inrush, fuse size
Rated for 60º C (140º F)
Rated for 90º C (194º F)
175 amps
N/A
67.5 mm2 (2/0)
mm2
220 VAC
3
98 amps
150 amps
85.2
(3/0)
42.4 mm2 (1 AWG)
240 VAC
3
90 amps
150 amps
85.2 mm2 (3/0)
42.4 mm2 (1 AWG)
mm2
380 VAC
3
57 amps
90 amps
33.6
(2 AWG)
21.2 mm2 (4 AWG)
400 VAC
3
54 amps
80 amps
26.7 mm2 (3 AWG)
21.2 mm2 (4 AWG)
415 VAC
3
52 amps
80 amps
26.7 mm2 (3 AWG)
21.2 mm2 (4 AWG)
440 VAC
3
49 amps
80 amps
26.7
(3 AWG)
21.2 mm2 (4 AWG)
480 VAC
3
45 amps
70 amps
21.2 mm2 (4 AWG)
13.3 mm2 (6 AWG)
600 VAC
3
36 amps
50 amps
13.3
mm2
mm2
(6 AWG)
8.3 mm2 (8 AWG)
Note: Wire AWG recommendations came from Table 310-16 of the National Electric Code Handbook (USA).
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Line disconnect switch
The line disconnect switch serves as the supply-voltage disconnecting (isolating) device. Install this
switch near the power supply for easy access by the operator.
Installation must be performed by a licensed electrician and according to applicable national and local
codes.
The switch should:
SWITCH BOX
•
Isolate the electrical equipment and disconnect all live conductors from the supply voltage when in
the “OFF” position
•
Have one “OFF” and one “ON” position clearly marked with “O” (OFF) and “l” (ON)
•
Have an external operating handle capable of being locked in the “OFF” position
•
Contain a power-operated mechanism that serves as an emergency stop
•
Have slow-blow fuses installed for the proper breaking capacity (see table on previous page).
7 Main power cable
Wire sizes vary based on the temperature rating of the cable insulation and the distance of the unit from the main box.
Use a 4-conductor Type SO input power cable with a conductor temperature rating of 60° C (140° F) or 90° C (194° F).
Installation must be performed by a licensed electrician.
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Installation
Connect the power
WARNING!
ELECTRIC SHOCK CAN KILL
The line disconnect switch must be in the OFF position before making the power cable connections.
In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other countries, follow
appropriate national and local safety procedures.
1. Insert the power cable through the strain relief at the rear of the power supply.
2. Connect the ground lead (PE) to the GROUND connector as shown below.
3. Connect the power leads to the contactor terminals as shown below. For models with an EMI filter, connect the
power leads to the EMI filter terminal block. Recommended torque on contactor or EMI filter terminals is 7-8 Nm
(60–70 in-lbs).
4. Verify that the line disconnect switch is in the OFF position and remains in the OFF position for the
remainder of the installation of the system.
5. Connect the power cord leads to the line disconnect switch following national and local electrical codes.
North American wire colors
European wire colors
U = Black
V = White
W = Red
(PE) Earth ground = Green/yellow
U = Black
V = Blue
W = Brown
(PE) Earth ground = Green/yellow
4 3
2
1
62
1
Ground
2
L1
3
L2
4
L3
MAXPRO200 Instruction Manual 807700 Revision 1
Installation
Torch coolant requirements
The system is shipped without any coolant in the tank. Before filling the coolant system, determine what coolant mix is
correct for your operating conditions.
Observe the warning and cautions below. Refer to the Material Safety Data Sheets appendix for data on safety,
handling and storage of propylene glycol and benzotriazole.
WARNING!
COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED.
Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed.
Upon contact, flush skin or eyes with water. If swallowed, seek immediate medical attention.
CAUTION!
Never use automotive antifreeze in place of propylene glycol. Antifreeze contains corrosion inhibitors
that will damage the torch coolant system.
Always use purified water in the coolant mixture to prevent damage to the pump and corrosion in the
torch coolant system.
Premixed coolant for standard operating temperatures
Use Hypertherm premixed coolant (028872) when operating in a temperature range of -12° C to 40° C (10° F to 104° F).
Refer to the custom coolant mix recommendations, if temperatures during operation are ever outside of this range.
Hypertherm premixed coolant consists of 69.8% water, 30% propylene glycol, and 0.2% benzotriazole.
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Installation
Custom Coolant mix for cold operating temperatures (below -12° C / 10° F)
CAUTION!
For operating temperatures colder than the temperature stated above, the percentage of propylene
glycol must be increased. Failure to do so could result in a cracked torch head, hoses or other damage
to the torch coolant system due to freezing.
Use the chart below to determine what percentage of propylene glycol to use in the mixture.
Mix 100% propylene glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of
glycol in the premixed Hypertherm coolant. The 100% glycol solution can also be mixed with purified water (see the chart
below for water purity requirements) to achieve the required protection from freezing.
Note: The maximum percentage of propylene glycol should never exceed 50%.
Temperature
Freezing Point of Propylene Glycol Solution
°C
°F
4
40
-1
30
-7
20
-12
10
-18
0
-23
-10
-29
-20
-34
-30
-40
-40
-46
-50
-51
-60
-57
-70
Hypertherm pre-mix
(028872)
Maximum glycol percentage
0
10
20
30
40
50
60
% of Propylene Glycol
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MAXPRO200 Instruction Manual 807700 Revision 1
Installation
Custom Coolant mix for hot operating temperatures (above 38° C / 100° F)
Treated water (with no propylene glycol) can only be used as coolant when operating temperatures are never below 0° C
(32° F). For operations in very warm temperatures, treated water will provide the best cooling properties.
Treated water refers to a mixture of purified water, that meets the specifications below, and 1 part benzotriazole (BZT) to
300 parts of water. BZT (128020) acts as a corrosion inhibitor for the copper based coolant system contained in the
plasma system.
Water purity requirements
It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or
cooling system.
Always use water that meets the minimum and maximum specifications in the table below when using a custom coolant
mix.
Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will
alter the water flow and produce an unstable arc.
Water that does not meet the maximum purity specifications below can also cause problems. Deionized water that is too
pure will cause leaching problems with the coolant system plumbing.
Use water purified by any method (deionization, reverse osmosis, sand filters, water softeners, etc.) as long as the water
purity meets the specifications in the table below. Contact a water specialist for advice in choosing a water filtration
system.
Water purity measurement method
Water purity
Pure water (for reference
only)
Conductivity
μS/cm
at 25° C (77° F)
Resistivity
mΩ-cm
at 25° C (77° F)
Dissolved solids
(ppm of NaCl)
Grains per gallon
(gpg of CaCO2)
0.055
18.3
0
0
Maximum purity
0.5
2
0.206
0.010
Minimum purity
18
0.054
8.5
0.43
1000
0.001
495
25
Maximum potable water
(for reference only)
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Installation
Fill the power supply with coolant
The system will take 14.2 liters to 17.0 liters (3.75 to 4.5 gallons) of coolant depending on the length of the torch leads.
1. Add coolant to the power supply until the tank is full.
2. Turn ON the power supply, then press and
release the amps selector knob as many times as
needed until the flow symbol is selected. The flow
rate will be shown in the three digit display. There
is a 45 second delay before the system will report
a low coolant flow error. If the flow rate has not
reached 1.9 liters per minute (lpm) (0.5 gallons
per minute [gpm]) the system will turn off the
pump.
3. If the system displays an error, turn OFF the power to the
system and add coolant to the tank until it is full again.
Repeat steps 2 and 3 until no error is displayed.
4. Add coolant to the power supply until the tank is
full and replace the filler cap.
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Connect the supply gases
Air/air cutting
Note: Verify that the plasma gas line and the shield gas line are properly connected before connecting the air
supply hose and supplying pressurized gas to the system.
Connect the air supply hose to the filter regulator as shown below.
N2/N2 supply gas connection
1. Disconnect the air supply hose from the filter regulator.
2. Remove the Air fitting 015012 (1/4 inch NPT X #6 MALE) from the filter/regulator.
a.
Install an 015103 adaptor to use the nitrogen supply gas hose offered by Hypertherm.
b.
Use the 1/4 inch NPT Female port from which the air fitting was removed to connect a user supplied N2 supply
gas hose.
3. Set the gas pressure regulators. See Setting the supply gas regulators on page 71.
O2/Air Supply gas hook up
1. Disconnect the air supply from the system.
2. Remove the plasma supply tube from filter/regulator output port.
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Installation
3. Use the supplied plug to block the open plasma outlet port of the filter/regulator.
4. Connect only filtered and regulated oxygen to the plasma gas Inlet. See Gas regulators on page 72 for a suitable
oxygen regulator.
Note: An oxygen fitting kit (428054) with the parts described below is available from Hypertherm.
There are several options for connecting the oxygen supply gas line:
a.
Remove the 015811 fitting and put on an 015009 fitting (user must order the part. See the note above). Use the
correct Hypertherm supply gas tubing (046231) to connect to the fitting.
015811
68
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Installation
b.
Use a suitable O2 fitting to connect to the 8 mm (5/16 inch) tubing that you removed from the plasma gas Inlet.
c.
Remove the plasma gas tubing and 8 mm (5/16 inch) fitting (015811) and connect to the 1/4 inch NPT female
threads.
015811
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Installation
d.
Remove the bushing and fitting to connect to 1/4 inch “G” female threads.
015810
and
and
051811
5. Reconnect the air supply.
6. Set the gas pressure regulators. See Setting the supply gas regulators on page 71.
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Gas requirements
The system is configured for air/air cutting when it is shipped. Connect an air supply to the filter/regulator that is mounted
on the rear panel of the power supply. If cutting with O2/air or N2/N2 you will have to make changes to the gas
connections. See Connect the supply gases on page 67.
CAUTION!
Gas supply pressures not within the specifications in Section 2 can cause poor cut quality, poor
consumable life, and operational problems.
If the purity level of the gas is too low, or if there are leaks in the supply hoses or connections:
•
Cut speeds can decrease
•
Cut quality can deteriorate
•
Cutting thickness capability can decrease
•
Parts life can shorten
Setting the supply gas regulators
1. Turn OFF the power to the system. Set all the supply gas regulator pressures to 6.2 bar (90 psi).
2. Turn ON the power to the system.
3. After the purge cycle is complete, press the current selection knob to get to the test mode. When the test mode icon
is illuminated, turn the knob to get to test 005, “Flow gas at full pressure”. Set all supply regulators to a system inlet
pressure of 6.2 bar (90 psi).
4. Press and release the current selection knob until the amps icon is illuminated.
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Installation
Gas regulators
Note: A separate gas regulator is needed only when cutting with oxygen.
Use a high-quality, 1-stage, gas regulator to maintain consistent gas supply pressure, if using liquid cryogenic or bulk
storage. Use a high-quality, 2-stage, gas regulator to maintain consistent gas supply pressure from high pressure gas
cylinders.
The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association
(CGA) specifications. In other countries, select gas regulators that conform to national or local codes.
2-stage regulator
1-stage regulator
Part number
Description
128544
Kit: Oxygen 2-stage regulator*
128548
Kit: Oxygen 1-stage regulator (for use with cryogenic liquid nitrogen or oxygen)
022037
2-stage oxygen regulator
* Kit includes the 2-stage regulator (022037) and the appropriate fittings
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Installation
Supply gas plumbing
•
Rigid copper plumbing or suitable flexible hose may be used for all gas supplies.
•
Do not use steel, black iron, or aluminum pipe.
•
After installation, pressurize the entire system and check for leaks.
•
Recommended hose diameters are 9.5 mm (3/8 in) for lengths < 23 m (75 ft) and 12.5 mm (1/2 in) for
lengths > 23 m (75 ft).
For flexible-hose systems, use a hose designed for inert gas to carry air or nitrogen. See Supply gas hoses on page 74
for part numbers.
Caution: Never use teflon tape
Caution: When connecting oxygen to the power supply, make sure that
all hoses, hose connections, and fittings are acceptable for use with
oxygen. Installation must be made in accordance with national
and local codes.
Note: When cutting with oxygen as the plasma gas, air must also be connected to the filter regulator.
WARNING!
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION
Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched
atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation
system be installed when cutting with oxygen.
Flashback arrestors are required (unless not available for specific gases or required pressures) to
prevent fire from propagating back to supply gas.
MAXPRO200 Instruction Manual 807700 Revision 1
73
Installation
Supply gas hoses
Caution: Never use teflon tape
4 Air
Part number
Length
Part number
Length
024671
3 m (10 ft)
024740
25 m (82 ft)
024658
4.5 m (15 ft)
024744
35 m (115 ft)
024659
7.5 m (25 ft)
024678
45 m (150 ft)
024765
10 m (35 ft)
024680
60 m (200 ft)
024660
15 m (50 ft)
024767
75 m (250 ft)
024766
20 m (65 ft)
5 Oxygen
Part number
Length
Part number
Length
024607
3 m (10 ft)
024738
25 m (82 ft)
024204
4.5 m (15 ft)
024450
35 m (115 ft)
024205
7.5 m (25 ft)
024159
45 m (150 ft)
024760
10 m (35 ft)
024333
60 m (200 ft)
024155
15 m (50 ft)
024762
75 m (250 ft)
024761
20 m (65 ft)
Part number
Length
6 Nitrogen
Part number
Length
024210
3 m (10 ft)
024739
25 m (82 ft)
024203
4.5 m (15 ft)
024451
35 m (115 ft)
024134
7.5 m (25 ft)
024120
45 m (150 ft)
024211
10 m (35 ft)
024124
60 m (200 ft)
024112
15 m (50 ft)
024764
75 m (250 ft)
024763
20 m (65 ft)
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Daily start-up
Before turning on the power to the system make sure that the cutting environment and clothing worn by users in that
environment meet all the safety requirements outlined in Safety on page 9.
DANGER!
ELECTRIC SHOCK CAN KILL
Before operating this system, you must read the safety section thoroughly. Turn OFF the power
supply’s main disconnect switch before proceeding with the following steps.
1. Turn OFF the main disconnect switch to the power supply.
2. Remove the consumables from the torch and check for worn or damaged parts. Always place the consumables
on a clean, dry, oil-free surface after removing. Dirty consumables can cause the torch to malfunction
and can shorten the life of the coolant pump.
•
See Install and inspect consumables on page 90 for details.
•
Refer to Cut charts to choose the correct consumables for your cutting needs.
3. Replace consumable parts. See Install and inspect consumables on page 90 for details.
4. Make sure that the torch is perpendicular to the workpiece.
2
1
1
3
4
5
6
Shield
4
Swirl ring
2
Nozzle retaining cap
5
Electrode
3
Nozzle
6
Torch main body (quick-disconnect torch shown)
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Operation
Controls and indicators
1
2
3
4
5
6
7
Control panel descriptions
1
Power switch
2
3-digit display area
3
Current selection knob
4
2-digit plasma display area
5
Plasma gas knob
6
2-digit shield display area
7
Shield gas knob
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Power supply operation
General
•
The system runs a number of tests automatically when the system is turned ON. See Automatic
chopper and current sensor tests during power-up on page 152.
•
There is power to the control board and other non-high power components when the main disconnect
switch is on, even if the switch on the Power Supply is off. The switch is illuminated to indicate that
there is power to the system. Non-high power components include the low power control circuitry in
the chopper, but not the high-power IGBTs which are switched by the contactor.
•
The 3-digit display counts from 1 to 6 to indicate the 6 second purge that occurs when you turn ON
the power supply (you will only actually see 1 thru 5). If the system is powered up with the start signal
on, the 3-digit display will continue to count up.
•
When you turn ON the power to the system the displays shows the last process used.
•
The user can lock out all inputs (current, plasma gas, and shield gas) to the system by pressing and
holding both the amps and shield gas control knobs until LOC appears in the 3-digit display. The same
process unlocks the system and ULC appears in the 3-digit display. The user can still cycle through the
functions in the 3-digit display area (current, fault, coolant flow, and test).
•
All three displays show actual values during cutting. The user can make changes to the current, the
plasma gas, and the shield gas settings unless the inputs have been locked out or the system is being
controlled remotely. The displays show the set values when idle.
•
A blinking red dot appears in the bottom right corner of each display when the parameters have been
changed from the default setting.
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Operation
3-digit display functions
Turn the current selection knob to increase or decrease the amperage. Push and release the current selection knob to
move from one function to the next.
3-digit display icons
1
Name
Description
1 Remote
The remote icon illuminates when there is serial communication with
the power supply. You can still cycle through the functions but cut
parameters can only be changed through the CNC.
2 Amps
Increase or decrease the amperage by selecting the amps icon and
turning the knob. The current increases or decreases in 1 amp
increments when you turn the knob slowly. You can jump from one
process amperage to another when you turn the knob quickly.
2
3
4
5
6
7
The fault icon illuminates when an error occurs.
If the error code number is 60 or less, press the current selection
knob to navigate to the illuminated fault icon. When the fault icon is
selected the error code appears in the 3-digit display.
3 Fault
If the error code is 60 or greater the system automatically selects the
fault icon and the error code number flashes in the 3-digit display.
Press and hold the current selection knob to see the power supply
status number for both types of error code.
78
4 Coolant flow
When the coolant flow icon is selected the display shows the coolant
flow in gallons per minute. When you turn ON the power to the
system and select the coolant flow icon before the power supply
finishes the purge count, the flow switch is overridden and coolant
will continue to flow for 30 seconds.
5 Test
When test icon is selected the system is in test mode. A number of
functions can be accessed by turning the current selection knob. See
the maintenance section for detailed information.
6 Plasma start lamp
This white lamp illuminates when the plasma start signal is given and
stays illuminated until the start signal is removed.
7 Arc transfer lamp
This green lamp illuminates when the arc transfers to the workpiece.
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Choosing a cutting process
1. Use the current selection knob to set the amperage. Turning the knob slowly increases or decreases the current
1 amp at a time. Turning the knob fast lets you jump quickly to the next process current (50A, 130A, and 200A).
A blinking red dot appears in the bottom right corner of each display when the parameters have been changed from
the default setting. You can return to the default setting by pressing and releasing the knob until you return to the
original selection.
2. Push and release the plasma gas knob to cycle through the plasma gas selections. The pressure will automatically be
set when you choose a gas. Turning the knob increases or decreases the pressure. A blinking red dot appears in the
bottom right corner of each display when the parameters have been changed from the default setting. You can return
to the default setting by pressing and releasing the knob until you return to the original gas selection.
3. The shield gas pressure is set automatically when you choose a plasma gas. Turning the knob increases or decreases
the pressure. A blinking red dot appears in the bottom right corner of each display when the parameters have been
changed from the default setting. You can return to the default setting by pressing and releasing the knob until you
return to the original gas selection.
Note: The example shown below is the 50 amp, mild steel, air/air process. See the cut chart for details.
3
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79
Operation
CAUTION!
SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the
torch, sparks and hot metal will spray out from the nozzle. Point the torch away
from yourself and others. Always use the proper protective equipment. See
Safety on page 9 for more information.
Handheld cutting
Specifications
Materials
Mild steel, stainless steel, and aluminum
Current
50A, 130A, and 200A
Plasma gas types
Air, O2, N2
Shield gas types
Air, N2
Torch weight (without lead)
See Specifications on page 33
Consumable selection and gas settings
Refer to Cutting parameters on page 86 for consumable and process information.
Starting a cut
1. Start cutting from the edge of the workpiece (see figure below) unless you must pierce. For the best results, the
nozzle orifice should overlap the edge of the workpiece about halfway, and the torch (arc) axis should be
perpendicular to the cut surface.
Note: 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.
2. Hold the torch lightly on the metal or just off the metal and drag the torch across the metal. The arc transfers once the
torch is within 6 mm (1/4 inch) of the workpiece.
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Operation
3. Pull the torch through the cut. Pulling it is easier than pushing it.
4. Hold the torch so the arc is vertical and watch the arc as it cuts along the line (see figure below). By lightly dragging
the shield on the workpiece, you can maintain a steady cut. For straight-line cuts, use any straight edge as a guide.
Piercing
1. Start by holding the torch so that the shield is approximately 1.5 mm (1/16 inch) away from the workpiece before
squeezing the trigger switch. This method maximizes the life of the consumables. See figures below.
2. Hold the torch at about a 45º angle to the workpiece pointing away from yourself, then slowly roll it to a vertical
position. This is particularly important when cutting thicker material. Make sure that the torch is pointed away from
you and the people around you to avoid any danger from sparks and hot metal. Starting the pierce at an angle
permits the hot metal to escape to one side rather than splashing back against the shield, protecting the operator
from the sparks and extending the life of the shield.
3. When the pierce is complete, proceed with the cut.
1
2
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81
Operation
Gouging
Specifications
Materials
Mild steel, stainless steel, and aluminum
Current
200 Amps
Plasma gas types
Air, O2
Shield gas types
Air
Torch weight (without lead)
See the Specification section
Gouging safety
When gouging, it is absolutely necessary to wear full protection:
•
A welding helmet with at least a #12 glass
•
Welding gloves and a welding jacket.
•
A heat shield (127389) can be purchased for further protection.
Gouge a workpiece
Note: To choose the correct consumables see Hand held
cutting and gouging consumable selection on page 87.
1. Hold the torch so that the torch tip is within 1.5 mm
(1/16 inch) from the workpiece before firing the torch.
2. Hold the torch at a 45° angle to the workpiece with a small
gap between the torch tip and the workpiece. Press the
trigger to obtain a pilot arc. Transfer the arc to the work piece.
3. Maintain an approximate 45° angle to the workpiece as you
feed into the gouge. Push the plasma arc in the direction of
the gouge you want to create. Keep a small distance between
the torch tip and the molten metal to avoid reducing
consumable life or damaging the torch.
Note: Changing the torch’s angle changes the dimensions of
the gouge.
Feeding into the gouge
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Gouging techniques
Straight gouging
Straight gouge
Weaving gouge
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83
Operation
Side gouging
Side gouge
Weaving gouge
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Gouge profiles and metal removal rates
1
2
3
Operating parameters
1
Speed
635 to 1270 mm/minute (25 to 50 ipm)
2
Angle
35 to 45 degrees
3
Standoff
12.7 to 19.0 mm (0.5 to 0.75 inches)
Maximum arc stretch
76 mm (3 inches)*
*For infrequent use, not 100% duty cycle
Typical gouge profile for 200A, air
Metal removal rate on mild steel – 18.7 Kg/hr (41.2 lbs/hr)
Speed
1270 mm/min (50 ipm)
Stand off
12.7 mm (0.5 inch)
Angle
35º
5
4
4
10.7 mm (0.42 inches)
5
4.4 mm (0.18 inches)
Typical gouge profile for 200A, O2
Metal removal rate on mild steel – 20.5 Kg/hr (45 lbs/hr)
Speed
1270 mm/min (50 ipm)
Stand off
12.7 mm (0.5 inch)
Angle
35º
6
6
10.4 mm (0.41 inches)
7
5.4 mm (0.21 inches)
7
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85
Operation
Varying the gouge profile
You can vary the gouge profile and the metal removal rate by varying the speed of the torch over the workpiece, varying
the distance between the torch and the workpiece, varying the angle of the torch to the workpiece, and varying the
current output of the power supply.
The following actions have the stated effects on the gouge profile:
•
Increasing the speed of the torch will decrease width and decrease depth.
•
Decreasing the speed of the torch will increase width and increase depth.
•
Increasing the standoff of the torch will increase width and decrease depth.
•
Decreasing the standoff of the torch will decrease width and increase depth.
•
Increasing the angle of the torch (more vertical) will decrease width and increase depth.
•
Decreasing the angle of the torch (less vertical) will increase width and decrease depth.
•
Increasing the current of the power supply will increase width and increase depth.
•
Decreasing the current of the power supply will decrease width and decrease depth.
Cutting parameters
The cut charts for the MAXPRO200 show the consumable parts, cutting speeds, and the gas and torch settings required
for each process, allowing for differences in the lead length. These parameters are used for cutting with both mechanized
and handheld torches, the consumable part numbers listed with each cut chart are specific to mechanized torches. Refer
to Hand held torch consumables below for the consumables to use with handheld torches.
The cut chart values in this document are recommended to provide high quality cuts with minimal dross. Because of
differences between installations and material composition, adjustments may be required to obtain desired results.
Mechanized consumables
The consumable part numbers listed above each cut chart are specific to mechanized torches.
Hand held torch consumables
The following sets of consumables are intended to be used with handheld torches for cutting mild steel, stainless steel,
and aluminum. Use the cutting parameters detailed in the Cut charts for cutting with the MAXPRO200 handheld torches.
Use the following consumables for each process.
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Hand held cutting and gouging consumable selection
The following sets of consumables are intended to be used with handheld torches for cutting mild steel, stainless steel,
and aluminum. You can use the cutting parameters detailed under Cut charts on page 101 with the MAXPRO200
handheld torches as long as you use the following consumables for each process.
Note: consumable part numbers listed above each cut chart are specific to mechanized torches.
Mild steel
50 A
Air Plasma
Air Shield
420063
220935
220890
220529
220528
420063
220935
220891
220529
220528
420061
220935
220892
220488
220487
420062
220935
220893
220488
220487
420058
220935
420044
420059
220935
420067
220935
420067
220935
50 A
O2 Plasma
Air Shield
130 A
Air Plasma
Air Shield
130 A
O2 Plasma
Air Shield
200 A
Air Plasma
Air Shield
220488
220937
220831
220834
220937
420066
220488
220937
220834
220937
200 A
O2 Plasma
Air Shield
200 A Gouging
Air Plasma
Air Shield
200 A Gouging
O2 Plasma
Air Shield
MAXPRO200 Instruction Manual 807700 Revision 1
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87
Operation
Stainless steel
50 A
Air Plasma
Air Shield
420063
220935
220890
220529
220528
420061
220935
220892
220488
220487
420061
220935
220892
220488
020415
130 A
Air Plasma
Air Shield
130 A
N2 Plasma
N2 Shield
200 A
Air Plasma
Air Shield
420058
220935
420044
420058
220935
420044
220488
220937
200 A
N2 Plasma
N2 Shield
220488
020415
220488
220937
200 A Gouging
Air Plasma
Air Shield
420067
88
220935
420066
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Aluminum
50 A
Air Plasma
Air Shield
420063
220935
220890
220529
220528
420061
220935
220892
220488
220487
420061
220935
220892
220488
020415
130 A
Air Plasma
Air Shield
130 A
N2 Plasma
N2 Shield
200 A
Air Plasma
Air Shield
420058
220935
420044
420058
220935
420044
220488
220937
200 A
N2 Plasma
N2 Shield
220488
020415
220488
220937
200 A Gouging
Air Plasma
Air Shield
420067
220935
MAXPRO200 Instruction Manual 807700 Revision 1
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89
Operation
Install and inspect consumables
WARNING!
Always disconnect power to the power supply before inspecting or changing torch consumable parts.
Use gloves when removing consumables. The torch might be hot.
Install consumables
Check the consumable parts daily for wear before cutting. See Inspect consumables on page 91. Before removing
consumables, bring the torch to the edge of the cutting table, with the torch lifter raised to its highest point to prevent the
consumables from dropping into the water of the water table.
Do not overtighten parts! Only tighten until mating parts are seated.
Apply a thin film of silicone lubricant on each o-ring. The o-ring
should look shiny, but there should not be any excess or built-up
lubricant.
Wipe the internal and external surfaces of the
torch with a clean cloth or paper towel.
Tool: 104119
1. Install the
electrode into
the torch head
90
2. Install the swirl
ring into the
nozzle
3. Install the
nozzle and swirl
ring into the
nozzle retaining
cap
4. Install the
nozzle retaining
cap onto the
torch head
5. Install the
shield onto the
nozzle retaining
cap
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Inspect consumables
Inspect
Shield
Look for
General:
Action
Erosion or missing material
Molten material attached
Blocked gas holes
Replace the shield
Replace the shield
Replace the shield
Center hole:
Must be round
Nozzle retaining cap
Replace the shield when the center hole is no longer round
General:
Erosion or missing material
Cracks
Burn marks
Nozzle
General:
Always replace the nozzle and
the electrode as a set
Erosion or missing material
Blocked gas holes
Replace the nozzle retaining cap
Replace the nozzle retaining cap
Replace the nozzle retaining cap
Replace the nozzle
Replace the nozzle
Center hole:
Must be round
Signs of arcing
Replace the nozzle when the center hole is no longer round
Replace the nozzle
O-rings:
Damage
Lubricant
Swirl ring
Replace the o-ring
Apply a thin film of silicone lubricant if the o-rings are dry
General:
Damage
Dirt or debris
Blocked gas holes
Replace the swirl ring
Clean and inspect for damage, and replace if damaged
Replace the swirl ring
O-rings:
Damage
Lubricant
Electrode
Center surface:
Always replace the nozzle and
the electrode as a set
Emitter
Emitter wear – a pit forms as
the emitter wears
Replace the o-ring
Apply a thin film of silicone lubricant if the o-rings are dry
In general, replace the electrode when the pit depth is
1 mm (0.04 in.) or greater.
O-rings:
Damage
Lubricant
MAXPRO200 Instruction Manual 807700 Revision 1
Replace the o-ring
Apply a thin film of silicone lubricant if the o-rings are dry
91
Operation
Torch maintenance
Poor cut quality and premature failure may occur if the torch is not maintained properly.
The torch is manufactured to very tight tolerances to maximize cut quality. The torch should not be subjected to hard
impacts that can cause critical features to become misaligned.
The torch should be stored in a clean location when not in use, to avoid contamination of critical surfaces and passages.
Routine maintenance
The following steps should be completed each time consumables are changed:
O-rings (2)
1. Use a clean cloth to wipe off the torch inside and outside. A cotton swab can be used
to access hard-to-reach internal surfaces.
2. Use compressed air to blow away any remaining dirt and debris from internal and
external surfaces.
3. Apply a thin film of silicone lubricant on each external o-ring. The o-rings should look
shiny, but there should not be any excess or built-up lubricant.
4. If consumables will be reused, use a clean cloth to wipe them off, and use compressed
air to blow them off before they are installed again. This is especially critical for the nozzle retaining cap.
Quick-disconnect maintenance
The following steps should be completed every 5–10
times consumables are changed:
O-rings
1. Remove the torch from the quick-disconnect
assembly.
2. Use compressed air to blow off all internal surfaces
and the external threads.
3. Use compressed air to blow off all internal surfaces
at the rear of the torch.
4. Inspect each of the 4 o-rings at the rear of the torch
and the o-ring on the quick-disconnect receptacle
for damage. Replace any damaged o-rings. If they
are not damaged, apply a thin film of silicone
lubricant on each o-ring. The o-rings should look
shiny, but there should not be any excess or built-up
lubricant.
External
threads
Rear view of torch
Maintenance kit
Even with proper care, the o-rings at the rear of the torch will need to be replaced periodically. Hypertherm provides a
quick-disconnect torch maintenance kit (228780) with replacement parts. The kit should be kept in stock and be used as
part of your routine maintenance schedule. The straight torch and the hand torches only have two replaceable o-rings.
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Torch connections
Quick-disconnect torch
1
1
2
2
3
5
3
4
4
Torch main body
1
5
Quick-disconnect receptacle
Shield gas
2
Pilot arc
3
Coolant return
4
Plasma gas
5
Coolant supply
Straight torch
2
1
4
1
Plasma gas
2
Coolant supply (also contains the negative lead)
3
Shield gas (also contains the pilot arc lead)
4
Coolant return
MAXPRO200 Instruction Manual 807700 Revision 1
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93
Operation
Replace the torch water tube
WARNING!
DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE. Always disconnect power to the
power supply before inspecting or changing torch consumable parts. Use gloves when removing
consumables. The torch might be hot.
Note: The water tube may seem loose when correctly inserted, but any side-to-side looseness will disappear after
the electrode is installed.
1. Turn OFF all power to the system.
2. Remove consumables from torch. See Install and inspect consumables on
page 90.
3. Remove the old water tube.
4. Apply a thin film of silicone lubricant on the o-ring, and install a new water
tube. The o-ring should look shiny, but there should not be any excess or
built-up lubricant.
5. Replace consumables. See Install and inspect consumables on page 90.
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Operation
Common cutting faults
Machine torch
•
•
•
•
•
Torch pilot arc will initiate, but will not transfer. Causes can be:
•
Work cable connection on the cutting table is not making good contact.
•
Malfunction in the system. See the Troubleshooting table on page 129 in the Maintenance section of this
manual.
•
Torch-to-work distance is too high.
The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece.
Causes can be:
•
Current is set too low (check cut chart information).
•
Cut speed or cut height is too high (check cut chart information).
•
Torch parts are worn or incorrect (see Install and inspect consumables on page 90).
•
Metal being cut is too thick.
Dross forms on the bottom of the cut. Causes can be:
•
Cutting speed is not correct (check cut chart information).
•
Arc current is set too low (check cut chart information).
•
Torch parts are worn or incorrect (see Install and inspect consumables on page 90).
Cut angle is not square. Causes can be:
•
Wrong direction of machine travel. High-quality side is on the right with respect to the forward motion of the
torch.
•
Torch-to-work distance is not correct (check cut chart information).
•
Cutting speed is not correct (check cut chart information).
•
Arc current is not correct (check cut chart information).
•
Damaged or worn consumable parts (see Install and inspect consumables on page 90).
Short consumable life. Causes can be:
•
Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as specified in
the Cut charts.
•
Attempting to cut highly magnetic metal plate, such as armor plate with a high nickel content, will shorten
consumable life. Long consumable life is difficult to achieve when cutting plate that is magnetized or becomes
magnetized easily.
•
Beginning or ending the cut beyond the plate surface. This draws the arc sideways and can damage the nozzle
or shield. To achieve consumable long life, all cuts must begin and end on the plate surface.
Hand torch
•
The torch does not cut completely through the workpiece. The causes can be:
•
The cut speed is too fast.
•
The consumables are worn.
•
The metal being cut is too thick for the selected amperage.
•
Gouging consumables are installed instead of drag-cutting consumables.
•
The work clamp is not attached properly to the workpiece.
•
The gas pressure or gas flow rate is too low.
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Operation
•
•
Cut quality is poor. The causes can be:
•
The metal being cut is too thick for the amperage.
•
The wrong consumables are being used (gouging consumables are installed instead of drag-cutting
consumables, for example).
•
Moving the torch too quickly or too slowly.
The arc sputters and consumables life is shorter than expected. The cause can be:
•
Moisture in the gas supply.
•
Incorrect gas pressure.
•
Consumables incorrectly installed.
Optimizing cut quality
The following tips and procedures will help produce square, straight, smooth, and dross-free cuts.
Tips for table and torch
•
Use a square to align the torch at right angles to the workpiece.
•
The torch may travel more smoothly if you clean, check, and
tune motion on the rails and drive system of the cutting table.
Unsteady machine motion can cause a regular, wavy pattern on
the cut surface.
•
The torch must not touch the workpiece during cutting. Contact
can damage the shield and nozzle, and affect the cut surface.
Plasma setup tips
Follow carefully each step in the Daily Start-up procedure described earlier in this section.
Purge the gas lines before cutting.
Maximize the life of consumable parts
Hypertherm’s LongLife® process automatically increases the gas and current flow at the start of each cut and decreases
them at the end to minimize erosion of the electrode’s center surface. The LongLife process also requires that cuts start
and stop on the workpiece.
•
•
The torch should never fire into the air.
•
Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air.
•
To start with a pierce, use a pierce height that is 1.5 to 2 times the cut height. Refer to the cut chart for your
process for more information.
Each cut should end with the arc still attached to the workpiece to avoid arc blow-outs (ramp-down
errors).
•
•
96
When cutting small parts that drop down after being cut from the workpiece, check that the arc remains attached
to the edge of the workpiece for proper ramp-down.
If arc blow-outs occur, try one or more of the following:
•
Reduce the cutting speed during the final part of the cut.
•
Stop the arc before the part is completely cut to allow completion of the cut during the ramp-down.
•
Program the path of the torch into the scrap area for ramp-down.
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Notes:
•
•
Program the path of the torch directly from one cut part into the next, without stopping and starting the
arc. However, do not allow the path to lead off the workpiece and back on.
It may be difficult to achieve the full benefits of the LongLife process in some conditions.
Additional factors of cut quality
Cut angle
•
A cut part whose 4 sides average less than 4° of cut angle is considered acceptable.
•
The squarest cut angle will be on the right side with respect to the forward motion of the torch.
•
To determine whether a cut-angle problem is being caused by the plasma system or the drive system:
•
a.
Make a test cut and measure the angle of each side.
b.
Rotate the torch 90° in its holder and repeat the process.
c.
If the angles are the same in both tests, the problem is in the drive system.
If a cut-angle problem persists after mechanical causes have been eliminated (see Tips for table and
torch), check the cut height, especially if cut angles are all positive or all negative.
•
A positive cut angle results when more material is removed from the top of the cut than from the bottom.
•
A negative cut angle results when more material is removed from the bottom of the cut.
Negative angle
Cause
Solution
The torch is too low.
Increase arc voltage to raise the torch
The torch is too high.
Decrease arc voltage to lower the torch.
Square
Positive angle
MAXPRO200 Instruction Manual 807700 Revision 1
97
Operation
Dross
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly
deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.
High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of solid
metal attached very closely to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce
high-speed dross:
•
Decrease the cutting speed.
•
Decrease arc voltage to decrease the torch-to-work distance.
Notes:
•
•
•
Dross is more likely to form on warm or hot metal than on cool metal. The first cut in a series of cuts will
likely produce the least dross. As the workpiece heats up, more dross may form during subsequent cuts.
Dross is more likely to form on mild steel than on stainless steel or aluminum.
Worn or damaged consumables may produce intermittent dross.
Straightness of the cut surface
A typical plasma cut surface is slightly concave.
The cut surface may become more concave, or convex. Correct torch height is required to keep the cut
surface acceptably close to straight.
A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc
voltage to increase the torch-to-work distance and straighten the cut surface.
A convex cut surface occurs when the cut height is too great or the cutting current is too high. First,
reduce the arc voltage, then reduce the cutting current. If there is overlap between different cutting
currents for that thickness, try the consumables designed for the lower current.
How to increase cutting speed
To increase cutting speed, you can decrease the torch-to-work distance. However, decreasing this distance will increase
the negative cut angle.
For mechanized applications the torch must not touch the workpiece while piercing or cutting.
For hand held applications the shield can be touching the workpiece to provide stability during cutting.
98
MAXPRO200 Instruction Manual 807700 Revision 1
MAXPRO200 Instruction Manual 807700 Revision 1
Estimated kerf-width compensation
The kerf widths in the following charts are for reference. Differences between installations and material composition may cause actual results to vary from
those shown in the tables.
Metric
Thickness (mm)
Mild steel
0.5
0.8
1
1.2
1.5
2
2.5
3
4
50A Air / Air
1.72
1.51
1.46
1.52
1.62
1.58
1.53
1.47
1.44
50A O2 / Air
1.36
1.35
1.36
1.37
1.39
1.41
1.42
5
6
8
10
12
15
20
25
32
2.45
2.48
2.68
3.08
3.46
3.98
38
44
50
1.57
1.44
1.51
1.52
130A Air / Air
2.08
2.21
2.38
130A O2 / Air
2.29
2.35
2.40
200A Air / Air
200A O2 / Air
2.56
2.63
2.92
3.45
3.82
4.33
4.78
2.68
2.90
2.98
2.95
3.12
3.53
3.98
4.20
4.37
5.02
5.69
2.55
2.95
3.11
3.04
3.13
3.44
3.96
4.60
5.15
5.77
6.40
10
12
15
20
25
32
38
44
50
Thickness (mm)
Stainless steel
50A Air / Air
0.5
0.8
1
1.2
1.5
2
2.5
3
4
1.45
1.71
1.77
1.68
1.56
1.52
1.50
1.55
1.66
5
130A Air / Air
130A N2 / N2
200A Air / Air
8
2.57
2.70
2.74
2.90
3.19
2.56
2.40
2.43
2.40
2.59
2.97
2.76
2.76
2.76
2.98
3.35
3.42
3.64
3.85
3.36
3.20
2.94
2.95
3.32
3.92
3.71
4.22
4.70
10
12
15
20
25
32
38
2.80
2.78
2.76
2.77
2.88
3.03
200A N2 / N2
6
1.71
4.67
Thickness (mm)
Aluminum
0.5
0.8
1
1.2
1.5
2
2.5
3
4
50A Air / Air
1.40
1.40
1.40
1.40
1.40
1.47
1.50
1.52
1.55
5
2.84
130A N2 / N2
200A N2 / N2
8
44
50
1.58
130A Air / Air
200A Air / Air
6
2.73
3.73
3.55
2.57
2.62
2.46
2.61
3.00
3.94
3.44
3.42
3.51
3.73
4.03
4.29
5.38
3.35
3.04
3.02
3.16
3.52
4.00
4.57
5.04
Operation
99
Thickness (inches)
Mild steel
0.018 0.020 0.024 0.030 0.036 0.048 0.060 0.075 0.105 0.125 0.135 3/16
50A Air / Air
0.069
0.065 0.061 0.056 0.060 0.064 0.063 0.059
0.056 0.058 0.063
1/4
50A O2 / Air
0.054
0.053 0.053 0.053 0.054 0.055 0.055 0.056
0.057 0.063 0.059
5/16
3/8
1/2
5/8
3/4
7/8
1
1-1/4 1-1/2 1-3/4
130A Air / Air
0.085 0.090 0.095
0.096 0.098 0.108 0.119
0.137 0.156
130A O2 / Air
0.092 0.093 0.095
0.100 0.105 0.119 0.133
0.151 0.170 0.188
2
200A Air / Air
0.111 0.114 0.118 0.116 0.126 0.135 0.147 0.158 0.165 0.172 0.200 0.227
200A O2 / Air
0.109
Stainless
steel
50A Air / Air
0.123 0.119 0.125 0.132 0.145 0.157 0.180 0.203 0.229 0.255
Thickness (inches)
.018
.020
0.056
.024
.030
.036
.048
.060
.075
.105
.125
.135
3/16
1/4
5/16
3/8
1/2
5/8
3/4
7/8
1
1-1/4 1-1/2 1-3/4
2
0.061 0.066 0.071 0.066 0.061 0.060 0.059 N/A 0.063 0.068 0.067
130A Air / Air
0.104
0.106 0.108 0.116 0.124
130A N2 / N2
0.101 0.093
0.096 0.094 0.105 0.116
200A Air / Air
0.119 0.105
0.109 0.109 0.120 0.131 0.135 0.134 0.143 0.152
200A N2 / N2
0.132 0.124
0.116 0.116 0.136 0.156 0.151 0.145 0.165 0.185
0.184
Thickness (inches)
Aluminum
50A Air / Air
.018
.020
.024
.030
.036
.048
.060
.075
.105
.125
0.055 0.055 0.055 0.055 0.055 0.055 0.055 0.055 0.061 0.061
.135
3/16
1/4
5/16
3/8
1/2
5/8
3/4
7/8
1
1-1/4 1-1/2 1-3/4
0.062 0.062
MAXPRO200 Instruction Manual 807700 Revision 1
130A Air / Air
0.112
0.110 0.109 0.109 0.108
130A N2 / N2
0.107 0.099
0.105 0.095 0.106 0.117
0.114
200A Air / Air
0.151 0.157
0.136 0.134 0.140 0.145 0.152 0.159 0.167 0.213
200A N2 / N2
0.140 0.130
0.120 0.119 0.127 0.135 0.147 0.159 0.179 0.199
2
Operation
100
English
Operation
Cut charts
The following cut charts for the MAXPRO200 show the consumable parts, cutting speeds, and the gas and torch
settings required for each process, allowing for differences in the lead length. While you can use these parameters for
cutting with both mechanized and handheld torches, the consumable part numbers listed with each cut chart are specific
to mechanized torches. Refer to Hand held cutting and gouging consumable selection on page 87 for the consumables
to use for handheld torches for each process.
The cut chart values in this document are recommended to provide high quality cuts with minimal dross. Because of
differences between installations and material composition, adjustments may be required to obtain desired results.
MAXPRO200 Instruction Manual 807700 Revision 1
101
Operation
Mild steel
Flow rates – lpm/scfh
Air Plasma / Air Shield
50 A Cutting
220532
220936* / 220935**
220890
Air (Plasma)
Air (Shield)
12/25
103/218
220529
220528
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
62
63
63
63
39
42
45
47
mm
Volts
mm
0.5
112
1.5
0.8
111
1.0
111
1.2
1.5
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
9400
3.0
200
0.0
1.5
8510
3.0
200
0.0
1.5
8050
3.0
200
0.1
110
1.8
7625
3.6
200
0.1
110
1.8
7370
3.6
200
0.1
2.0
110
1.8
6735
3.6
200
0.1
2.5
111
2.0
5080
4.0
200
0.2
3.0
111
2.0
3760
4.0
200
0.3
4.0
113
2.3
2415
4.6
200
0.4
6.0
118
2.5
1600
5.0
200
0.5
English
Plasma Cutflow
25 ft
Lead
62
50 ft
Lead
63
75 ft
Lead
63
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
63
25 ft
Lead
39
50 ft
Lead
42
75 ft
Lead
45
100 ft
Lead
47
in
Volts
in
0.018
112
0.024
112
0.030
Pierce Height
Pierce
Delay
ipm
in
Factor % Seconds
0.06
375
0.12
200
0.0
0.06
350
0.12
200
0.0
111
0.06
340
0.12
200
0.0
0.036
111
0.06
325
0.12
200
0.1
0.048
110
0.07
300
0.14
200
0.1
0.060
110
0.07
290
0.14
200
0.1
0.075
110
0.07
275
0.14
200
0.1
0.105
111
0.08
180
0.16
200
0.2
0.135
111
0.08
110
0.16
200
0.3
3/16
116
0.09
75
0.18
200
0.4
1/4
118
0.10
60
0.20
200
0.5
*with IHS tab / **without IHS tab
102
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Mild steel
Flow rates – lpm/scfh
O2 (Plasma)
Air (Shield)
12/25
73/155
O2 Plasma / Air Shield
50 A Cutting
220532
220936* / 220935**
220891
220529
220528
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead length.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
68
69
69
25
27
29
31
Pierce Height
Pierce
Delay
mm
Volts
mm
0.5
98
1.5
7550
3.0
200
0.0
0.8
96
1.5
7050
3.0
200
0.0
1.0
90
1.5
6775
3.0
200
0.1
1.2
94
1.5
6600
3.6
200
0.1
1.5
99
1.5
6150
3.6
200
0.1
2.0
99
1.5
5400
3.6
200
0.1
2.5
99
1.8
4300
4.0
200
0.2
3.0
99
1.8
3650
4.0
200
0.3
4.0
101
2.0
2800
4.6
200
0.4
6.0
103
2.5
1750
5.0
200
0.5
mm/min mm Factor % Seconds
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
68
75 ft
Lead
69
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
69
25 ft
Lead
25
50 ft
Lead
27
75 ft
Lead
29
100 ft
Lead
31
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
0.018
98
0.06
300
0.12
200
0.0
0.024
98
0.06
290
0.12
200
0.0
0.030
98
0.06
280
0.12
200
0.0
0.036
89
0.06
270
0.12
200
0.1
0.048
94
0.06
260
0.12
200
0.1
0.060
99
0.06
240
0.12
200
0.1
0.075
99
0.06
220
0.12
200
0.1
0.105
99
0.07
160
0.14
200
0.2
0.135
99
0.07
130
0.14
200
0.3
3/16
103
0.09
85
0.15
150
0.4
1/4
103
0.10
65
0.15
150
0.5
Factor % Seconds
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
103
Operation
Mild steel
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
33/70
68/145
Air Plasma / Air Shield
130 A Cutting
220536
220936* / 220935**
220892
220488
220487
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
69
70
71
22
24
26
28
Pierce Height
mm
Volts
mm
3.0
149
3.0
5350
6.0
4.0
147
3.0
4630
6.0
142
2.4
3865
10.0
152
4.1
12.0
154
15.0
155
20.0
25.0
32.0
Pierce
Delay
mm/min mm Factor % Seconds
200
0.1
6.0
200
0.2
7.2
300
0.3
2445
8.2
200
0.5
4.1
2045
8.2
200
0.5
4.4
1445
8.8
200
0.8
158
4.6
815
9.6
210
1.2
166
4.6
415
178
5.1
250
Edge start
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
69
75 ft
Lead
70
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
71
25 ft
Lead
22
50 ft
Lead
24
75 ft
Lead
26
100 ft
Lead
28
in
Volts
in
0.135
149
3/16
145
1/4
3/8
Pierce Height
Pierce
Delay
ipm
in
Factor % Seconds
0.12
220
0.24
200
0.1
0.12
160
0.24
200
0.2
141
0.10
150
0.28
300
0.3
151
0.16
100
0.32
200
0.5
1/2
154
0.16
75
0.32
200
0.5
5/8
155
0.18
50
0.36
200
0.8
3/4
156
0.18
35
0.38
210
1.2
1
167
0.18
15
1-1/4
178
0.20
10
Edge start
*with IHS tab / **without IHS tab
104
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Mild steel
Flow rates – lpm/scfh
O2 (Plasma)
Air (Shield)
20/42
86/183
O2 Plasma / Air Shield
130 A Cutting
220491
220936* / 220935**
220893
220488
220487
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
62
62
64
64
30
32
35
37
mm
Volts
mm
3.0
130
2.6
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
5900
5.2
200
0.1
4.0
131
2.7
5325
5.4
200
0.2
6.0
134
2.8
3925
5.6
200
0.3
10.0
136
3.0
2680
6.0
200
0.4
12.0
138
3.0
2200
6.0
200
0.5
15.0
140
3.6
1665
7.2
200
0.7
20.0
145
3.9
1195
7.8
200
1.0
25.0
151
4.1
685
32.0
158
4.6
515
38.0
163
4.6
310
Edge start
English
Plasma Cutflow
25 ft
Lead
62
50 ft
Lead
62
75 ft
Lead
64
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
64
25 ft
Lead
30
50 ft
Lead
32
75 ft
Lead
35
100 ft
Lead
37
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
0.135
130
0.10
240
0.20
200
0.1
3/16
132
0.11
190
0.22
200
0.2
1/4
134
0.11
150
0.22
200
0.3
3/8
136
0.12
110
0.24
200
0.3
1/2
138
0.12
80
0.24
200
0.5
5/8
141
0.15
60
0.30
200
0.7
3/4
144
0.15
50
0.30
200
1.0
1
151
0.16
25
1-1/4
158
0.18
20
1-1/2
163
0.18
12
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
105
Operation
Mild steel
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
32/68
123/260
Air Plasma / Air Shield
200 A Cutting
420045
220936* / 220935**
420044
220488
220937
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
52
54
55
56
48
50
54
58
mm
Volts
mm
6.0
147
1.0
8.0
148
10.0
151
12.0
153
15.0
158
20.0
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
4885
3.0
300
0.3
1.3
4515
3.9
300
0.5
3.0
3556
5.2
200
0.8
3.0
2794
6.0
200
0.9
4.3
2265
8.6
200
1.0
165
4.8
1415
9.6
200
1.4
25.0
172
6.4
940
12.8
200
1.7
32.0
176
6.4
630
12.8
200
2.3
38.0
179
6.4
510
44.0
189
6.4
320
50.0
199
6.4
215
Edge start
English
Plasma Cutflow
25 ft
Lead
52
50 ft
Lead
54
75 ft
Lead
55
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
56
25 ft
Lead
48
50 ft
Lead
50
75 ft
Lead
54
100 ft
Lead
58
in
Pierce Height
Pierce
Delay
Volts
in
ipm
in
Factor % Seconds
1/4
145
0.04
190
0.12
300
0.3
5/16
148
0.05
180
0.15
300
0.5
3/8
151
0.10
140
0.20
200
0.8
1/2
154
0.13
110
0.25
200
0.9
5/8
159
0.19
85
0.38
200
1.0
3/4
164
0.19
60
0.38
200
1.2
7/8
169
0.19
50
0.38
200
1.4
1
173
0.25
35
0.45
180
1.7
1-1/4
176
0.25
25
0.45
180
2.3
1-1/2
179
0.25
20
1-3/4
190
0.25
12
2
200
0.25
8
Edge start
*with IHS tab / **without IHS tab
106
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Mild steel
Flow rates – lpm/scfh
O2 (Plasma)
Air (Shield)
32/67
123/260
O2 Plasma / Air Shield
200 A Cutting
220832
220936* / 220935**
220831
220834
220937
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
69
70
71
48
50
54
58
Pierce Height
Pierce
Delay
mm
Volts
mm
6.0
146
1.5
6210
3.0
200
0.3
mm/min mm Factor % Seconds
8.0
150
3.4
4850
5.1
150
0.4
10.0
156
4.6
3735
6.9
150
0.4
12.0
154
3.8
3415
9.5
250
0.6
15.0
153
3.1
2845
7.8
250
0.7
20.0
154
3.0
1920
7.5
250
0.8
25.0
154
3.2
1430
8.0
250
1.0
32.0
161
3.1
805
7.8
250
1.3
38.0
168
4.4
570
44.0
175
4.4
395
50.0
180
4.4
270
Edge start
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
69
75 ft
Lead
70
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
71
25 ft
Lead
48
50 ft
Lead
50
75 ft
Lead
54
100 ft
Lead
58
in
Volts
in
1/4
143
3/8
157
1/2
5/8
Pierce Height
Pierce
Delay
ipm
in
Factor % Seconds
0.08
235
0.15
200
0.3
0.19
150
0.28
150
0.3
153
0.14
130
0.28
200
0.3
153
0.12
105
0.28
250
0.5
3/4
154
0.12
80
0.28
250
0.6
7/8
154
0.13
65
0.31
250
0.7
1
154
0.13
55
0.31
250
0.8
1-1/4
161
0.13
32
0.35
280
1.5
1-1/2
168
0.18
22
1-3/4
175
0.18
15
2
181
0.18
10
Edge start
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
107
Operation
Stainless steel
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
12/25
103/218
Air Plasma / Air Shield
50 A Cutting
220532
220936* / 220935**
220890
220529
220528
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
62
63
63
63
39
42
45
47
mm
Volts
mm
0.5
101
1.5
0.8
102
1.0
102
1.2
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
8000
3.0
200
0.0
1.6
7750
3.2
200
0.0
1.8
7115
3.6
200
0.1
103
1.8
6350
3.6
200
0.1
1.5
106
1.8
5335
3.6
200
0.1
2.0
108
2.0
4200
4.0
200
0.1
2.5
111
2.0
3300
4.0
200
0.2
3.0
112
2.0
2800
4.0
200
0.3
4.0
116
2.2
2300
4.4
200
0.4
6.0
123
2.5
1400
5.0
200
0.5
English
Plasma Cutflow
25 ft
Lead
62
50 ft
Lead
63
75 ft
Lead
63
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
63
25 ft
Lead
39
50 ft
Lead
42
75 ft
Lead
45
100 ft
Lead
47
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
0.018
101
0.06
300
0.12
200
0.0
0.024
101
0.06
275
0.12
200
0.0
0.030
102
0.06
265
0.12
200
0.0
0.036
102
0.06
250
0.12
200
0.1
0.048
103
0.07
225
0.14
200
0.1
0.060
106
0.07
190
0.14
200
0.1
Factor % Seconds
0.075
107
0.07
165
0.14
200
0.1
0.105
112
0.08
125
0.16
200
0.2
0.135
113
0.08
85
0.16
200
0.3
3/16
119
0.09
55
0.18
200
0.4
1/4
124
0.10
45
0.20
200
0.5
*with IHS tab / **without IHS tab
108
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Stainless steel
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
33/70
69/145
Air Plasma / Air Shield
130 A Cutting
220536
220936* / 220935**
220892
220488
220487
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
69
70
71
22
24
26
28
mm
Volts
mm
6.0
147
3.5
10.0
153
12.0
155
15.0
20.0
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
2625
7.0
200
0.3
4.1
1700
8.2
200
0.5
4.1
1380
8.2
200
0.8
160
4.4
900
170
4.6
430
Edge start
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
69
75 ft
Lead
70
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
71
25 ft
Lead
22
50 ft
Lead
24
75 ft
Lead
26
100 ft
Lead
28
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
1/4
148
0.14
100
0.28
200
0.3
3/8
152
0.16
70
0.32
200
0.5
1/2
156
0.16
50
0.32
200
0.8
5/8
162
0.18
30
3/4
168
0.18
20
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
109
Operation
Stainless steel
Flow rates – lpm/scfh
N2 (Plasma)
N2 (Shield)
32/68
104/218
N2 Plasma / N2 Shield
130 A Cutting
220536
220936* / 220935**
220892
220529
020415
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
69
70
71
36
39
42
44
Pierce Height
Pierce
Delay
mm
Volts
mm
5.0
148
3.0
3140
6.1
200
0.3
mm/min mm Factor % Seconds
6.0
151
3.0
2980
6.1
200
0.3
10.0
152
3.3
1830
6.6
200
0.5
12.0
154
3.3
1510
6.6
200
0.8
15.0
158
3.6
1120
20.0
166
3.8
470
Edge start
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
69
75 ft
Lead
70
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
71
25 ft
Lead
36
50 ft
Lead
39
75 ft
Lead
42
100 ft
Lead
44
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
3/16
149
0.12
125
0.24
200
0.3
1/4
151
0.12
115
0.24
200
0.3
3/8
152
0.13
75
0.26
200
0.5
1/2
154
0.13
55
0.26
200
0.8
5/8
159
0.14
40
3/4
165
0.15
25
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
110
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Stainless steel
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
32/68
123/260
Air Plasma / Air Shield
200 A Cutting
420045
220936* / 220935**
420044
220488
220937
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
52
54
55
56
48
50
54
58
mm
Volts
mm
4.0
148
2.7
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
5695
5.4
200
0.4
6.0
150
3.0
3105
6.0
200
0.4
10.0
150
3.2
2485
6.4
200
0.5
12.0
152
3.2
2245
6.4
200
0.8
15.0
157
3.8
1700
7.6
200
0.8
20.0
164
4.9
1155
9.8
200
1.0
25.0
168
5.6
670
11.8
210
1.6
32.0
174
5.6
515
38.0
180
5.6
310
50.0
188
5.6
203
Edge start
English
Plasma Cutflow
25 ft
Lead
52
50 ft
Lead
54
75 ft
Lead
55
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
56
25 ft
Lead
48
50 ft
Lead
50
75 ft
Lead
54
100 ft
Lead
58
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
3/16
149
0.11
240
0.22
200
0.4
1/4
150
0.12
210
0.24
200
0.4
3/8
150
0.13
170
0.25
200
0.5
1/2
153
0.13
120
0.25
200
0.8
5/8
159
0.16
85
0.32
200
0.8
3/4
163
0.19
60
0.38
200
1.0
7/8
166
0.21
50
0.42
200
1.4
0.45
210
1.6
1
168
0.22
40
1-1/4
174
0.22
20
1-1/2
180
0.22
12
2
188
0.22
8
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
111
Operation
Stainless steel
Flow rates – lpm/scfh
N2 (Plasma)
N2 (Shield)
37/79
107/225
N2 Plasma / N2 Shield
200 A Cutting
420045
220936* / 220935**
420044
220529
020415
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
69
70
71
72
42
45
48
51
Pierce Height
Pierce
Delay
mm
Volts
mm
5.0
156
3.2
4460
6.4
200
0.4
mm/min mm Factor % Seconds
6.0
159
3.2
3980
6.4
200
0.4
10.0
160
3.2
2900
6.4
200
0.5
12.0
162
3.2
2260
6.4
200
0.8
15.0
165
3.4
1760
7.9
230
0.9
20.0
172
4.2
1190
10.1
240
1.1
25.0
185
6.4
790
11.4
180
2.0
32.0
191
6.4
520
38.0
197
6.4
310
Edge start
English
Plasma Cutflow
25 ft
Lead
69
50 ft
Lead
70
75 ft
Lead
71
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
72
25 ft
Lead
42
50 ft
Lead
45
75 ft
Lead
48
100 ft
Lead
51
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
3/16
159
0.13
180
0.25
200
0.4
1/4
159
0.13
150
0.25
200
0.4
3/8
160
0.13
120
0.25
200
0.5
1/2
163
0.13
80
0.25
200
0.8
5/8
166
0.14
65
0.32
230
0.9
3/4
170
0.16
50
0.38
240
1.0
7/8
178
0.19
40
0.38
200
1.5
0.45
180
2.0
1
186
0.25
30
1-1/4
191
0.25
21
1-1/2
197
0.25
12
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
112
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Aluminum
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
12/25
104/218
Air Plasma / Air Shield
50 A Cutting
220532
220936* / 220935**
220890
220529
220528
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
62
63
63
63
39
42
45
47
mm
Volts
mm
0.5
112
1.5
0.8
113
1.0
114
1.2
1.5
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
8000
3.0
200
0.0
1.6
7750
3.2
200
0.0
1.8
7115
3.6
200
0.1
114
1.8
6350
3.6
200
0.1
115
1.8
5335
3.6
200
0.1
2.0
120
2.0
4200
4.0
200
0.1
2.5
123
2.0
3300
4.0
200
0.2
3.0
124
2.0
2800
4.0
200
0.3
4.0
125
2.2
2300
4.4
200
0.4
6.0
130
2.5
1400
5.0
200
0.5
English
Plasma Cutflow
25 ft
Lead
62
50 ft
Lead
63
75 ft
Lead
63
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
63
25 ft
Lead
39
50 ft
Lead
42
75 ft
Lead
45
100 ft
Lead
47
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
0.018
112
0.06
325
0.12
200
0.0
0.020
112
0.06
315
0.12
200
0.0
0.024
112
0.06
305
0.12
200
0.0
0.030
113
0.06
295
0.12
200
0.1
0.036
114
0.07
280
0.14
200
0.1
0.048
114
0.07
230
0.14
200
0.2
0.060
115
0.07
195
0.14
200
0.2
0.075
120
0.08
160
0.16
200
0.2
0.105
123
0.08
120
0.16
200
0.3
0.125
124
0.08
100
0.16
200
0.3
3/16
126
0.09
75
0.18
200
0.4
1/4
131
0.10
50
0.20
200
0.5
Factor % Seconds
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
113
Operation
Aluminum
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
33/70
69/145
Air Plasma / Air Shield
130 A Cutting
220536
220936* / 220935**
220892
220488
220487
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
69
70
71
22
24
26
28
mm
Volts
mm
6.0
156
2.8
10.0
161
12.0
163
15.0
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
2370
5.6
200
0.2
3.0
1470
6.0
200
0.3
3.0
1230
6.0
200
0.5
165
3.2
1050
6.4
200
0.8
20.0
169
3.6
725
7.9
220
1.3
25.0
175
4.0
525
Edge start
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
69
75 ft
Lead
70
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
71
25 ft
Lead
22
50 ft
Lead
24
75 ft
Lead
26
100 ft
Lead
28
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
1/4
156
0.11
90
0.22
200
0.2
3/8
160
0.12
60
0.24
200
0.3
1/2
164
0.12
45
0.24
200
0.5
5/8
166
0.13
40
0.26
200
0.8
3/4
168
0.14
30
0.31
220
1.3
1
176
0.16
20
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
114
MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Aluminum
Flow rates – lpm/scfh
N2 (Plasma)
N2 (Shield)
32/68
104/218
N2 Plasma / N2 Shield
130 A Cutting
220536
220936* / 220935**
220892
220529
020415
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
68
69
70
71
36
39
42
44
Pierce Height
Pierce
Delay
mm
Volts
mm
5.0
153
3.0
3140
6.1
200
0.2
mm/min mm Factor % Seconds
6.0
154
3.0
2980
6.1
200
0.2
10.0
158
3.3
1830
6.6
200
0.3
12.0
160
3.3
1510
6.6
200
0.5
15.0
162
3.6
1120
7.1
200
0.8
20.0
166
3.9
470
8.7
220
1.4
English
Plasma Cutflow
25 ft
Lead
68
50 ft
Lead
69
75 ft
Lead
70
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
71
25 ft
Lead
36
50 ft
Lead
39
75 ft
Lead
42
100 ft
Lead
44
in
Pierce Height
Pierce
Delay
Volts
in
ipm
in
Factor % Seconds
3/16
153
0.12
125
0.24
200
0.2
1/4
154
0.12
115
0.24
200
0.2
3/8
158
0.13
75
0.26
200
0.3
1/2
160
0.13
55
0.26
200
0.5
5/8
163
0.14
40
0.28
200
0.8
3/4
165
0.15
25
0.33
220
1.3
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
115
Operation
Aluminum
Flow rates – lpm/scfh
Air (Plasma)
Air (Shield)
32/68
123/260
Air Plasma / Air Shield
200 A Cutting
420045
220936* / 220935**
420044
220488
220937
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
52
54
55
56
48
50
54
58
mm
Volts
mm
4.0
150
2.2
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
6215
4.4
200
0.5
6.0
156
3.0
5195
6.0
200
0.5
10.0
156
3.3
3930
6.6
200
0.5
12.0
159
3.7
3370
7.4
200
0.5
15.0
163
4.0
2625
8.0
200
0.8
20.0
169
4.9
1625
9.8
200
1.0
25.0
177
5.6
1050
11.4
210
1.4
32.0
187
5.6
515
11.4
210
1.7
38.0
195
5.6
310
Edge start
English
Plasma Cutflow
25 ft
Lead
52
50 ft
Lead
54
75 ft
Lead
55
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
56
25 ft
Lead
48
50 ft
Lead
50
75 ft
Lead
54
100 ft
Lead
58
in
Volts
3/16
1/4
Pierce Height
Pierce
Delay
in
ipm
in
Factor % Seconds
150
0.10
230
0.20
200
0.5
158
0.13
200
0.25
200
0.5
3/8
155
0.13
160
0.25
200
0.5
1/2
160
0.15
125
0.30
200
0.5
5/8
164
0.16
95
0.32
200
0.8
3/4
168
0.19
70
0.38
200
1.0
7/8
173
0.21
50
0.42
200
1.2
1
178
0.22
40
0.45
210
1.4
1-1/4
187
0.22
20
0.45
210
1.7
1-1/2
195
0.22
12
Edge start
*with IHS tab / **without IHS tab
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MAXPRO200 Instruction Manual 807700 Revision 1
Operation
Aluminum
Flow rates – lpm/scfh
N2 (Plasma)
N2 (Shield)
37/79
107/225
N2 Plasma / N2 Shield
200 A Cutting
420045
220936* / 220935**
420044
220529
020415
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings may be needed for shorter lead lengths.
Metric
Plasma Cutflow
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead
69
70
71
72
42
45
48
51
mm
Volts
mm
5.0
164
3.2
Pierce Height
Pierce
Delay
mm/min mm Factor % Seconds
4770
6.4
200
0.5
6.0
165
3.2
4530
6.4
200
0.5
10.0
165
3.2
3930
6.4
200
0.5
12.0
164
3.2
3370
6.4
200
0.5
15.0
169
4.1
2620
8.1
200
0.8
20.0
179
5.1
1630
10.2
200
1.2
25.0
189
6.4
1050
32.0
198
6.4
500
38.0
206
6.4
310
Edge start
English
Plasma Cutflow
25 ft
Lead
69
50 ft
Lead
70
75 ft
Lead
71
Material
Arc
Cut Cutting
Thickness Voltage Height Speed
Shield Cutflow
100 ft
Lead
72
25 ft
Lead
42
50 ft
Lead
45
75 ft
Lead
48
100 ft
Lead
51
Pierce Height
Pierce
Delay
in
Volts
in
ipm
in
3/16
165
0.13
190
0.25
200
0.5
1/4
165
0.13
175
0.25
200
0.5
3/8
165
0.13
160
0.25
200
0.5
1/2
164
0.13
125
0.25
200
0.5
5/8
171
0.16
95
0.32
200
0.8
3/4
177
0.19
70
0.38
200
1.0
7/8
183
0.25
50
0.45
180
1.5
1
190
0.25
40
1-1/4
198
0.25
20
1-1/2
206
0.25
12
Factor % Seconds
Edge start
*with IHS tab / **without IHS tab
MAXPRO200 Instruction Manual 807700 Revision 1
117
Operation
118
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Introduction
Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level
electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge
of final isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.
CAUTION!
Use extreme care when working near the chopper modules. Each large electrolytic capacitor
(blue-cased cylinder) stores large amounts of electrical energy. Even if the power is off, dangerous
voltages may remain at the capacitor terminals, on the chopper, and the diode heatsinks. Never
discharge any capacitor with a screwdriver or other implement… explosion, property damage
and/or personal injury will result.
Preventive maintenance
For a complete list of preventive maintenance recommendations, see the Preventive Maintenance Master Schedule on
page 159. Contact the Technical Services department listed at the front of this manual with any questions regarding the
maintenance schedule or procedures.
MAXPRO200 Instruction Manual 807700 Revision 1
119
Maintenance
Power supply status
The status (state) of the power supply is shown in the three digit display. To view the power supply status, navigate to the
fault icon and press and hold the current selection knob until the status code appears.
Status code
number
120
Name
00
Power up
01
Initial checks
02
Gas purge
03
Ready for start
04
Preflow
05
Preflow hold
06
Ignite
07
Pilot arc
08
Rampup
09
Main arc
10
Rampdown
11
Rampdown complete
12
End of cycle
14
Shutdown
17
Standby
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Sequence of operation and power supply status
Power up (status 00)
1. Initialization of microprocessor hardware.
2. Initialization of power supply, gas system, and display.
3. System will display dots on the current display.
4. System will look for shield gas button press to indicate USB host firmware update.
5. System will stay in this state until the rocker switch is turned on.
Initial checks (status 01)
1. System will turn on the plasma gas channel at 100% flow and will measure the pressure. The system will use this
value as the inlet pressure. If the inlet is above or below the minimum, the system will generate error code 63.
2. System will read the torch ID jumpers, and verify it’s a valid ID. If no torch ID is detected the system will generate
error code 99.
3. System will perform a chopper test, verifying there is no output.
a.
Main contactor off (open), IGBTs off
• If there is current on channel A the system will generate error code 401
• If there is current on channel B the system will generate error code 402
• If there is current on both channels the system will generate error code 400
b.
Main contactor on (closed), IGBTs off
• If there is current on channel A the system will generate error code 406
• If there is current on channel B the system will generate error code 407
• If there is current on both channels the system will generate error code 408
4. System will verify that there is
a.
No transfer signal or the system will generate error code 108
b.
No start signal or the system will generate error code 50
c.
No coolant flow or the system will generate error code 109
5. System will verify that
a.
Temperatures are above the minimum
• Chopper temperature is above minimum or the system will generate error code 300
• Transformer temperature is above minimum or the system will generate error code 301
• Inductor 1 temperature is above minimum or the system will generate error code 302
• Inductor 2 temperature is above minimum or the system will generate error code 303
• Coolant temperature is above minimum or the system will generate error code 304
b.
Temperatures are below the maximum values.
• Chopper temperature is below maximum or the system will generate error code 65
• Transformer temperature is below maximum or the system will generate error code 67
• Inductor 1 temperature is below maximum or the system will generate error code 68
• Inductor 2 temperature is below maximum or the system will generate error code 69
• Coolant temperature is below maximum or the system will generate error code 71
6. After about 1 second the system will advance to state 2 (Gas purge) if there are no high priority errors (See Error
codes on page 127). If a high priority error is generated the system will go to state number 13 (Shutdown).
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121
Maintenance
Gas purge (status 02)
1. System turns on the plasma and shield gases.
2. System counts the time in seconds and this is displayed on the 3-digit current display.
3. System turns on the coolant pump.
4. After six seconds the system will verify the coolant flow is greater than the minimum value.
5. If the coolant flow is above the minimum the system will do a high power test on the chopper.
Note: the system is “live” at this time. The system is applying power to the torch even though no arc will
be present at the torch.
6. Chopper LEM Test
a.
Main contactor closed, IGBTs on
• If there is no current on channel A the system will generate error code 409
• If there is no current on channel B the system will generate error code 410
• If there is no current on both channels the system will generate error code 408
b.
Main contactor closed, IGBTs on
• If channel A current does not go to 0 the system will generate error code 411
• If channel B current does not go to 0 the system will generate error code 412
• If the current on both channels does not go to 0 the system will generate error code 413
c.
Main contactor closed, IGBTs on
• Channel A current detected on channel B input the system will generate error code 415
• Channel B current detected on channel A input the system will generate error code 416
• Channel A current detected on channel B input and Channel B current detected on channel A input the
system will generate error code 414
d.
Main contactor closed, IGBTs on
• Channel A current higher than expected: the system will generate error code 417
• Channel B current higher than expected: the system will generate error code 418
• Both channels current higher than expected: the system will generate error code 419
7.
If the chopper test is successful and there are no other severe errors the system will advance to state 3 (Ready for
start), otherwise the system will go to state 13 (Shutdown).
Ready for start (status 03)
1. System is waiting for a plasma start signal.
2. System is monitoring the over-current signals, and over-temperature conditions.
• Chopper temperature in range or the system will generate error code 65
• Transformer temperature in range or the system will generate error code 67
• Inductor 1 temperature in range or the system will generate error code 68
• Inductor 2 temperature in range or the system will generate error code 69
• Coolant temperature in range or the system will generate error code 71
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
3. System is monitoring the pilot arc duty cycle to ensure it is less than 50%.
4. Diagnostic mode is active, the system will perform the function for the mode that is selected.
a.
Test gas – the plasma and shield gases flow at a set value
b.
Revision – the display will show the software revision
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MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
c.
Plasma leak check – the plasma channel will be pressurized then the pressure trapped. The display on the power
supply control panel will show actual pressures. The system will remain in this state until commanded to another
test. The pressure in the plasma channel is expected to remain within 2 psi for a period of 5 minutes. The shield
gas channel is expected to drop to near 0 psi.
d.
Test gas full pressure – plasma and shield gases flow at full pressure. Low pressure errors will be typical in this
mode as the system is attempting to achieve the maximum flow possible.
e.
Torch ID – the display on the power supply control panel will show the torch ID
f.
In-line valve test – the plasma channel will briefly pressurize, then the system will close the Burkert valve in the
power supply and open the in-line torch valve. The plasma pressure is expected to drop to near 0 psi (less than
5 psi), in less than 30 seconds.
5. If a plasma start signal is received and there are no temperature errors, the system will advance to state 4 – Preflow.
Preflow (status 04)
1. System will turn on plasma and shield gases.
2. System will verify gas pressures are above the minimum and below the maximum values.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will charge the surge injection circuit.
4. System will check for an over-current condition.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
5. After 1 second the system will advance to state 5 (Preflow hold).
Preflow hold (status 05)
1. System will continue running the plasma and shield gas until the hold signal is removed.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for an over-current condition.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. If the hold signal is active for more than 60 seconds, the system will generate error code 32.
5. When the hold signal is removed the system will advance to state 6 (Ignite).
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123
Maintenance
Ignite (status 06)
1. System will execute the ignition sequence by turning off the torch valve, then turning on the High Frequency. The
system will turn on the torch valve again, while continuing to activate the High Frequency.
2. The system will monitor for pilot arc current. If pilot arc current is not detected, the ignition sequence will be repeated
up to 5 times, after that the system will have error code 20 (Pilot arc fault) and advance to state 11 (Rampdown
Complete).
3. System will check for an over-current condition.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. If chopper current is detected during the sequence the system will advance to state 7 (Pilot Arc).
Pilot arc (status 07)
1. System will display actual gas pressures on the 2-digit pressure displays.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for over-current.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. System will check for minimum coolant flow. If it is below minimum the system will generate error code 93.
5. System will check for minimum chopper current. If it is below minimum the system will generate error code 24
(Lost Current Fault).
6. System will check for the arc transfer signal, once it is active the system will advance to state 8, (Rampup).
7.
If the transfer signal in not present within 0.5 seconds (Mechanized) or 5.0 seconds (Hand torch) the system will
have error code 21 (Transfer fault) and advance to state 11 (Rampdown complete).
Rampup (status 08)
1. System will ramp up the current based on the process parameters.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for over-current.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. Once the ramp up is finished the system will advance to state 9 (Main arc).
Main arc (status 09)
1. System will display actual current and pressures.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure and the system will generate error code 44
• High plasma pressure and the system will generate error code 45
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Maintenance
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for over-current.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. System will check for minimum coolant flow, error code 93.
5. System will check the bus voltage (equivalent to Line voltage).
• Bus voltage high: the system will generate error code 5
• Bus voltage low: the system will generate error code 6
6. System will check for phase loss (error code 27).
7.
System will check for over-temperature conditions.
• Chopper overtemperature: the system will generate error code 65
• Transformer overtemperature: the system will generate error code 67
• Inductor 1 overtemperature: the system will generate error code 68
• Inductor 2 overtemperature: the system will generate error code 69
• Coolant overtemperature: the system will generate error code 71
8. System will check for lost chopper current – error code 24 (Lost Current Fault).
9. System will check for lost transfer – error code 26 (Lost Transfer Fault).
10. If the plasma start signal is removed the system will advance to state 10 (Rampdown).
Rampdown (status 10)
1. System will shut off the plasma and shield gases.
2. System will rampdown the current.
3. When the system reaches the final current, it will advance to state 11 (Rampdown Complete).
Rampdown complete (state 11)
1. Ensure all power supply outputs are off except the main contactor.
2. Advance to state 12 (End of Cycle).
End of cycle (status 12)
1. Turn on plasma and shield gases for postflow.
2. System will verify coolant flow is above the minimum (error code 93).
3. System will verify the plasma start signal is off.
4. Once the plasma start signal is off the system will advance to state 3 (Ready for start).
Shutdown (status 14)
1. System will turn off all power supply, coolant, and gas outputs.
Standby (status 17)
1. If the rocker switch is turned off the system will enter the standby state.
2. When the rocker switch is turned on the system will advance to state 0 (Power up).
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125
126
Chopper
power
Chopper board PCB2
Chopper Chopper
A
B
current current
Bus voltage
Plate temp
PWM A
PWM B
PA Enable
Control board PCB1
Transfer
PA emitter
PA collector
Work
Chopper B output
Chopper A output
High
Freq
Enable
Torch valve
Trigger switch (Hand torch system only)
Lead length ID
Cutting table
controller
Arc voltage
Machine interface cable
Plasma interface
board (optional)
CNC interface cable
Sensor THC
(Sensor PHC)
I/O Board
PCB3
Plasma
valve
Maintenance
PCB block diagram
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Error codes
When the fault indicator is illuminated the error code number can be seen in the three digit display.
There are three general types of error codes:
•
Self clearing – An overtemperature error, for example, will clear when the power supply cools off.
•
Low priority – The user must select the fault icon and press the current selection knob to see the error
code. This type of error can be cleared with the start signal.
High priority – The system will automatically select the fault icon and show the error code. This type of error requires the
power to the system to be turned off and then on again, after the cause of the error has been corrected.
3-digit display icons
1
Name
Description
1 Remote
The remote icon illuminates when there is serial communication with
the power supply. You can still cycle through the functions but cut
parameters can only be changed through the CNC.
2 Amps
Increase or decrease the amperage by selecting the amps icon and
turning the knob. The current increases or decreases in 1 amp
increments when you turn the knob slowly. You can jump from one
process amperage to another when you turn the knob quickly.
2
3
4
5
6
7
The fault icon illuminates when an error occurs.
If the error code number is 60 or less, press the current selection
knob to navigate to the illuminated fault icon. When the fault icon is
selected the error code appears in the 3-digit display.
3 Fault
If the error code is 60 or greater the system automatically selects the
fault icon and the error code number flashes in the 3-digit display.
Press and hold the current selection knob to see the power supply
status number for both types of error code.
4 Coolant flow
When the coolant flow icon is selected the display shows the coolant
flow in gallons per minute. When you turn ON the power to the
system and select the coolant flow icon before the power supply
finishes the purge count, the flow switch is overridden and coolant
will continue to flow for 30 seconds.
5 Test
When test icon is selected the system is in test mode. A number of
functions can be accessed by turning the current selection knob. See
the maintenance section for detailed information.
6 Plasma start lamp
This white lamp illuminates when the plasma start signal is given and
stays illuminated until the start signal is removed.
7 Arc transfer lamp
This green lamp illuminates when the arc transfers to the workpiece.
MAXPRO200 Instruction Manual 807700 Revision 1
127
Maintenance
Diagnostic functions
Press and release the current selection knob until the Test icon in the 3-digit display is selected. Turn the current
selection knob to access the functions shown in the table below. The function activates when the function number
appears in the 3-digit display.
Function
Description
000
No function. Gases will stop flowing if the system was in another test mode.
001
Flow gas at set pressure. Plasma and shield gases flow at the set value.
002
Display software revision. Shows the current software revision of the power supply.
003
Plasma gas leak check. The plasma channel is pressurized and the pressure trapped. The 3-digit display shows the
actual pressure. The system remains in this state until you select another function or return to cutting. The pressure
in the plasma channel should remain stable (+/- 2 psi) for 5 minutes. The shield gas channel should drop to near
zero psi (less than 5 psi).
004
Flow gas at full pressure. The plasma and shield gases flow at full pressure. It is typical to see low pressure errors
during this function because the system is attempting to achieve the maximum flow possible. Function 4 is used
when setting the supply gas regulators.
005
Display torch ID. The torch ID indicates the lead length that is connected to the system.
006
In-line valve check. The plasma channel is pressurize, the system closes the Burkert valve and opens the in-line
torch valve. The plasma pressure is expected to drop to near zero psi (less than 5 psi) in less than 30 seconds.
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Maintenance
Troubleshooting table
Number Name
000
005
006
020
021
024
026
027
Description
Corrective action
No Error
System is ready to run
None
Low line voltage
Line voltage is close to or less than
the lower limit of 102 VAC (120 VAC
-15%). The normal lower limit for
operation is 108 VAC (120 VAC
-10%).
Verify the line voltage at the control transformer and
the fuses on the control board.
High line voltage
Line voltage is close to or greater than
the upper limit of 138 VAC (120 VAC
Verify the line voltage at the control transformer and
+15%). The normal upper limit for
the fuses on the control board.
operation is 132 VAC (120 VAC
+10%).
No pilot arc
No arc transfer
Lost current on chopper
Lost transfer
Lost phase
No current detected from chopper at
ignition and before 1-sec timeout
1. Verify that the correct consumable parts are
installed and in good condition.
2. Perform the gas checks (See Control board on
page 144).
3. Verify that there is spark across spark gap.
4. Inspect CON1 for excessive wear.
5. Perform the torch lead test (See Torch lead test on
page 155).
6. Perform the start circuit test (See Start circuit
troubleshooting on page 149).
No current detected on work lead
500-msec after pilot arc current was
established
1. Verify proper transfer/pierce height.
2. Verify proper cutflow settings.
3. Inspect the work lead for damage or loose
connections.
4. Perform the torch lead test (See Torch lead test on
page 155).
Lost current from chopper after
transfer
1. Verify that the correct consumable parts are
installed and in good condition.
2. Verify proper cutflow gas settings.
3. Verify the pierce height setting.
4. Verify the pierce delay time.
5. Verify that the arc did not lose contact with the
plate while cutting (hole cutting, scrap cutting,
etc.).
Lost the transfer signal after transfer
completed.
1. Verify that the correct consumable parts are
installed and in good condition.
2. Verify proper cutflow gas settings.
3. Verify the pierce height setting.
4. Verify pierce delay time.
5. Verify that the arc did not loose contact with the
plate while cutting (hole cutting, scrap cutting,
etc.).
6. Inspect the work lead for damage or loose
connections.
7. Try connecting the work lead directly to the plate.
Phase imbalance to chopper after
contactor engaged or while cutting
1. Verify phase-to-phase voltage to power supply.
2. Disconnect power to power supply, remove cover
on contactor and inspect contacts for excessive
wear.
3. Inspect power cord, contactor, and input to
chopper for loose connections.
4. Perform phase loss test. See Phase loss detection
on page 154.
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129
Maintenance
Number Name
Description
Corrective action
1. Check the interface cable for damage. The hold
wires may be short-circuiting inside.
2. The CNC is maintaining this input, it could be
Hold signal was active for longer than
waiting for an IHS complete input from another
60 seconds
torch.
3. If the CNC interface cable is good and it is a
1-torch system, change the control board.
032
Hold timeout
044
1. Inspect gas supply pressure and volume of gas
remaining in supply tanks.
2. Verify the gas settings on the front panel with the
parameters in the cut charts.
Plasma gas pressure is less than 25%
Low plasma gas pressure
3. See Setting the supply gas regulators on page 71.
of the set (desired) value
4. Perform the Flow gas at set pressure test (001),
and verify the gas settings on the front panel with
the parameters in the cut charts. See Control
board on page 144.
045
1. Verify gas supply pressure settings.
2. Perform the Flow gas at set pressure test (001),
and verify the gas settings on the front panel with
the parameters in the cut charts. See Control
board on page 144.
3. See Setting the supply gas regulators on page 71.
4. The In-line valve may not be opening. Perform the
Plasma leak check (003) and the in-line valve
check (006). See Control board on page 144.
050
High plasma gas
pressure
Start lost
Plasma gas pressure is greater than
25% of the set (desired) value
Start signal was received and then
lost before an arc was established
1. If a mechanical relay is being used to provide the
system with a start signal, this relay is either
bouncing when activated or the contacts are
faulty. Replace the relay.
2. Inspect the interface cable for damage; faulty
crimps, or poor electrical connections.
3. If the interface cable is good and a relay is not
driving the start input, the CNC is dropping the
start signal before a steady state arc has been
established.
NOTE: It is normal to see an 050 error when cutting
with the hand torch if the start signal is removed
before the pilot arc time (5 seconds) has expired.
1. Allow the power supply to idle with the fans
running for 10 seconds.
Maximum pilot arc duration exceeded
2. Verify that the pierce height is correct.
3. Minimize pilot arcing off the plate.
051
Pilot Arc Over-temp
053
1. Verify gas supply pressure and that sufficient gas
remains in your supply.
2. Perform the Flow gas at set pressure test (001),
Shield gas pressure is less than 25%
Low shield gas pressure
and verify the gas settings on the front panel with
of the set (desired) value
the parameters in the cut charts. See Control
board on page 144.
3. See Setting the supply gas regulators on page 71.
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MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Number Name
Description
Corrective action
High shield gas pressure
Shield gas pressure is 25% greater
than the set (desired) value
1. Check for a restriction or dross on the shield cap
2. Perform the Flow gas at set pressure test (001),
and verify the gas settings on the front panel with
the parameters in the cut charts. See Control
board on page 144.
3. Verify that the pressure transducers are providing
the system with the proper pressures.
060
Low coolant flow
1. Verify that the correct consumables are properly
Coolant flow is less than the required
installed.
2.3 lpm (0.6 gpm)
2. Perform the coolant flow test procedure. See
Coolant flow test on page 140.
063
Inlet Pressure Fault
Inlet pressure measured was greater
than 135 or less than 40 psi
Chopper over-temp at
power-up
1. Verify that the heat exchanger fan is spinning.
2. Blow dust out the heat exchanger with
compressed air to clean off the fins.
3. Verify that the level of coolant is at the proper
height.
4. Verify that the coolant mixture is correct
Chopper is indicating an over-temp at
(% propylene glycol). A mixture with a high
power-up
percentage of propylene glycol will have a lower
cooling capacity.
5. Change the consumables. Older consumables
emit more heat into the cooling loop.
6. Verify the pump flow rate. If it is less than 2.3 lpm
(0.6 GPM) troubleshoot the low flow rate issue.
054
065
067
068
Magnetics over temp
Inductor A over temp
Verify that the input pressures at the regulators are in
range.
Main transformer has over heated
1. Verify that the magnetics fan is operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of the system especially from fans
and the main transformer.
3. If voltage is low or near 0 VDC, inspect wiring
between the transformer’s temperature sensor and
J1.12, pins 1 and 2 on the control board. Look for
shorts between wires or to ground.
4. If wiring is good, the transformer has overheated.
Allow the power supply to idle with the fans
running for a minimum of 30 minutes to cool the
main transformer.
Inductor has over heated
1. Verify that the magnetics fan is operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of the system especially from fans
and inductors.
3. If voltage is low or near 0 VDC, inspect wiring
between inductor A’s temperature sensor and
J1.12, pins 4 and 5 on the control board. Look for
shorts between wires or to ground.
4. If wiring is good, the inductor has overheated.
Allow the power supply to idle with the fans
running for a minimum of 30 minutes to cool the
inductors.
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131
Maintenance
Number Name
Description
Corrective action
Inductor has over heated
1. Verify that the magnetics fan is operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of the system especially from fans
and inductors.
3. If voltage is low or near 0 VDC, inspect wiring
between inductor B’s temperature sensor and
J1.12, pins 7 and 8 on the control board. Look for
shorts between wires or to ground.
4. If wiring is good, the inductor has overheated.
Allow the power supply to idle with the fans
running for a minimum of 30 minutes to cool the
inductors.
Coolant over temp
Torch coolant has overheated
1. Verify that the heat exchanger fan is spinning.
2. Blow dust out the heat exchanger with
compressed air to clean off the fins.
3. Verify that the level of coolant is at the proper
height.
4. Verify that the coolant mixture is correct
(% propylene glycol). A mixture with a high
percentage of propylene glycol will have a lower
cooling capacity.
5. Change the consumables. Older consumables
emit more heat into the cooling loop.
6. Verify the pump Flow rate. If it is less than 0.5 gpm
troubleshoot the low flow rate issue.
7. Replace the coolant temperature sensor if it is
open or shorted. Replacement part number is
229474.
093
No coolant flow
1. Verify that the level of coolant is at the proper level.
2. Verify that the coolant filter is in good condition.
replace if necessary.
3. The pump motor may have reached its internal
Coolant flow was below 1.9 lpm
thermal trip point. Make sure the side panel is
(0.5 gpm) while the system was
installed, for proper airflow, and that the heat
running or the coolant flow was below
exchanger fan is working properly.
1.7 lpm (0.45 gpm) while cutting.
4. Perform the coolant flow test. See Coolant flow
test on page 140.
5. See the corrective actions for the low coolant flow
error (60).
097
No Torch Found
Torch or torch ID jumper missing or
installed incorrectly
1. Verify that the torch connection by the I/O panel
(CPC plug) is good.
2. Verify the pin out on the torch lead connection.
A fault was detected on channel A of
the chopper
1. Turn OFF the line power to the system. Check the
wiring between the control board and the chopper
for damaged wires and proper connections and
then turn ON the line power again so the
automatic diagnostic checks will run.
2. If the error changes to a 409 error replace the
chopper assembly.
069
071
102
132
Inductor B over temp
Current Sensor A Fault
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Number Name
108
109
134
138
161
190
Description
Corrective action
Transfer at power-up
The system has detected current on
the work lead during power-up
1. Verify that the chopper PCB is functioning
properly by checking the LEDs on the board
against the LED list in the Maintenance section.
See Start circuit troubleshooting on page 149.
2. Replace the chopper PCB if connections are
correct and not damaged.
3. Verify that the main contactor (CON1) is not
welded closed, or closing at power-up.
Coolant Flow At
power-up
1. Verify that the shield cap is properly installed. A
loose shield cap can allow shield gas to get into
the coolant, and cause a coolant flow error.
2. Verify that the torch lead connections are good.
Coolant flow measured during
3. Turn off the power to the system, wait 30 seconds,
power-up and before pump motor has
and turn the power back on. Sometimes if you turn
been turned on.
the power off and then on too quickly it may cause
a 109 error.
4. Disconnect the transfer sensor on the I/O board,
turn off the power to the system and turn it on
again to see if that clears the error.
Chopper A over current
Chopper B over current
High coolant flow rate
Current Sensor B Fault
Chopper A current exceeded
maximum
1. Verify that the chopper PCB is functioning
properly by checking the LEDs on the board
against the LED list in the Maintenance section.
2. Turn off the power to the system and then turn it
on again to verify that the system passes the initial
power up test.
3. Verify the current output on J2.1 white to black
(4 VDC=100 amps).
4. If the wiring is good, the IGBT may have failed.
Replace the chopper assembly.
Chopper B current has exceeded
maximum
1. Verify that the chopper PCB is functioning
properly by checking the LEDs on the board
against the LED list in the Maintenance section.
See Start circuit troubleshooting on page 149.
2. Turn off the power to the system and then turn it
on again to verify that the system passes the initial
power up test.
3. Verify the current output on J2.6 white to black
(4 VDC=100 amps).
4. If the wiring is good, the IGBT may have failed.
Replace the chopper assembly.
Coolant flow rate has exceeded
maximum
1. Check to make sure the shield cap is properly
installed. A loose shield cap can allow shield gas
to get into the coolant, and cause this error.
2. Check to make sure the consumables are installed
properly and are not damaged.
A fault was detected on channel B of
the chopper
1. Turn OFF the power to the system. Check the
wiring between the control board and the chopper
for damaged wires and proper connections and
then turn ON the power again so the automatic
diagnostic checks will run.
2. If the error changes to a 410 error replace the
chopper assembly.
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133
Maintenance
Number Name
Description
Corrective action
1. Verify that the red and black wires on chopper J2.8
are plugged into the control board at J1.22.
2. Verify the cold plate temperature sensor wires are
plugged into the chopper at J2.9 (10K ohm
nominal).
300
Temp sensor unplugged
Chopper
The temperature reading was
unexpectedly low, possibly indicating
the sensor is unplugged
301
Temp sensor unplugged
Transformer
The temperature reading was
unexpectedly low, possibly indicating
the sensor is unplugged
Verify the electrical connection back to the control
board at J1.12 pins 1-2 (10K ohm nominal).
302
Temp sensor unplugged
Inductor 1
The temperature reading was
unexpectedly low, possibly indicating
the sensor is unplugged
Verify the electrical connection back to the control
board at J1.12 pins 4-5 (10K ohm nominal).
303
Temp sensor unplugged
Inductor 2
The temperature reading was
unexpectedly low, possibly indicating
the sensor is unplugged
Verify the electrical connection back to the control
board at J1.12 pins 7-8 (10K ohm nominal).
304
Temp sensor unplugged
Coolant
The temperature reading was
unexpectedly low, possibly indicating
the sensor is unplugged
Verify the electrical connection back to the control
board at J1.18 pins 6-7 (10K ohm nominal).
400
1. Verify that the contactor is not welded shut or
always ON.
Current sensor A and
During the chopper test, current was
2. Verify that there is no DC output on the I/O board
Current sensor B current detected on channel A and on channel
from the Torch to Work connections. If DC output
with contactor off
B when no current was expected
is found, replace the chopper.
3. Verify that the LED for PWM is not active.
401
During the chopper test, current was
Current sensor A current
detected on channel A when no
with contactor off
current was expected
1. Verify that the contactor is not welded shut or
always ON.
2. Verify that there is no DC output on the I/O board
from the Torch to Work connections. If DC output
is found, replace the chopper.
3. Verify that the LED for PWM is not active.
402
During the chopper test, current was
Current sensor B current
detected on channel B when no
with contactor off
current was expected
1. Verify that the contactor is not welded shut or
always ON.
2. Verify that there is no DC output on the I/O board
from the Torch to Work connections. If DC output
is found, replace the chopper.
3. Verify that the LED for PWM is not active.
405
Current sensor A and
1. Verify that the LED for PWM is not active.
During the chopper test, current was
Current sensor B current
2. Verify that there is no DC output on the I/O board
detected on channel A and on channel
with contactor on and
from the Torch to Work connections. If DC output
B when no current was expected
PWM off
is found, replace the chopper.
406
Current sensor A current During the chopper test, current was
with contactor on and
detected on channel A when no
PWM off
current was expected
1. Verify that the LED for PWM is not active.
2. Verify that there is no DC output on the I/O board
from the Torch to Work connections. If DC output
is found, replace the chopper.
407
Current sensor B current During the chopper test, current was
with contactor on and
detected on channel B when no
PWM off
current was expected
1. Verify that the LED for PWM is not active.
2. Verify that there is no DC output on the I/O board
from the Torch to Work connections. If DC output
is found, replace the chopper.
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Maintenance
Number Name
Description
Corrective action
408
1. Verify the output voltage from the contactor.
2. Verify the DC voltage on both bridges of the
Chopper.
With choppers active, no
3. Verify the DC output on the I/O board for each
current on Current
No current detected on channel A and
chopper test.
sensor A and Current
channel B when current was expected 4. Verify that the 10 Ohm resistor on the I/O board is
sensor B during chopper
not damaged.
test
5. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
6. Replace the chopper.
409
1. Verify the output voltage from the contactor.
2. Verify the DC voltage on Chopper.
3. Verify the DC output on the I/O board for each
With choppers active, no
chopper test.
current on Current
No current was detected on channel A
4. Verify that the 10 Ohm resistor on the I/O board is
sensor A during chopper when current was expected
not damaged.
test
5. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
6. Replace the chopper.
410
1. Verify the output voltage from the contactor.
2. Verify the DC voltage on Chopper.
3. Verify the DC output on the I/O board for each
With choppers active, no
chopper test.
current on Current
No current was detected on channel B
4. Verify that the 10 Ohm resistor on the I/O board is
sensor B during chopper when current was expected
not damaged.
test
5. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
6. Replace the chopper.
411
Current detected for
longer than expected on
Current sensor A and
Current sensor B
Current on channel A and channel B
did not return to 0 as expected
412
Current detected for
longer than expected on
Current sensor A
Current on channel A did not return to Verify that the surge circuit on the I/O board is
0 as expected
functioning properly.
413
Current detected for
longer than expected on
Current sensor B
Current on channel B did not return to Verify that the surge circuit on the I/O board is
0 as expected
functioning properly.
414
Current sensor A and
Current from output A was detected
Current sensor B signals on channel B and output from channel Verify that the current sensor wiring is not crossed.
crossed
B was detected on channel A
415
Current detected on
Current sensor B when
expected on Current
sensor A
Current from output A was detected
on channel B
MAXPRO200 Instruction Manual 807700 Revision 1
Verify that the surge circuit on the I/O board is
functioning properly.
Verify that the current sensor wiring is not crossed.
135
Maintenance
Number Name
Description
Corrective action
416
Current detected on
Current sensor A when
expected on Current
sensor B
Current from output B was detected
on channel A
Verify that the current sensor wiring is not crossed.
417
Current too high on
Current sensor A
Current exceeded the maximum
expected value on channel A
1. Verify that the 10 Ohm resistor on the I/O board is
not damaged.
2. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
418
Current too high on
Current sensor B
Current exceeded the maximum
expected value on channel B
1. Verify that the 10 Ohm resistor on the I/O board is
not damaged.
2. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
419
Current too high on
Current sensor A and
Current sensor B
Current exceeded the maximum
expected value on channel A and
channel B
1. Verify that the 10 Ohm resistor on the I/O board is
not damaged.
2. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
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MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Initial checks
Before trouble-shooting, do a visual check and verify that proper voltages are present at the power source, transformers
and power distribution board.
DANGER!
ELECTRIC SHOCK HAZARD
Always use caution when servicing a power supply when plugged in and the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death.
1. Disconnect line power by turning OFF the main disconnect switch.
2. Remove the power supply’s top panel and 2 side panels.
3. Inspect interior of power supply for discoloration on PC boards, or other apparent damage. If a component or module
is obviously defective, replace it before doing any testing. Refer to the Parts List section to identify parts and part
numbers.
4. If no damage is apparent, connect power to the power supply, and turn ON the main disconnect switch.
5. Measure the voltage between the L1, L2 and L3 terminals of TB1 located on the left side of the power supply. See
figure on next page. Also refer to the wiring diagram in Section 7, if required. The voltage between any 2 of the 3
terminals should be equal to the supply voltage. If there is a problem at this point, disconnect main power and check
all connections, the power cable, and fuses at the line disconnect switch. Repair or replace any defective component.
MAXPRO200 Instruction Manual 807700 Revision 1
137
Maintenance
Power measurement
DANGER!
ELECTRIC SHOCK HAZARD
There is line voltage at the contactor when the main disconnect switch is on. Use extreme care when
measuring primary power in these areas. Voltages present at the terminal block and contactors can
cause injury or death.
4 3
2
1
1
Ground
2
L1
3
L2
4
L3
Check the lines in the following order:
•
L1 to L2
•
L1 to L3
•
L2 to L3
Check each line to ground. If one line is 10% or higher than the other two, put that leg on L1.
138
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Power supply coolant system servicing
Draining the coolant system
1. Turn OFF the power and remove the right side panel from the power supply.
2. Locate the coolant drain valve and use a 20 liter (5 gallon) container to catch the coolant. Coolant will flow as
soon as the drain is opened. Close the drain valve when the coolant stops flowing. Always dispose of coolant
according to local and national codes.
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139
Maintenance
Coolant flow test
The control board receives an electrical signal in Hz from the flow sensor, that is converted and shown as flow in gallons
per minute (gpm). Normal flow is 4.5 lpm (1.2 gpm), but this will vary depending on lead lengths and whether the power
is 50 Hz or 60 Hz. PCB4 will allow the system to operate if the coolant flow is 1.9 lpm (0.5 gpm) or greater. If the system
shows a coolant flow error (093) the system will need to be turned OFF and then ON again and the following test needs
to be performed to determine if the problem is coolant flow or the flow switch.
1. Turn OFF the power, and remove the right-side panel from the power supply.
2. Remove the return hose at the top of the coolant tank. Push the connector-collar toward the fitting, and pull the hose
away from the fitting This will release the coolant hose. No tools required. Put the end of the return hose into a 4 liter
(1 gallon) container.
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MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
3. You will need to enable the flow function before the count reaches 5 in the 3-digit display. Turn ON the power and
press and release the current knob twice until the flow function is enabled. Turn OFF the power after the coolant
flows for 30 seconds.
4. Measure the amount of coolant in the container. There should be about 2 liters (0.5 gallon). If there is less than 1 liter
(0.25 gallon) there may be a restriction in the coolant system or a problem with the pump or flow sensor.
5. Verify the flow sensor output by measuring the flow output (in frequency) at the control board. Measure the
Frequency on J21 pin 3 (pulse) and pin 2 (ground). Once you have the frequency use the chart below to get the flow
sensors measured flow rate. If this number differs more than 0.8 lpm (0.2 gpm) from your bucket test, the flow sensor
may need to be replaced.
Note: The 3-digit display shows actual coolant flow. You can compare that measurement to the measurement
you get in step 5 to troubleshoot for a PCB problem.
1.4
Flow rate (gpm)
1.2
1
0.8
0.6
0.4
0.2
0
0
20
40
60
80
100
120
140
Measured frequency
MAXPRO200 Instruction Manual 807700 Revision 1
141
Maintenance
CAUTION!
Coolant will flow from the filter when the housing is removed.
Drain coolant before replacing the filter.
Coolant system filter replacement
1. Make sure the coolant has been drained from the system, then turn OFF all power to the system.
2. Remove the filter housing. Make sure the o-ring inside the filter housing remains in place.
3. Remove and discard the filter element.
4. Install the new filter element 027005.
5. Make sure the o-ring is properly installed before re-installing the housing.
6. Refill the power supply with coolant. See Fill the power supply with coolant on page 66.
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MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Air filter element replacement
1. Disconnect the electrical power and the gas supply and
remove the filter bowl and the old filter element.
a.
Pull down and hold the black release tab.
b.
Rotate the filter bowl in either direction until it
releases.
c.
Pull the filter bowl down to remove it. The bowl has
an o-ring around the top. Do not discard the o-ring. If
the o-ring needs to be replaced, use part number
011105.
A
B
C
2. Turn the plastic disk under the filter element
counter-clockwise about 1/4 turn and remove the old
filter element. Install the new filter element 011093.
3. Re-install the filter bowl.
a.
Hold down the black tab and slide the filter bowl
over the new filter element.
b.
Rotate the filter bowl until it locks in place.
A
B
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143
Maintenance
Control board
Control board LED list
LED
Description
LED
Description
D1
Torch ID 0
D46
High frequency ignition (ON = HF circuit active)
D2
Torch ID 1
D51
Contactor output (ON = contacts closed)
D3
Torch ID 2
D61
Torch valve driver error (ON = error)
D4
Torch ID 3
D62
Torch valve driver OK (ON = 24V power is OK)
D6
CNC start signal (ON = active)
D64
Not used
D9
Hold input (ON = active)
D65
Transfer detect (ON = 3.5A or more detected on the
work lead)
D12
Motion output
D68
Coolant flow input (pulses from flow sensor)
D14
Error output
D70
Pump enable (ON = pump motor active)
D15
Hold output
D71
Serial communications TX
D16
CAN RX
D96
USB BUS voltage error flag
D17
CAN TX
D100
Over current on chopper B (ON = overcurrent)
D26
+15/-15V voltage indicator
D101
Chopper A PWM
D31
Fused side of 240VAC input power
D102
Chopper B PWM
D33
+3.3V voltage indicator
D103
Pilot arc enable
D35
Overcurrent on chopper A (ON = overcurrent)
D104
Plasma valve PWM
D37
+5V voltage indicator
D105
Shield valve PWM
D40
+24V voltage indicator
D106
Torch valve enable
D41
Fused side of 120VAC input power
D107
D42
240V input detection (ON = 240VAC input detected) D111
D44
120V input detection (ON = 120VAC input detected)
Not used
Serial communications RX
Control board test points
Test
point
Description
Test
point
Description
TP1
+15V
TP18
+5V regulated
TP2
Analog 3.3V
TP19
+5V unregulated (should be 7V or higher)
TP3
Signal ground
TP20
+24V
TP4
+3.3V
TP21
Not used
TP5
-15V
TP22
Serial communications RX
TP6
PWM channel A (5V)
TP23
CNC start +
TP7
PWM channel B (5V)
TP24
CNC start -
TP8
Pilot arc enable (5V)
TP25
Serial communications TX
TP9
Shield valve output (24V)
TP26
15VAC power output to chopper
TP10
Plasma valve enable (5V)
TP27
Inductor 2 temp input (analog 3.3V)
TP11
Shield valve enable (5V)
TP28
Inductor 1 temp input (analog 3.3V)
TP12
Plasma valve output (24V)
TP29
Main transformer temp input (analog 3.3V)
TP13
Plasma valve enable
TP30
Multiplexed transformer and inductor temps input
TP14
Digital logic ground
TP31
+24V (same connection as TP20)
TP15
Power ground
TP32
Spare input not used (analog 3.3V)
TP16
Analog/signal ground
TP33
Plasma pressure input (analog 5V)
TP17
Pump motor enable (5V)
TP34
Shield pressure input (analog 5V)
144
MAXPRO200 Instruction Manual 807700 Revision 1
J3
J3
1
BAT1
BAT1
1
+
PART NUMBER
D31
240VAC IN
TESTED LABEL
J13
SHIELD
J13
J9
141169 REV C
D96
J9
J19
J19
1
J11
SERIAL NUMBER
D41
120VAC IN
J11
PLASMA
CM LABEL
1
1
1
J18
J18
+24V
1
D40
+24V
1
J8
J15
J8
J15
D70
TP17 PUMP
TP2
A3.3V
TP2
PUMP TP17
J14
J14
A3.3V
240VAC OUT
D33
TP27
D42
D51
D46
TP19
1
+5VUN
TP32
FIRMWARE
LABEL
TP19
TP14
HF
HF
TP14
TP4
+5V
D44
OCA
TX
TX
D100
OCB
TP20
OCB
D35
OCA
TP18
LABEL
TP18
PA
TP8
TP10
TP8
TP7
PWMB
+5V
PWMA
TP6
PL
PA
TP7
TP10
SH
TP25
+ TCHVLV -
TP11
TP21
TP11
TP21
PL
PWMB
TP13
TP13
SH
PWMA
- TCHVLV +
+24V
+5V
CANRX
FIRMWARE
TP20
J7
CANTX
120VAC OUT
+5V
D111
J7
+3.3V
TP4
D37
TP25
+3.3V
J20
120VAC OUT
U3
D17 D16
1
1
TP16
TP32
CNTOR
TP29 TP28
U56
TP16
CNTOR
TP28 TP29
+3.3V
+24V
TP30
TP27
TP30
+3.3V
1
J12
J12
240VAC OUT
J1
TP6
D101
D103
D102
RX
D104
D105
MOTN
D107
D12
-15V
TP5
ERR
MOTN
ERR
D15
HLDO
D106
D14
HLDO
5
TP15
D68
PWRGND
TP15
D9
D65
D26
+/-15V
+15V
9
PWRGND
+15V
+24V
TP1
J5
TP22
TP22
TP5 -15V
RX
J4
TP1
+24V
6
HLDI
TP31
TP31
FLAG
TID2
TID1
TID0
START
TP24
D62
1
D64
OKFLG
TP23
15VAC
SHVLV
J2
J6
J2
TP12
J16
J17
1
PLVLV
TP9
TP9
1
TP26
TID3
TP24
TP3
1
D61
PGOK
D4
J16
D3
1
J21
D2
OKFLG
D1
FLAG
SHVLV
TID3
PLVLV
TID2
TP26
TP23
TID1
PGOK
D6
TID0
TP3
START
J21
1
J22
J22
J5
D71
J17
145
J6
146
Maintenance
Gas leak tests
Note: See Diagnostic functions on page 128 for details about getting to the gas test functions.
Function
Description
001
Flow gas at set pressure. Plasma and shield gases flow at the set value.
003
Plasma gas leak check. The plasma channel is pressurized and the pressure trapped. The 3-digit display shows the
actual pressure. The system remains in this state until you select another function or return to cutting. The pressure
in the plasma channel should remain stable (+/- 2 psi) for 5 minutes. The shield gas channel should drop to near
zero psi (less than 5 psi).
004
Flow gas at full pressure. The plasma and shield gases flow at full pressure. It is typical to see low pressure errors
during this function because the system is attempting to achieve the maximum flow possible. Function 4 is used
when setting the supply gas regulators.
006
In-line valve check. The plasma channel is pressurized, the system closes the Burkert valve and opens the in-line
torch valve. The plasma pressure is expected to drop to near zero psi (less than 5 psi) in less than 30 seconds.
MAXPRO200 Instruction Manual 807700 Revision 1
147
Maintenance
Start circuit
Operation
The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead.
the start circuit is built into the chopper in the MAXPRO200. The start circuit performs 2 functions:
1. It allows the initial pilot arc current to flow through the pilot arc lead quickly, with little impedance.
2. After initial pilot arc current is established, the start circuit introduces impedance to the pilot arc lead to aid in
transferring the arc to the workpiece. See schematic below.
Start circuit functional schematic
Plasma power supply
1
2
5
3
4
7
6
8
Number
148
Description
1
Chopper
2
Choke
3
Power supply control board
4
IGBT
5
Power resistors
6
Diode
7
Cutting arc
8
Pilot arc
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Start circuit troubleshooting
DANGER!
ELECTRIC SHOCK CAN KILL
Before operating this system, you must read the safety section thoroughly. Turn OFF the power
supply’s main disconnect switch before proceeding with the following steps.
D14 should always be illuminated.
Note: Reference the chopper PCB figure on the next page.
D3 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece. If arc transfer is
immediate, the LED may not illuminate.
If there is no arc at the torch or if the arc will not transfer:
1. Turn OFF all power to the system.
2. Remove the 6 AWG wire labeled R36
from the R36 power resistor terminal
(PA WORK). Not the smaller 140 mm
(5.5 inch) 10 AWG wire that connects
to R34.
1
2
1 R34 (J2 COLLECTOR)
2 R35
3 R36 (PA WORK)
3. Verify a series resistance of 3 Ω
between J2 (COLLECTOR, wire
labeled J2.2) and R36 (PA WORK). If
the resistance value is not correct,
check the wiring connections between
J2 (COLLECTOR, wire labeled J2.2)
and R34, between R34 (no label on
wire) and R35, and between R35 (no
label on wire) and R36.
Note: Resistance value may slowly
increase to the correct value due to the
capacitance in the circuit.
3
4. Verify a resistance of 1 Ω across each of R34, R35, and R36.
• The work lead should not have any cuts or breaks. Verify a resistance of 1Ω or less. The work lead connection to
the cutting table should be clean and have good contact to the table.
• Verify that D14 is illuminated. If it is not illuminated the board may need to be replaced or the board may not be
receiving power.
• Fire the torch in the air and verify that D3 is illuminated. If it is not illuminated, but a pilot arc is established, the pilot
arc IGBT (Q7) may need to be replaced.
5. Place a 10 AWG (6 mm2) jumper in parallel across the work lead (WORK, H8, wire labeled J2.9) and J7 (Nozzle, H9,
wire labeled J2.7). Perform a test cut. The nozzle will wear out after just a few starts. If the arc transfers, check, R34,
R35, R36, Q7, the chopper, and the wiring between them. replace parts as necessary.
Chopper PCB
MAXPRO200 Instruction Manual 807700 Revision 1
149
Maintenance
Test
point
Description
TP88
Chopper ground
TP89
+15V (chopper A)
TP90
-15V (chopper A)
TP91
IGBT chopper B gate drive
MTG1
Chopper +15V power indicator
TP93
-15VB
-
Bus voltage +5V circuit power indicator
D22
J2
D20
J7 (H9, NOZZLE)
J6
Pilot arc circuit power indicator
D7
D14
D8
Gate drive optocoupler +5V power
indicator
D12
D10
R33
+18V/-5V chopper circuit power
indicator
J7
D6
C54
Pilot arc enable
C60
Chopper B PWM
D3
H9
D2
R1
Chopper A PWM
R2
R3
Description
D1
R36
LED
U3
+
C2
CHA
D1
+
+
C4
TP89
+15VA
TP97
+18VIN
1 J1
TP111
Isolated Bus voltage (0–5V analog)
TP112
Bus voltage +5V
TESTED LABEL
150
SERIAL NUMBER
IGBT chopper A gate drive
PART NUMBER
TP115
1C
D28
TP114
2C
C24
Chopper A PWM
Pilot arc unregulated +18V (should be
+18.5 or higher)
1B
J2 (H8, WORK)
D29
TP113
-
Chopper +18V
2B
+
TP110
+
Non-isolated Bus voltage (0–5V analog)
HYPERTHERM
200A CHP
TP109
C1
C14
Non-isolated chopper ground
-
TP108
1A
-
Pilot arc +18V
TP27
TP107
2A
+
+
Chopper temp (0–5V analog)
C5
TP90
-15VA
TP108
PWRGND
TP46
Signal (chopper temp) ground
TP106
-
PWRGND
1
TP105
C3
CHB
D2
TP99
+15V
TP111
TP102
BUS
SIGNAL
VOLTAGE
TP109
TP103
TP112 VB3
-5V TP110
+VBUS
TP101
+18V
U4
Pilot arc ground
TP88
PWRGND
T1
Chopper -5V
TP104
1
TP103
D3
Signal (Bus voltage) ground
J3
TP102
D10
Chopper ground
PILOT
ARC
TP101
TP115
GA
J11
Chopper +15V
TP98
PWR
GND
TP106
TEMPADC
1
Chopper ground
TP99
TP91
GB
TP105
SIGNAL
J10
TP98
D14
Chopper unregulated +18V (should be
+18.5 or higher)
DCKB
A+5V
TP97
TP113
D22
+15V
Pilot arc circuit ground
TP100
P-5V
T2
TP96
1
C61
Chopper B PWM
TP94
D+5V
TP95
J9
Gate drive optocoupler +5V
TP95
TP96
PWR
1
1
TP94
TP107
P+18V
TP114
P+18V
J8
-15V (chopper B)
TP104
PAGND
1
+15V (chopper B)
TP93
J16
TP92
TP92
+15VB
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Pilot arc current levels
Plasma gas
50 Amps
130 Amps
200 Amps
Air
20 Amps
35 Amps
40 Amps
N2
—
35 Amps
40 Amps
O2
20 Amps
35 Amps
40 Amps
Transfer current
Transfer is determined by CS1 on PCB3 (I/O board). Transfer occurs when the current on the work lead is > 7 Amps.
MAXPRO200 Instruction Manual 807700 Revision 1
151
Maintenance
Chopper tests
WARNING!
ELECTRIC SHOCK HAZARD
Use extreme care when working near the chopper modules. Each large electrolytic capacitor
(blue-cased cylinder) stores large amounts of energy in the form of electric voltage. Even if the power
is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks.
Never discharge any capacitor with a screwdriver or other implement… explosion, property damage
and/or personal injury will result.
Automatic chopper and current sensor tests during power-up
After you turn ON the power to the system and the preflow starts, the system will automatically run the following series of
tests:
The system performs a chopper test verifying there is no output current. Less than 5 amps is considered “no current”.
1. The main contactor is open, IGBTs are off
a.
If there is current on channel A, error code 401 is displayed
b.
If there is current on channel B, error code 402 is displayed
c.
If there is current on both channels, error code 400 is displayed
2. The main contactor is closed, IGBTs are off
a.
If there is current on channel A, error code 406 is displayed
b.
If there is current on channel B, error code 407 is displayed
c.
If there is current on both channels, error code 408 is displayed
If the coolant flow is above the minimum level the system will do a high power test on the chopper.
Note: the system is “live” at this time. The system is applying power to the torch even though no arc will be present
at the torch.
The system performs a chopper LEM Test. The test checks for current between 10–60 amps. Less than 5 amps is
considered “no current”.
3. The main contactor is closed, IGBTs are on
a.
If there is no current on channel A, error code 409 is displayed
b.
If there is no current on channel B, error code 410 is displayed
c.
If there is no current on both channels, error code 408 is displayed
4. The main contactor is closed, IGBTs are on
a.
If channel A current does not go to 0, error code 411 is displayed
b.
If channel B current does not go to 0, error code 412 is displayed
c.
If the current on both channels does not go to 0, error code 413 is displayed
5. The main contactor is closed, IGBTs are on
a.
Channel A current detected on channel B input, error code 415 is displayed
b.
Channel B current detected on channel A input, error code 416 is displayed
c.
Channel A current detected on channel B input and Channel B current detected on channel A input, error code
414 is displayed
152
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
6. The main contactor is closed, IGBTs are on
a.
Channel A current higher than expected, error code 417 is displayed
b.
Channel B current higher than expected, error code 418 is displayed
c.
Current on both channels is higher than expected, error code 419 is displayed
If the chopper test is successful and there are no other severe errors the system will advance to state #3, “Ready for
start”, otherwise the system will go to state #14 “Shutdown”.
Using a meter to measure open circuit voltage (OCV)
The OCV is 360VDC with no load on the system and can only be measured when the contactor is closed. The VAC on
the chopper bridges are 127 VAC on 1A-1B-1C & 2A-2B-2C.
1. It is best to use clip-on test leads to keep your hands and the meter outside the power supply. Connect the meter to
J9 (WORK) and J7 (NEGATIVE) on the I/O board.
2. Turn ON the power to the system.
3. The automatic chopper test will begin when the purge cycle starts. You will hear the main contactor close and 0 to
5 seconds later the meter should show 360 VDC. This is the OCV for chopper channel A. The voltage will start to
decrease, then spike back up to 360 VDC again. The second reading represents the OCV for chopper channel B.
MAXPRO200 Instruction Manual 807700 Revision 1
153
Maintenance
Phase loss detection
1. Turn OFF all power to the system and remove the cover from the contactor (CON1).
2. Inspect the condition of the 3 contacts for excessive wear. If one or more of the contacts are worn excessively,
replace CON1 and restart the system.
OK
154
Excessive wear
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Torch lead test
1. Turn OFF all power to the system.
2. Locate the chopper board.
3. Install a temporary jumper wire between J7 (H9, NOZZLE) and the work lead connection, J9 (H8, WORK) on the
chopper board.
J8
J16
H9
C61
C60
C54
J7
R33
D12
J2
1
J6
D14
TP93
-15VB
R36
D8
TP92
+15VB
D3
1
1
A+5V
T1
U4
D1
TP98
PWR
GND
C2
D22
+15V
CHB
D2
TP91
GB
TP88
PWRGND
-
J11
1
D10
CHA
U3
J10
T2
PILOT
ARC
J3
J9
1
1
TP115
GA
D29
TP27
TP46
C24
TP90
-15VA
TP89
+15VA
TP94
D+5V
J7 (H8, NOZZLE)
TP107
P+18V
TP96
PWR
TP95
TP113
D7
1
TP104
PAGND
TP100
P-5V
DCKB
+
+
TP97
+18VIN
--
TP114
P+18V
TP108
PWRGND
-
TP105
SIGNAL
TP106
TEMPADC
TP99
+15V
TP111
TP102
BUS
SIGNAL
VOLTAGE
TP109
TP103
TP112 VB3
-5V TP110
+VBUS
TP101
+18V
PWRGND
2A
2B
J9 (H8, WORK)
2C
+
1 J1
C14
-
-
D28
C3
C4
C5
R3
C1
1A
1B
R2
1C
SERIAL NUMBER
PART NUMBER
TESTED LABEL
HYPERTHERM
200A CHP
+
+
+
MTG1
+
R1
4. Measure the ohm value between the nozzle and the plate. The reading should be < 4 ohms. A measurement
> 4 ohms indicates a faulty connection between the torch and I/O board, or between the I/O board and the power
supply.
5. Verify that the pilot arc wire on the torch lead is not damaged. If it is damaged, replace the lead. If it is not damaged,
replace the torch head.
MAXPRO200 Instruction Manual 807700 Revision 1
155
Maintenance
Preventive maintenance
Introduction
Deteriorating consumable parts life is one of the first indications that something is wrong with a plasma system. Reduced
parts life increases operating costs in two ways: the operator must use more electrodes and nozzles to cut the same
amount of metal, and the work of cutting must stop more often to change consumables.
Proper maintenance often eliminates the problems that shorten the life of consumable parts. Since labor and overhead
can account for 80% of the cost of cutting, improved productivity can reduce cutting costs dramatically.
Preventive maintenance protocol
If inspection suggests that a component is worn and might require replacement, and you would like confirmation of your
decision, please contact Hypertherm’s Technical Service.
The power supply
DANGER!
ELECTRIC SHOCK CAN KILL
Turn off all electrical power before removing the power supply cover and set the line
disconnect switch to OFF. In the U.S., use a “lock-out and tag-out” procedure until
the service or maintenance is complete. In other countries, follow appropriate local
or national safety procedures.
1. Turn OFF the power supply and remove all side panels. Use compressed air to blow out any accumulation of dust
and particulates.
2. Inspect wiring harnesses and connections for wear, damage, or loose connections. If you see any discoloration that
might indicate overheating, contact Hypertherm Technical Service.
3. Inspect the main contactor for excessive pitting on the contacts, characterized by a blackened, rough surface on any
of the contacts. If this condition exists, replacement is recommended.
156
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Cooling system
4. Inspect the coolant-circulating system’s filter element at the rear of the power supply. If the filter is a brownish color,
replace it. Consult the Parts List in this manual for part numbers.
5. Perform a coolant flow test as described in this manual, then check for coolant leaks. Inspect these locations:
a.
The back of the power supply
b.
Ignition enclosure
c.
Torch main body
Also, check the coolant tank for dirt and particulates. Verify that proper Hypertherm coolant is being used. Proper
Hypertherm coolant (028872) is a pink liquid.
Torch main body
6. Verify that the water tube is straight and has no pitting on the end.
7.
Inspect the current ring inside the torch main body. The current ring should be smooth and not pitted. If no pitting is
observed, clean the current ring with a clean cotton swab and hydrogen peroxide. Do not use alcohol. Pitting on the
current ring generally indicates improper maintenance (for example, lack of regular cleaning).
8. Clean all threads on the front end of the torch head with hydrogen peroxide and a cotton swab, pipe cleaner or clean
cloth. Do not use alcohol. Damage to the threads usually results from not cleaning the torch and retaining cap
threads properly, so that dirt and particulates accumulate in the threads.
9. Inspect the torch insulator for cracks. Replace the torch if you find cracks.
10. Inspect all o-rings on the torch body and consumables. Make sure that the correct amount of lubricant – a thin film –
is applied to these o-rings. Too much lubricant may obstruct gas flows.
11. Check that the retaining or shield cap is tightened securely to the torch main body.
12. Inspect all hose fittings at the rear of the torch for wear. Damage to the fitting threads may indicate that overtightening
has occurred.
13. Check that all connections between the torch and torch leads are tight, but do not overtighten. See torque specs in
the Installation section of this manual.
When removing consumables, always place them on a clean, dry, oil-free surface, since dirty consumables may cause the
torch to malfunction.
Gas flows
14. Perform the appropriate gas flow tests described under Diagnostic functions on page 128.
MAXPRO200 Instruction Manual 807700 Revision 1
157
Maintenance
15. If the gas line pressures hold steady, perform a system gas leak test as specified in this manual.
16. Check for hose restrictions, as follows:
a.
Check all hoses to verify that they have no kinks or sharp bends, which can restrict gas flow.
b.
If the cutting table uses a power track system to support leads from the power supply to the gas console or
torch, check the position of the leads in the power track to ensure the leads do not twist or kink, causing a
possible restriction.
Cable connections
17. All cables should be checked for chafing or unusual wear. If the outside insulation has been cut or otherwise
damaged, replace the cable.
Ignition enclosure
18. Remove the panel from the ignition enclosure and use compressed air to blow out any accumulation of dust and
particulates. If moisture is present, dry the inside of the enclosure with a cloth and try to identify the source of the
moisture.
19. Ensure that all wiring connections are secure. Verify that the enclosure panel fits properly.
20. Inspect the torch leads. Ensure that they are fastened tightly to the outside of the ignition console.
System grounding
21. Verify that all components of the system are individually grounded to a driven earth ground, as described in the
Installation and Grounding sections of this manual.
a.
All metal enclosures, such as the power supply, ignition console and gas console, should be connected
individually to a ground point. These connections should be made with 10 mm2 (#8 AWG) wire (USA), or
equivalent-size wire.
22. Check the work lead (+) connection, particularly where the work lead (+) connects to the cutting table. This must be
a good, clean connection because a poor connection may cause arc-transfer problems.
23. Complete the Preventive Maintenance worksheet on the next page, for future reference.
158
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Preventive Maintenance Master Schedule
Daily:
•
Verify proper inlet gas pressure.
•
Verify proper gas flow settings. – Mandatory at every consumable change.
•
Inspect torch and replace consumables as needed.
Weekly:
Week
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
1
2
3
4
5
•
Clean power supply with dry, oil free compressed air or vacuum.
•
Verify cooling fans are working properly.
•
Clean torch threads and current ring.
•
Verify proper coolant level.
Semi-annually:
Year
•
1st Service
2nd Service
Replace service parts per the Service part Replacement Schedule.
Annually:
Year
•
Replace service parts per the Service Part Replacement Schedule.
MAXPRO200 Instruction Manual 807700 Revision 1
159
Maintenance
Preventive Maintenance Protocol Checklist
Location: ________________________________________
Hypertherm system: _______________________________
Contact: ________________________________________
System Serial #: _________________________________
Date: ___________________________________________
System arc hours: ________________________________
(if equipped with an hour meter)
Comments
P – Performed NP – Not present on system
Power supply
P NP
P NP
P NP
Cable connections
1. Use compressed air or a vacuum to clean
out dust and particulates.
2. Inspect wiring harnesses.
3. Inspect main contactor.
Coolant system
P NP
P NP
P NP
4. Inspect filter element.
5. Perform coolant flow test. Coolant flow
checked at _______ gpm (_______ l/min).
6. Use compressed air or a vacuum to clean
out the heat exchanger.
P NP
15. Inspect torch height control cables.
Ignition enclosure
P NP
P NP
16. Inspect for moisture, dust, and particulates.
17. Inspect torch leads.
System grounding
P NP
P NP
18. Inspect for proper system component
grounding.
19. Inspect connection from cutting table to
workpiece (+) lead.
Torch main body
P
P
P
P
P
P
P
NP
NP
NP
NP
NP
NP
NP
7. Inspect water tube.
8. Inspect current ring.
9. Clean threads on torch front end.
10. Inspect torch and consumable o-rings.
11. Verify proper fit of retaining or shield cap.
12. Inspect hose fittings.
13. Inspect torch-to-torch-lead connections.
Gas flows
P NP
P
P
P
P
P
P
14. Inspect plumbing from the gas supply.
NP
NP
NP
NP
NP
NP
A. Oxygen
B. Nitrogen
C. Air
D. Inspect supply gas filter
E. Inspect hoses for restrictions
F. Perform the plasma gas leak test.
Pressure drops ________ psi
(________ bar) in 5 minutes.
General comments and recommendations:
_____________________________________________________________________________________________________
_____________________________________________________________________________________________________
_____________________________________________________________________________________________________
Preventive maintenance performed by: ______________________________________ Date:___________________
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MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Year 1 preventive maintenance (PM) kits
Torch configuration
Input Voltage
Quick-disconnect
Straight
65° Hand
90° Hand
200V – 240V
428051
428052
428053
428082
380V – 600V
428083
428084
428085
428086
Maintenance kits parts list
Each of the preventive maintenance kits contains the following parts:
Description
Quantity Description
Quantity Description
Quantity
Air filter element
2
Coolant solution
8
Torch main body
1
Coolant filter element
2
Main contactor
1
Torch bullet plug kit
(Quick-disconnect PM kit only)
1
Service parts replacement schedule
Timeline
Component
6 months / 300 arc hours
Main contactor (choose one)
1 year / 600 arc hours
Torch main body (choose one)
1.5 years / 900 arc hours
Main contactor (choose one)
2 years / 1200 arc hours
Torch main body (choose one)
Part number Quantity
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Main contactor 200V – 240V
003233
Main contactor 380V – 600V
003249
Torch main body (straight torch)
420087
Torch main body (quick-disconnect torch)
220921
Torch main body (90° Hand torch)
420070
Torch main body (65° Hand torch)
420109
1
1
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Main contactor 200V – 240V
003233
Main contactor 380V – 600V
003249
Torch main body (straight torch)
420087
Torch main body (quick-disconnect torch)
220921
Torch main body (90° Hand torch)
420070
Torch main body (65° Hand torch)
420109
Air filter element
011093
1
Pump replacement kit
428043
1
System
dependant
1
Torch leads
MAXPRO200 Instruction Manual 807700 Revision 1
1
1
161
Maintenance
Timeline
Component
2.5 years / 1500 arc hours
Main contactor (choose one)
3 years / 1800 arc hours
Torch main body choose one)
3.5 years / 2100 arc hours
Main contactor (choose one)
4 years / 2400 arc hours
Torch main body (choose one)
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Main contactor 200V – 240V
003233
Main contactor 380V – 600V
003249
Main contactor (choose one)
5 year / 3000 arc hours
Torch main body (choose one)
162
1
Torch main body (straight torch)
420087
Torch main body (quick-disconnect torch)
220921
Torch main body (90° Hand torch)
420070
Torch main body (65° Hand torch)
420109
Air filter element
011093
Fan: 450–550 cfm, 120 VAC 50–60 Hz (10
inches)
027079
Heat exchanger fan (11 inches)
127091
1
Coolant filter element
027005
1
1
1
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Main contactor 200V – 240V
003233
Main contactor 380V – 600V
003249
Torch main body (straight torch)
420087
Torch main body (quick-disconnect torch)
220921
Torch main body (90° Hand torch)
420070
Torch main body (65° Hand torch)
420109
Air filter element
011093
1
Pump replacement kit
428043
1
System
dependant
1
Torch leads
4.5 years / 2700 arc hours
Part number Quantity
1
1
Pump motor replacement kit
428039
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Main contactor 200V – 240V
003233
Main contactor 380V – 600V
003249
Torch main body (straight torch)
420087
Torch main body (quick-disconnect torch)
220921
Torch main body (90° Hand torch)
420070
Torch main body (65° Hand torch)
420109
Air filter element
011093
1
1
1
MAXPRO200 Instruction Manual 807700 Revision 1
Maintenance
Timeline
Component
5.5 years / 3300 arc hours
Main contactor (choose one)
Torch main body (choose one)
6 years / 3600 arc hours
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
Coolant filter element
027005
1
Coolant solution 70/30
028872
4
Main contactor 200V – 240V
003233
Main contactor 380V – 600V
003249
Torch main body (straight torch)
420087
Torch main body (quick-disconnect torch)
220921
Torch main body (90° Hand torch)
420070
Torch main body (65° Hand torch)
420109
1
1
Air filter element
011093
1
Pump replacement kit
428043
1
System
dependant
1
Torch leads
6.5 years / 3900 arc hours
Part number Quantity
Fan: 450–550 cfm, 120 VAC 50–60 Hz (10
inches)
027079
Heat exchanger fan (11 inches)
127091
1
Coolant filter element
027005
1
1
Coolant solution 70/30
028872
4
Torch o-ring
044026
2
Air filter element
011093
1
MAXPRO200 Instruction Manual 807700 Revision 1
163
Maintenance
164
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Control panel
1
2
5
4
Item
3
Part Number
Description
1
428032
Control panel replacement kit
1
2
108797
Knob: soft black, no pointer
3
3
007050
Rocker switch bezel
1
4
005678
Rocker switch
1
5
075237
Screw (control panel and enclosure panels): 10-32, Torx T-25
18
MAXPRO200 Instruction Manual 807700 Revision 1
Quantity
165
Parts List
Power supply
1
2
Power supplies
Part number
Voltage (AC)
078610
200/208 volt
078611
220 volt
078612
240 volt
078613
380 volt
078614
400 volt
078615
415 volt
078616
440 volt
078609
480 volt
078617
600 volt
3
8
4
7
5
6
Item
Part Number
Description
1
See chart above
Power supply
2
428033
Lift eye replacement kit
1
3
428031
Top panel replacement kit
1
4
027967
Handle: side panels
2
5
428029
Right side panel replacement kit
1
6
101188
Front panel
1
7
428030
Left side (not shown) panel replacement kit
1
8
428032
Control panel replacement kit
1
Optional caster (wheel) kit
1
Not shown 428035
166
Quantity
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Power supply
1
2
3
4
5
6
8
7
Item
Part Number
Description
Quantity
1
141171
Control Board
1
2
110261
Label: Warning instant start
1
3
010298
Label: Warnings
1
4
011114
Air filter/regulator: 7–125 psi, 1/4 inch, auto drain with valve
1
011093
Air filter element
1
5
228862
Gas hoses kit (not all hoses shown above)
1
6
428038
Coolant filter replacement kit
1
7
228861
Coolant hose kit (not all hoses shown above)
1
8
109377
Resistor: 1 ohm, 500 watts
3
027005
Coolant filter element
MAXPRO200 Instruction Manual 807700 Revision 1
1
167
Parts List
Power supply
1
2
3
13
12
11
4
5
10
Item
168
9
8
6
7
Part Number
Description
1
428036
Chopper replacement kit
Quantity
2
127014
Coolant reservoir cap
1
3
002546
Coolant reservoir
1
4
006099
Coolant drain valve
1
5
228993
Coolant solenoid valve replacement kit
1
6
428039
Pump motor replacement kit
1
7
015665
Fitting: male elbow, 3/8 inch NPT x 1/2 inch push-in tube
2
8
428043
Pump replacement kit
1
9
015815
Fitting: elbow, 1/2 inch x 1/2 inch push-in tube, brass
2
1
10
074354
Cable holder: for 1/2 inch diameter cable
17
11
104407
Bushing: dust seal
6
12
074353
Cable holder: for 1/4 inch diameter cable
10
13
074355
Cable holder: for 3/4 inch diameter cable
10
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Power supply
1
2
3
3
10
4
9
8
7
6
5
Item
Part Number
Description
1
015669
Male connector 3/8 inch NPT x 1/2 inch
2
428034
Gas manifold replacement kit
1
3
428042
Pressure transducer replacement kit
2
4
428037
Flow meter replacement kit
1
5
109636
EMI filter: 250 VAC, 1 amp, 1 phase
2
6
229474
Thermistor: 3/8 inch diameter, copper pipe clip with connector
1
7
015663
Male connector 1/4 inch NPT x 1/2 inch tube
1
8
006075
Check valve
1
9
015664
Male elbow 1/4 inch NPT x 1/2 inch push-in tube
1
10
229482
Heat exchanger (with fan)
1
Heat exchanger fan only
1
127091
MAXPRO200 Instruction Manual 807700 Revision 1
Quantity
7
169
Parts List
Power supply
2
1
8
7
3
6
Item
5
4
Part Number
Description
Quantity
1
209177
EMI filter, 400V and 415V power supplies
2
008301
Fuse holder
1
108571
Fuse holder cover
1
110513
Fuse label: F1–F2
1
008551
Fuse: 7.5 amp, 600 volt: 380V, 400V, 415V, 440V, 480V, and 600V power supplies
2
008709
Fuse: 20 amp, 500 volt: 200/208V, 220V, and 240V power supplies
2
3
027567
Fan guard
1
4
014373
Inductor
2
5
074212
Cable holder: self sticking, for 1/2 inch diameter cable
5
6
074356
Cable holder: for 1.0 inch diameter cable
5
7
108671
Terminal block: 14 AWG – 2/0
1
8
003249
Contactor: 380V, 400V, 415V, 440V, 480V, and 600V power supplies
1
003233
Contactor: 200/208V, 220V, and 240V power supplies
1
170
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Power supply
1
Control transformers
Part number
Description
Part number
Description
229535
200 volt, 50–60 Hz
229538
415 volt, 50–60 Hz
229536
220 volt, 50–60 Hz
229539
440 volt, 50–60 Hz
229537
240 volt, 60 Hz
229488
480 volt, 60 Hz
229514
380 volt, 50 Hz
229540
600 volt, 50–60 Hz
229515
400 volt, 50 Hz
1
6
5
2
4
3
Item
Part Number
Description
1
See table above
Control transformer
1
2
027079
Fan: 450–550 cfm, 120 VAC 50–60 Hz
1
3
101205
Ignition enclosure panel (ignition)
1
4
428044
Inlet gas-plug replacement kit
1
5
015812
Adaptor:1/4 inch NPT o-ring x 5/16 inch
1
6
010875
Label: Danger voltage
1
Not shown 428054
Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit)
1
Not shown 015015
Adapter: 1/4 inch NPT, #6, Male, 90 degree
1
Not shown 015817
Adapter: 3/8 inch FNPT x 1/2 inch push-in tube
1
MAXPRO200 Instruction Manual 807700 Revision 1
Quantity
171
Parts List
Ignition enclosure
1
2
3
5
Item Part Number
4
Description
Quantity
1
428040
2
428041
I/O panel replacement kit (includes PCB)
1
3
229487
Ignition transformer
1
4
109636
EMI filter
1
5
008482
Power cord strain relief (380V, 400V, 415V, 440V, 480V, and 600V power supplies)
1
008052
Power cord strain relief (200/208V, 220V, and, 240V power supplies)
1
172
I/O PCB replacement kit
1
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Height control connection kits
Sensor THC connection kit – 428023
The kit contains a PCB (141201), and a wire harness (229554). A CNC interface cable is not supplied. The desired
length should be ordered separately.
Sensor PHC connection kit – 428022
The kit contains a PHC plasma interface assembly (228256) with a 1.3 m (5 feet) interface cable attached. A CNC
interface cable is not supplied. The desired length should be ordered separately.
Wire groups and harnesses
Part Number
Description
229437
Main wire harness: all power supplies
229438
Primary power wire group for 380V, 400V, 415V, 440V, 480V, and 600V power supplies
229439
EMI filter wire group for 400V and 415V power supplies
229558
Contactor wire adaptors
229561
Primary power wire group for 200/208V, 220V, and 240V power supplies
USB cables for software updates
Cable for USB update – 223291
Note: This cable allows the system software to be upgraded using a USB memory stick.
Cable for USB update – 223273
Note: This cable allows the system software to be upgraded using a laptop.
Power supply gas hose kit – 228862
The kit contains:
Part Number
Description
Length
046077
Tubing: 1/4 inch OD, blue
1 foot
046078
Tubing: 1/4 inch OD, black
1 foot
046231
Tubing: 5/16 inch OD, black
2 feet
173
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Machine torches
Straight torch
1
4
5
Item
1
2
3
4
3
Part Number
Description
Quantity
428024
Machine torch assembly with 2.0 inch mounting sleeve
1
228937
Machine torch assembly with 1-3/4 inch mounting sleeve
1
220943
Torch Mounting sleeve: 2 inch
1
220942
Torch Mounting sleeve: 1-3/4 inch
1
420087
Straight torch main body
1
044026
5
2
O-ring: 1.239 inch x 0.070 inch
220521
2
Water tube
1
Quick-disconnect torch
1
6
Item
1
2
Part Number
3
2
Description
Quantity
428027
Quick-disconnect torch assembly with 2.0 inch mounting sleeve
1
428028
Quick-disconnect torch assembly with 1-3/4 inch mounting sleeve
1
220943
Torch Mounting sleeve: 2 inch
1
220942
Torch Mounting sleeve: 1-3/4 inch
1
3
420033
Quick-disconnect torch receptacle
1
4
220921
Quick-disconnect torch main body
1
5
6
174
4
5
044026
220521
O-ring: 1.239 inch x 0.070 inch
Water tube
2
1
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Leads and cables
Machine torch leads
Part Number
Length
229477
7.5 m (25 feet)
229478
15 m (50 feet)
229479
23 m (75 feet)
229480
30 m (100 feet)
CNC cables
Part Number
Length
223327
1.3 m (5 feet)
223328
3.0 m (10 feet)
223329
7.5 m (25 feet)
223330
15 m (50 feet)
223331
23 m (75 feet)
223332
30 m (100 feet)
Work leads
Part Number
Length
223335
7.5 m (25 feet)
223336
15 m (50 feet)
223337
23 m (75 feet)
223338
30 m (100 feet)
Work clamp
Part Number
Description
008539
Ground clamp
Hand torch leads
Part Number
Length
229498
7.5 m (25 feet)
229499
15 m (50 feet)
229500
23 m (75 feet)
229501
30 m (100 feet)
Inline valve kit
Part Number
Description
428055
Replacement for the valve located in the torch lead
Hand torch heat shield – 127389
MAXPRO200 Instruction Manual 807700 Revision 1
175
Parts List
90 degree hand torch
1
2
2
4
3
Item
1
2
Part Number
Description
420108
90 degree hand torch assembly
1
228980
90 degree hand torch assembly with 7.5 m (25 feet) lead
1
228981
90 degree hand torch assembly with 15 m (50 feet) lead
1
228982
90 degree hand torch assembly with 23 m (75 feet) lead
1
228983
90 degree hand torch assembly with 30 m (100 feet) lead
1
228985
4
176
Quantity
Handle replacement kit
1
001905
90 degree torch handle (left and right sides)
1
002244
Safety trigger
1
027254
Safety trigger spring
1
075841
Pan head screws
6
210185
Hand torch label
1
Hypertherm IEC label
1
210209
3
2
420070
044026
Torch main body
O-ring: 1.239 inch x 0.070 inch
1
2
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
65 degree hand torch
2
1
2
4
2
3
Item
1
2
Part Number
Description
420107
65 degree hand torch assembly
1
228976
65 degree hand torch assembly with 7.5 m (25 feet) lead
1
228977
65 degree hand torch assembly with 15 m (50 feet) lead
1
228978
65 degree hand torch assembly with 23 m (75 feet) lead
1
228979
65 degree hand torch assembly with 30 m (100 feet) lead
1
228986
Handle replacement kit
1
001906
65 degree torch handle (left and right sides)
1
002244
Safety trigger
1
027254
Safety trigger spring
1
075841
Pan head screws
6
210184
Hand torch label
1
Hypertherm IEC label
1
210209
3
4
Quantity
420109
044026
Torch main body
O-ring: 1.239 inch x 0.070 inch
MAXPRO200 Instruction Manual 807700 Revision 1
1
2
177
Parts List
Consumable parts kits
Mechanized torch consumable kit – 428013
Part number
Description
020415
Electrode: 200A and 130A, N2
2
027055
Silicone lubricant: 1/4 ounce tube
1
044026
O-ring: 1.239 x 0.070
2
104119
Consumable tool
1
220487
Electrode: 130 A, O2/Air
4
220488
Swirl ring: 130 A, O2/Air and 200 A, Air
2
220491
Shield:130 A, O2
1
220521
Water tube
1
220528
Electrode 50 A, O2/Air
4
220529
Swirl ring: 50 A, O2/Air and 130A or 200A, N2
1
220532
Shield: 50A, O2/Air
1
220536
Shield:130A, Air/N2
1
220831
Nozzle: 200A, O2
2
220832
Shield: 200A, O2
1
220834
Swirl ring: 200A, O2
1
220890
Nozzle: 50A, Air
2
220891
Nozzle: 50A, O2
2
220892
Nozzle: 130A, Air/N2
2
220893
Nozzle: 130A, O2
2
220935
Shield cap: O2/Air/N2, clockwise
1
220936
Shield cap: O2/Air/N2, clockwise, with IHS tab
1
220937
Electrode: 200, O2/Air
6
420044
Nozzle: 200A, Air/N2
6
420045
Shield: 200A, Air/N2
2
428054
Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit)
1
881430
MAXPRO200 machine torch brochure
1
178
Quantity
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Hand torch consumable kit – 428014
Part number
Description
027055
Silicone lubricant: 1/4 ounce tube
1
044026
O-ring: 1.239 x 0.070
2
104119
Consumable tool
1
220488
Swirl ring: 130A, O2/Air and 200 A, Air
2
220521
Water tube
1
220831
Nozzle: 200A, O2
2
220834
Swirl ring: 200A, O2
1
220935
Shield cap: O2/Air/N2, clockwise
2
220937
Electrode: 200A, O2/Air
8
420044
Nozzle: 200A, Air/N2
4
420058
Shield: 200A, Air/N2
2
420059
Shield: 200A, O2
1
420066
Nozzle: 200A, Air, Gouging
2
420067
Shield: 200A, Air, Gouging
2
428054
Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit)
1
881440
MAXPRO200 hand torch brochure
1
MAXPRO200 Instruction Manual 807700 Revision 1
Quantity
179
Parts List
Supply gas hoses
Caution: Never use teflon tape on any joint preparation
Oxygen
Part number
Length
Part number
Length
024607
3 m (10 ft)
024738
25 m (82 ft)
024204
4.5 m (15 ft)
024450
35 m (115 ft)
024205
7.5 m (25 ft)
024159
45 m (150 ft)
024760
10 m (35 ft)
024333
60 m (200 ft)
024155
15 m (50 ft)
024762
75 m (250 ft)
024761
20 m (65 ft)
Part number
Length
Nitrogen
Part number
Length
024210
3 m (10 ft)
024739
25 m (82 ft)
024203
4.5 m (15 ft)
024451
35 m (115 ft)
024134
7.5 m (25 ft)
024120
45 m (150 ft)
024211
10 m (35 ft)
024124
60 m (200 ft)
024112
15 m (50 ft)
024764
75 m (250 ft)
024763
20 m (65 ft)
Air
Part number
Length
Part number
Length
024671
3 m (10 ft)
024740
25 m (82 ft)
024658
4.5 m (15 ft)
024744
35 m (115 ft)
024659
7.5 m (25 ft)
024678
45 m (150 ft)
024765
10 m (35 ft)
024680
60 m (200 ft)
024660
15 m (50 ft)
024767
75 m (250 ft)
024766
20 m (65 ft)
180
MAXPRO200 Instruction Manual 807700 Revision 1
Parts List
Recommended spare parts
Part number
Description
Quantity
003233
Contactor: 200/208V, 220V, and 240V power supplies
1
003249
Contactor: 380V, 400V, 415V, 440V, 480V, and 600V power supplies
1
011093
Air filter element
1
027005
Coolant filter element
1
027055
Silicone lubricant: 1/4 ounce tube
1
027079
Fan: 450–550 cfm, 120 VAC 50–60 Hz
1
028872
Coolant solution, 70/30 PG, 1 gallon
4
127091
Heat exchanger fan
1
141171
Control Board
1
220921
Quick-disconnect torch main body
1
220942
Torch Mounting sleeve: 1-3/4 inch
1
220943
Torch Mounting sleeve: 2 inch
1
420033
Quick-disconnect torch receptacle
1
420070
90 degree torch main body
1
420087
Straight torch main body
1
420109
65 degree torch main body
1
428034
Gas manifold replacement kit
1
428035
Castor wheel kit
1
428036
Chopper replacement kit
1
428037
Flow meter replacement kit
1
428038
Coolant filter replacement kit
1
428039
Pump motor replacement kit
1
428040
I/O PCB replacement kit
1
428041
I/O panel replacement kit (includes PCB)
1
428042
Pressure transducer replacement kit
1
428043
Pump replacement kit
1
428044
Inlet gas-plug replacement kit
1
428054
Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit)
1
428055
In-line valve replacement kit
1
MAXPRO200 Instruction Manual 807700 Revision 1
181
Parts List
182
MAXPRO200 Instruction Manual 807700 Revision 1
Wiring Diagrams
This section contains the wiring diagrams for the system. When you trace a signal path, or reference the Parts List or
Troubleshooting sections, the following conventions will help you understand the organization of the wiring diagrams:
•
Sheet numbers are located in the lower, right-hand corner of each page.
•
References to other pages use the following connection symbol:
Sheet
4-D3
Sheet number
C
Coordinates
Reference block
Use the sheet number to find the reference sheet. Line up the coordinates A–D on the Y axis and numbers 1–4 on the X
axis of each sheet to find the reference blocks (similar to a road map).
MAXPRO200 Instruction Manual 807700 Revision 1
183
Wiring Diagrams
Wiring diagram symbols
184
Battery
Ground clamp
Receptacle
Cap, polarized
Ground, chassis
Relay, coil
Cap, not polarized
Ground, earth
Relay, normally closed
Cap, feed-through
IGBT
Relay, normally open
Circuit breaker
Inductor
Relay, solid state, AC
Coax shield
LED
Relay, solid state, DC
Current sensor
Lamp
Relay, solid state, dry
Current sensor
MOV
Resistor
DC supply
Pin
SCR
Diode
Socket
Shield
Door interlock
Plug
Shunt
Fan
PNP transistor
Spark gap
Feedthrough LC
Potentiometer
Switch, flow
Filter, AC
Push button, normally closed
Switch, level, normally closed
Fuse
Push button, normally open
Switch, pressure,
normally closed
MAXPRO200 Instruction Manual 807700 Revision 1
Wiring Diagrams
Switch, pressure, normally open
Time delay open, NO/off
Valve, solenoid
Switch, 1 pole, 1 throw
Time delay open, NC/on
Voltage source
Switch, 1 pole, 2 throw
Time delay closed, NO/off
Zener diode
Switch, 1 pole, 1 throw,
center off
Transformer
Switch, temperature,
normally closed
Transformer, air core
Switch, temperature,
normally open
Transformer, coil
Terminal block
Triac
Time delay closed, NC/off
VAC source
Torch symbols
Electrode
Nozzle
Shield
Torch
Torch, HyDefinition™
MAXPRO200 Instruction Manual 807700 Revision 1
185
Wiring Diagrams
186
MAXPRO200 Instruction Manual 807700 Revision 1
MAXPRO 200
Gas Schematic
Air/Air
N2/N2
Air
O2/AIR
Air
N2
Filter
Regulator
Pressure gage
Filter
Regulator
Pressure gage
Filter
Regulator
Pressure gage
Shield
Shield
Plasma
B2
P2
P2
P1
Shield Gas & Pilot Arc
Blue Hose
B2
B1
P2
P1
Shield Gas & Pilot Arc
Blue Hose
Plasma Gas
Black Hose
21', 46', 71', 96'
Torch Valve
B1
P1
I/O board
I/O board
I/O board
Plasma
Power Supply
B2
B1
Plugged
Shield
Plasma
Power Supply
Power Supply
02
Shield Gas & Pilot Arc
Blue Hose
Plasma Gas
Black Hose
21', 46', 71', 96'
Torch Valve
Plasma Gas
Black Hose
21', 46', 71', 96'
Torch Valve
4'
4'
4'
Hand/Mech
Torch
Hand/Mech
Torch
Hand/Mech
Torch
187
4
3
2
1
D
D
Torch Lead Assembly
Plasma Gas Lead
Gas Solenoid Valve Enable
Cooling Supply Lead
Gas 1
Gas 2
Unit 1
Power Supply
Cooling Return Lead
Shield Gas Lead
Negative Lead
Start Trigger
Pilot Arc Lead
Plasma Gas Lead
Gas Solenoid Valve Enable
Plasma
Solenoid
Lead Length ID
Unit M
Torch
Lifter
(Optional Unit)
C
3 Phase
Power
w/ Ground
C
Torch
Work Lead
Workpiece
B
B
CNC
CUSTOMER
SUPPLIED
A
A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 1 OF 9
4
188
3
2
1
A
4
3
1
A
BLK
J18
RED
J2.8
1
2
009045
FILTER
3-B1
PILOT ARC ENABLE
SHEET
3-B1
J2.3
RED
CLR
BLK
RED
CLR
BLK
RED
CLR
BLK
B2
B3
TRANSFORMER TEMP
SHEET
3-C4
E1 SHEET
BUS VOLTAGE
3-A3
J3
1
2
3
4
5
6
7
8
9
10
D+5V
PWM CHP A
GND
D+5V
PWM CHP B
GND
D+5V
PILOT ARC EN
GND
CHASSIS
GND
BUS VOLTAGE
GND
D1
D2
RED
BLK
P+18V/-5V
+18V
+15V
D+5V
A+5V
RED/BLK 20
RED
19
1
2
J11
INPUT POWER
FROM FACILITY
PE L1 L2 L3
V
T1
1A
PE
0
P2
CON1
P3
D14
D6
D22
D10
D20
RED
GRN
BLK
WHT
INDUCTOR 1
H SHEET
3-C4
TEMP
2
J4
T2
J4
C4
0.22uF
009224
1KV
NEG 1 (-)
L1
J7
J3.7
J5
CS2
NEG 2 (-)
L2
1B
1C
1C
2A
2A
2B
2B
+15V
2C
-15V
GND
SIG
T3
1
2
CHOPPER CURRENT B
RED
BLK
5
1
2
3
4
6
J2.9
H8
J2.2
Shown for 480V
L SHEET INDUCTOR 2
3-C4
TEMP
CHOPPER
M SHEET CURRENT B
3-A4
J2.6
J6
SHOWN WIRED FOR 480V
SEE PAGES 6 AND 7 FOR
OTHER CONFIGURATIONS
RED
GRN
BLK
WHT
C6
350UF
C7
0.22uF
009224
1KV
B
J3.6
(++)POSITIVE
R6
C8
.022UF 10K
CS1
R34
1R
COLLECTOR
R35
1R
COLD PLATE
TEMP
ORN 240VAC
J2.9 J9
1
2
(-)NEGATIVE
TORCH (-)
R4
100K
R5
10R
J3.10
WORK
PA LEAD TO TORCH
R1 R2 R3
9.1K 9.1K 9.1K
R36
1R
J9
POSITIVE (+)
WORK(+)
C9
R7
.22UF 10K
J8
T2
RED 120VAC
C
J5
J10
1B
CONTROL
TRANSFORMER
YEL 24VAC
T2
009793
I/O
BOARD
141216
RED
BLK
PILOT ARC
CONTROLLER
A
ARC VOLTAGE
B4 SHEET
9-A3
J3
BLU
BLK
RED
GRY
WHT
5
1
2
3
4
6
1
CS1
1400pF 20kV
ARC VOLTAGE WIRES NEED TO BE CONNECTED IF
A PLASMA INTERFACE BOARD IS INSTALLED.
WIRE RUNS ARE TO A TERMINAL BLOCK NEAR
PLASMA INTERFACE BOARD MOUNTING LOCATION
J2.1
J1
+15V
-15V
GND
SIG
CHOPPER
CURRENT A
1A
2C
F2
SHEET
3-A4
F
0
0
* OPTIONAL
SG1
C5 C4 C3
T1
F1
109344
5kV
J12
BLK L2
BLK L3
B
A4
B4
C4
L1
L2
L3
J2
J1
BLK
RED
SHLD
009975
W
P1
W
V
U
PE
D
CHOPPER TEMP
E2 SHEET
3-A3
SG2
CHOPPER CURRENT A
C
HF EN
G SHEET
3-D1
2
T1
129854
D3
CONTACTOR ENABLE
D SHEET
3-D1
3
4
5
6
7
GND
TEMP ADC
CHOPPER
141188
C
J10 J2.10
BLU
1
WHT
2
1
2
PWM CHP B SHEET
D
B1
3
3-B1
1
PWM CHP A SHEET
J8
15VAC
PWR IN
RED/BLK
RED
GRN
1
2
3
YEL/BLK
YEL
SHEET
CHOPPER PWR 3-D1
2
H9
J2.7
NOZZLE
A+5V
SIG
N
SHEET
3-A2
WORK LEAD CURRENT
A
K SHEET
3-D4
CONTROL
XFORMER
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 2 OF 9
4
3
2
A
1
189
4
YEL
24VAC YEL
RED
120VAC RED
ORN
240VAC ORN
D
1
2
3
4
5
6
POWER SUPPLY CONTROL BOARD
141201
24VAC
120VAC F2
120VAC SWITCHED
240VAC SWITCHED
240VAC F1
GND
K1
J4
POWER SWITCH
2
3
8
G
6
A
C
INDUCTOR 1 SHEET
TEMP 2-C2
INDUCTOR 2 SHEET
TEMP 2-B2
C
H
L
POWER ON
STANDBY
D33
3.3V
D37
5V
D40
24V
D41
120V FUSED AC INPUT
D42
240V INPUT DETECTED
D44
120V INPUT DETECTED
AC RTN
D70
D35
CHOPPER A OVER CURRENT
D100
CHOPPER B OVER CURRENT
PUMP MOTOR ENABLE
FAN
SHEET GAS CONSOLE/
B5 9-C1
PLASMA INTRFC
INDUCTOR 2 TEMPERTURE
D104
D105
D65
J18
1 2 3 4 5 6 7 8
8
WHT
BLU
RED
GRN
BLK
WHT
RED
GRN
BLK
WHT
BLK
RED
WHT
BLU
J1.21
M
E1
12
TORCH VALVE ENABLE
13
14
15
D101
D102
D103
CHOPPER A PWM
CHOPPER B PWM
PILOT ARC ENABLE
16
17
18
BLK
RED
SHLD
SV1
SHEET
SHEET
SHEET
B3 2-D3
1 2 3 4
PLASMA VALVE
SV1
SV2
B1 2-D3
B2 2-D3
Z
1 2
SHEET
D106
11
BLK
RED
SHLD
RED
RED
RED
BLK
BLK
BLK
CLR
CLR
CLR
SHIELD VALVE
SV2
B
PWM CHP A
PWM CHP B
PILOT ARC ENABLE
J1.17
RED
BLK
CLR
RED
BLK
BLU
J1.18
F
E2
P+5V
1 2 3 4 5 6
SHEET
4-A4
TORCH VALVE
J9
FL1
3 2 1
A
FL1
ELEC SCH:MAXPRO200 POWER SUPPLY
COOLANT TEMP
WORK LEAD CURRENT SHEET
2-A1
190
BLK
BLK
J17
J21
3 2 1
4
+24V
10
WORK LEAD CURRENT
D68
COOLANT FLOW
WL +15V
CLT +15V
COOLANT TEMPERATURE
FA3.3V
PILOT ARC TEMP
BUS VOLTAGE
CHOPPER TEMP
CHOPPER CURENT B
SHEILD
PRESSURE
F-15V
PLASMA PRESSURE
SHEET
2-D2
BUS VOLTAGE 2-D2
5
9
1 2
CHOPPER TEMP
4
6
J1.15
A
PLASMA VALVE PWM
SHIELD VALVE PWM
7
1 2 3 4 5 6 7 8 9 10 11 12
CHOPPER CURENT B SHEET
2-B2
J16 J1.16
RED
1
RED
2
+24V
J15
2-C2
C
3
2
3
4
5
6
CHOPPER CURENT A SHEET
CLT SOL
1 3 2 J13
WHT J17
HEAT XCHANGER
BLK
INDUCTOR 1 TEMPERATURE
CHOPPER CURENT A
BLK
YLW
PUMP MOTOR
WHT
BLK
TRANSFORMER TEMPERATURE
F+15V
BLU
BLK
PS
1 2 3
P2
WHT
BLK
PS
J1.13 J13
RED
1
1 2 3 4
BRN
B
1 3 2 J14
1 2 3
P2
D
TRANSFORMER
FAN
1 2 3
BLU
BLK
HIGH FREQUENCY
ENABLE
1 2 3
P1
120VAC FUSED
240VAC RELAY
240VAC SWITCH OUT
G SHEET
2-D1
RED/BLK
RED
FA3.3V
J1.11 J11
RED
1
2
BLK
3
YLW
4
5
6
1 2 3 4
BRN
CONTACTOR ENABLE
HIGH FREQ ENABLE
MAGNETICS FANS
D51
D46
+15V
P1
J14 J1.14
RED/BLK
1
RED/BLK
2
RED/BLK
3
RED
4
RED
5
RED
6
RED
7
WHT
8
WHT
9
RED/BLK
10
BLK
11
BLK
12
1 2
2-D4
J1.12 J12
RED
1
BLK
2
3
RED
4
BLK
5
6
RED
7
BLK
8
9
10
+24V
240V FUSED AC INPUT
CONTACTOR ENABLE
1 2
TRANSFORMER
TEMP SHEET
1
2
3
4
5
6
7
D31
D SHEET
2-D4
1 2
7
J8
15V
CHOPPER POWER
1 2
J1.8
OPTIONAL
CUSTOMER BLK
REMOTE
ON/OFF
BLU
WHT
BLK
YLW
RED
D26
A SHEET
2-D3
J22 J1.22
RED
+15VAC_2
BLK
1 2
TRANSFORMER
J9
TCHVLV-
J1.9
TCHVLV+
K
1
2
RED
BLK
SHEET
CONTROL 2-A4
3
3
013384
N
SHEET 3 OF 9
2
1
A
3
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10
J3
ISPTDI
+3.3V
ISPTDO
ISPTCK
JCLK PE6
JCLK PE5
JCLK PE4
JCLK PE3
NRST
JTDI
JTD0
JCLK PE2
D
JTMS-SWCLK
J20
+3.3V
JTMS-SWDIO
J1
ISPTMS
4
SDIO D2
SDIO D3
SDIO CMD
+3.3V
SDIO CK
JTAG CPLD
JTAG MICRO
USB MICRO SD
J6
1
2
3
4
5
6
7
8
SEE PAGE 9 FOR CONNECTION
TO SENSOR PHC. FOR CONNECTIONS
TO A CNC PLEASE REFERANCE THEIR
MANUAL
IN START +
CNC START CNC HOLD +
CNC HOLD CNC MOTION +
CNC MOTION CNC ERROR +
CNC ERROR -
POWER SUPPLY CONTROL
141171
D6
SDIO D0
SDIO D1
SDIO CD
D
J19
D9
D12
CNC INTERFACE
USB OTG
D14
CNC HOLD OUT+
CNC HOLD OUT-
1
2
3
4
5
6
7
8
9
10
USB VBUS
USB DM
USB DP
USB ID
USB GND
1
2
3
4
5
6
7
D15
C
C
MANUAL
TORCH
START
SHEET
4-A2
Y
J1.2 J2
RED
WHT
BLK
BLK
BLK
BLK
RED
GRN
WHT
B
1
2
3
4
5
6
7
8
9
10
CNC START +
IN START +
IN START -
J5
TORCH
INTERFACE
+24V
TORCH ID0
TORCH ID1
TORCH ID2
TORCH ID3
RS422 TXRS422 RXRS422 TX+
D1
D2
D3
D4
RS422
RS422 GND
RS422 RX+
D16 CAN RX
Z
FILTER
1
2
3
1
2
BLK
RED
RED
BLK
GRN/YLW
1
2
A
14 13 12 11 10 9 8 7 6 5 4 3 2 1
TORCH VLV TORCH VLV +
J7
4
WHT
GRN
RED
BLK
BLK
BLK
BLK
WHT
RED
SHEET
3-B1
1
2
3
RED
BLK
SHEET
Y 4-C3
B
J7
MANUAL
TORCH
START
1 2 3 4 5
POWER SUPPLY
A
TO TORCH LEADS
ID3
ID2
ID1
ID0
GND
GND
IN START IN START +
CNC START +
TORCH
VALVE
FILTER
WHT
CAN
CANH
CANL
PWR GND
CAN +24V
D17 CAN TX
1
2
3
4
5
6
7
8
9
10
11
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
MECHANIZED TORCH: PIN 1 SHORTED TO PIN 2
MANUAL TORCH: START SWITCH ACROSS PIN 1 AND PIN 3
3
SHEET 4 OF 9
2
A
1
191
3
4
2
WIRED FOR 480V 60HZ
1
WIRED FOR 200V 50-60HZ
WIRED FOR 240V 60HZ
D
INPUT POWER
FROM FACILITY
V
P1 0
W
V
U
PE
A4
B4
C4
L1
L2
L3
P2 0
2A
P3 0
F2
P1 0
A4
B4
C4
L1
L2
L3
1C
P3 0
F1
2C
INPUT POWER
FROM FACILITY
L1
L2
L3
F2
BLK
T2
1C
2A
P3 0
F1
1B
P2 0
CON1
2B
2B
F2
2C
2C
T1
T1
A4
B4
C4
PE
T1
T2
T2
C
C
WIRED FOR 400V 50-60HZ
V
B
W
V
U
PE
INPUT POWER
FROM FACILITY
WIRED FOR 415V 50-60HZ
T1
1A
PE L1 L2 L3
V
P1 0
EMI FILTER
L1
L2
L3
L1
L2
L3
A4
B4
C4
F1
W
1B
P1 0
1C
P2 0
2A
CON1
PE
T1
1A
PE L1 L2 L3
W
P3 0
INPUT POWER
FROM FACILITY
W
V
U
PE
EMI FILTER
L1
L2
L3
L1
L2
L3
A4
B4
C4
F2
F1
2A
2B
F2
2C
T1
T2
WHT
GRY
WHT
T1
BLU
1C
P3 0
2B
B
1B
P2 0
CON1
PE
2C
T2
A
A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 5 OF 9
4
192
D
W
P1 0
W
V
U
PE
2A
CON1
PE
1B
P2 0
2B
WHT
GRY
INPUT POWER
FROM FACILITY
W
V
U
PE
V
W
1B
1C
CON1
PE
F1
PE L1 L2 L3
W
WHT
V
T1
1A
PE L1 L2 L3
BLK
PE L1 L2 L3
T1
1A
WHT
T1
1A
3
2
1
A
4
3
D
2
1
WIRED FOR 440V 50-60HZ
T1
1A
PE L1 L2 L3
V
W
V
U
PE
INPUT POWER
FROM FACILITY
T1
1A
PE L1 L2 L3
W
P1 0
L1
L2
L3
A4
B4
C4
1C
2A
CON1
PE
P3 0
F1
V
1B
P2 0
INPUT POWER
FROM FACILITY
W
V
U
PE
2B
W
1B
P1 0
L1
L2
L3
A4
B4
C4
P2 0
CON1
PE
1C
2A
2B
P3 0
F2
2C
2C
F1
C
F2
T1
C
GRY
T2
WHT
T1
WHT
BLK
D
WIRED FOR 600V 60HZ
T2
WIRED FOR 220V 50-60HZ
B
T1
1A
PE L1 L2 L3
V
INPUT POWER
FROM FACILITY
W
V
U
PE
WIRED FOR 380V 50-60HZ
V
W
P1 0
L1
L2
L3
A4
B4
C4
P2 0
2A
P3 0
F1
W
INPUT POWER
FROM FACILITY
W
V
U
PE
P1 0
A4
B4
C4
L1
L2
L3
P2 0
CON1
PE
B
1B
1B
1C
CON1
PE
T1
1A
PE L1 L2 L3
1C
2A
2B
P3 0
2B
2C
F2
F1
2C
F2
T1
T2
WHT
BLK
WHT
BRN
T1
T2
A
A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 6 OF 9
4
3
2
A
1
193
4
3
2
Air/N2
1
N2/02
D
D
SHIELD
PLASMA
POWER SUPPLY
B2
B1
P2
C
P1
C
I/O BOARD
21', 46', 71', 96'
B
B
TORCH VALVE
Plasma
4'
A
A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 7 OF 9
4
194
3
2
1
A
3
4
2
1
Power supply
D
D
CHECK VALVE
HEAT EXCHANGER
FLOW SENSOR
FINE FILTER
RESERVOIR
THERMISTOR
25', 50', 75' or 100'
C
C
INTERNAL BYPASS
COLD PLATE
POWER LEAD
DRAIN
COARSE
FILTER
PUMP
SHUT OFF VALVE
B
B
TORCH
A
A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 8 OF 9
4
3
2
A
1
195
3
4
2
1
D
D
SENSOR PHC
PLASMA INTERFACE I/O
J1
OPTO
J3
XFER
OPTO
F
1
2
3
4
5
D6
AC_LINE
AC_NEUT
D9
RED
RED/BLK
229554
J18
RED
RED/BLK
C
D12
D14
CNC HOLD OUT+
CNC HOLD OUT-
D15
ARC VOLTAGE INPUT
ELECTRODE (NEG)
SHIELD
HOLD
J1 J12.1
IN START +
CNC START CNC HOLD +
CNC HOLD CNC MOTION +
CNC MOTION CNC ERROR +
CNC ERROR -
1 2
+12V FIELD
C
1
2
3
4
5
6
7
8
2 1
1
2
3
4
5
RELAY
GAS CONSOLE/
B5 SHEET
PLASMA INTRFC
3-C1
CNC INTERFACE
J6
EMI GROUND
ELECTRODE
WORK
START
SENSOR THC
PLASMA INTERFACE I/O
141201
POWER SUPPLY CONTROL
141171
WORK (POS)
YEL
YEL/BLK
YEL
B
1 2 3 4 5
YEL/BLK
1 2
B
CONNECTIONS SHOWN FOR
SENSOR
PHC
OR SENSOR
YEL
YEL/BLK
THC
26
YEL
YEL/BLK
25
A
ARC
VOLTAGE
SHEET
2-C3
A
ELEC SCH:MAXPRO200 POWER SUPPLY
B4
013384
SHEET 9 OF 9
4
196
3
2
1
A
Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
1 - Identification of the substance/mixture and of the company undertaking
Product identifier
Torch coolant 30% PG mixture
GHS product identifier
Not applicable.
Chemical name
Not applicable.
Trade name
Torch coolant 30% PG mixture
CAS No.
Not applicable.
EINECS No.
Not applicable.
REACH registration no.
Not available.
Relevant identified uses of the substance or mixture and uses advised against
Identified use(s)
Industrial use only.
Uses advised against
Not available.
Details of the supplier of the safety data sheet
Company Identification
Hypertherm
Telephone
+1 (603) 643-5638 (USA), +31 (0) 165 596 907 (Europe)
E-Mail (competent person)
[email protected]
Address
P.O. Box 5010, Hanover, NH 03755 USA (USA),
Vaartveld 9, 4704 SE Roosendaal, Nederlands (Europe)
Emergency telephone number
(800) 255-3924 (USA), +1 (813) 248-0585 (International)
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Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
2 - Hazards identification
C Classification
None
GHS Classification Signal word(s)
None
According to regulation (EC) No. 1272/2008 (CLP)
None
According to Directive 67/548/EEC & Directive 1999/45/EC
None
Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Risk phrases
None
Safety phrases
None
Hazard statement(s)
None
Precautionary statement(s)
None
3 - Composition/information on ingredients
HAZARDOUS INGREDIENT 1
Propylene Glycol
% W/W
CAS No.
EC No.
EC Classification
30-50
57-55-6
200-338-0
None
GHS Classification
Not classified
HAZARDOUS INGREDIENT 2
Benzotriazole
None
% W/W
CAS No.
EC No.
EC Classification
<1.0
95-14-7
202-394-1
Xn, F
GHS Classification
WARNING
Acute Tox. 4 (Oral, Dermal, Inhalation)
Eye Irrit. 2, Aquatic Chronic 3
H302, 312, 319, 332, 412
For full text of R phrases see section 16. For full text of H/P phrases see section 16. Non-hazardous components are not
listed.
4 - First aid measures
Inhalation
Unlikely to be hazardous by inhalation unless present as an aerosol.
Remove patient from exposure.
Skin contact
Wash skin with water.
Eye contact
If substance has gotten into the eyes, immediately wash out with plenty of
water for several minutes.
Ingestion
Laxative. Do not induce vomiting. If swallowed, seek medical advice
immediately and show this container or label.
Further medical treatment
Unlikely to be required but if necessary treat symptomatically.
5 - Fire-fighting measures
Combustible but not readily ignited.
Extinguishing media
Extinguish preferably with dry chemical, foam or water spray.
Unsuitable extinguishing media
None known.
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Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
Fire fighting protective equipment
A self contained breathing apparatus and suitable protective clothing should
be worn in fire conditions.
6 - Accidental release measures
Personal precautions
Put on protective clothing.
Environmental exposure controls
Absorb spillages onto sand, earth or any suitable adsorbent material.
Other
None
7 - Handling and storage
Handling
Unlikely to cause harmful effects under normal conditions of handling and use.
Storage
Keep container tightly closed and dry. Keep away from heat. Keep out of the reach
of children. Keep away from oxidizing agents.
Storage temperature
Ambient
Storage life
Stable at ambient temperatures.
Specific use
Industrial use only.
8 - Exposure controls/personal protection
Respirators
Normally no personal respiratory protection is necessary. Wear suitable respiratory
protective equipment if exposure to levels above the occupational exposure limit is
likely. A suitable dust mask or dust respirator with filter type A/P may be appropriate.
Eye Protection
Safety spectacles.
Gloves
Wearing of chemical protective gloves is not necessary.
Body protection
None
Engineering Controls
Ensure adequate ventilation to remove vapors, fumes, dust etc.
Other
None
Occupational Exposure Limits
CAS No.
LTEL
(8 hr TWA ppm)
LTEL
8 hr TWA mg/m3)
STEL
(ppm)
STEL
(mg/m3)
Propylene Glycol
57-55-6
ne
10*
ne
ne
AIHA WEEL in
the USA
Benzotriazole
95-14-7
ne
ne
ne
ne
None
Substance
MAXPRO200 Instruction Manual 807700 Revision 1
Note
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Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
9 - Physical and chemical properties
Information on basic physical and chemical properties
Appearance:
Liquid
Vapor pressure (mm Hg):
Not available
Color:
Pinkish - Reddish
Vapor density (Air=1):
Not available
Odor:
Slight
Density (g/ml):
1.0 ± 0.1 g/ml
Odor threshold (ppm):
Not available
Solubility (water):
Soluble
pH (Value):
5.5-7.0 (Concentrated)
Solubility (other):
Not established
Melting point (°C) / freezing
point (°C):
< -0°C / (< 32°F)
Partition coefficient (n-octanol/
water):
Not available
Boiling point/boiling range (°C): >100°C (>212°F)
Auto ignition temperature (°C):
Not available
Flash point (°C):
>95°C (>203°F)
Decomposition temperature
(°C):
Not available
Evaporation rate:
Not available
Viscosity (mPa.s):
Not available
Flammability (solid, gas):
Non-flammable
Explosive properties:
Not explosive
Explosive limit ranges:
Not available
Oxidizing properties:
Not oxidizing
Other information:
None
10 - Stability and reactivity
Reactivity
None
Chemical stability
Stable under normal conditions
Possibility of hazardous reactions
None
Conditions to avoid
None anticipated
Incompatible materials
Keep away from oxidizing agents
Hazardous decomposition product(s)
Carbon monoxide, Carbon dioxide, Nitrogen oxides
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Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
11 - Toxicological information
11.1.1 - Substances
Acute toxicity
Ingestion
Low oral toxicity, but ingestion may cause irritation of the
gastrointestinal tract.
Inhalation
Unlikely to be hazardous by inhalation.
Skin Contact
Mild irritant to rabbit skin.
Eye Contact
Mild irritant to the eye.
Hazard label(s)
None
Serious eye damage/irritation
Mild irritant to the eye.
Respiratory or skin sensitization
Mild irritant to rabbit skin.
Mutagenicity
Not known
Carcinogenicity
IARC, NTP, OSHA, ACGIH do not list this product or any
components thereof as known or suspected carcinogen.
Reproductive toxicity
Not known
STOT-single exposure
Not known
STOT-repeated exposure
Not known
Aspiration hazard
Not known
12 - Ecological information
Toxicity
Do not let this chemical/product enter the environment.
Persistence and degradability
Biodegradable
Bioaccumulative potential
None anticipated
Mobility in soil
The product is predicted to have moderate mobility in soil.
Results of PBT and vPvB assessment
None assigned
Other adverse effects
None anticipated
13 - Disposal considerations
Waste treatment methods
Disposal should be in accordance with local, state or national legislation. No
special measures are required. No specific waste water pretreatment
required.
Additional Information
None
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Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
14 - Transport information
Not classified as dangerous for transport.
Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code.
15 - Ecological information
USA
TSCA (Toxic Substance Control Act)
Listed
SARA 302 - Extremely Hazardous Substances
Not applicable
SARA 313 - Toxic Chemicals
Not applicable
SARA 311/312 - Hazard Categories
None
CERCLA (Comprehensive Environmental Response
Compensation and Liability Act)
Not applicable
CWA (Clean Water Act) - CWA 307 - Priority
Pollutants
None
CAA (Clean Air Act 1990) CAA 112 - Hazardous Air None
Pollutants (HAP)
Proposition 65 (California)
Not applicable.
State Right to Know Lists
CAS No. 95-14-7 Listed in MA, NJ, PA
Canada
WHMIS Classification (Canada)
Not classified
Canada ingredient disclosure list
Not applicable
Canada (DSL/NDSL)
Listed.
EU
EINECS (Europe)
Listed.
Wassergefährdungsklasse (Germany)
None
16 - Other information
The following sections contain revisions or new statements: 1-16.
Legend
LTEL
Long Term Exposure Limit
STEL
Short Term Exposure Limit
STOT
Specific Target Organ Toxicity
DNEL
Derived No Effect Level
PNEL
Predicted No Effect Concentration
References:
Risk phrases and safety phrases
None. Preparation is not classified as hazardous in the sense of directive 1999/45/
EC and 2006/121/EC.
Hazard statement(s) and precautionary
statement(s).
None. Preparation is not classified as hazardous in the sense of directive 1999/45/
EC and 2006/121/EC.
Training advice
None
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Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture
Additional information
USA - NFPA (National Fire Protection Association) - NFPA Rating:
Flammability - 1
Health - 0
Instability/Reactivity - 0.
Information contained in this publication or as otherwise supplied to Users is believed to be accurate and is given in good
faith, but it is for the Users to satisfy themselves of the suitability of the product for their own particular purpose.
Hypertherm gives no warranty as to the fitness of the product for any particular purpose and any implied warranty or
condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. Hypertherm accepts
no liability for loss or damage (other than that arising from death or personal injury caused by defective product, if
proved), resulting from reliance on this information. Freedom under Patents, Copyright and Designs cannot be assumed.
Note: The original safety data sheet was authored in English.
Temperature
Freezing Point of Propylene Glycol Solution
°C
°F
4
40
-1
30
-7
20
-12
10
-18
0
-23
-10
-29
-20
-34
-30
-40
-40
-46
-50
-51
-60
-57
-70
0
10
20
30
40
50
60
% of Propylene Glycol
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204
MAXPRO200 Instruction Manual 807700 Revision 1
Revision Changes
MAXPRO200 Revision Changes
Changed page
Description of changes for revision 1 (date of revision March 2013)
Cover and Title Page Revision number and dates changed.
27 through 32
121 through 125
130
131
Font size changed for the Product Stewardship and Environmental Stewardship information to match font size
used for EMC and Warranty. This added two pages to the Product Stewardship section.
Headers updated to match the “Power supply status” table on page 118.
Updated the description for error code 51 from “The pilot arc temperature has exceeded it’s maximum rating”
to “Maximum pilot arc duration exceeded”. Changed corrective action 1 from “let the system cool off” to “Allow
the power supply to idle with the fans running for 10 seconds.”
Updated the description for error code 67 to say “Main” transformer has over heated. Changed corrective
action 2 and 4 to say “main transformer” instead of inductors.
Changed corrective action 3 for error code 69 to say “inductor B’s” instead of the transformer’s.
132
Changed corrective action 1 for error code 93 to say “level” instead of height. Added corrective action 3 “The
pump motor may have reached its internal thermal trip point. Make sure the side panel is installed, for proper
airflow, and that the heat exchanger fan is working properly.”
133
Added “If the wiring is good, the IGBT may have failed.” to corrective action 4 for error codes 134 and 138.
139
Corrected 20 liters to 4 liters in step 2.
141
Updated the graph to accurately reflect the new flow sensor.
150
Corrected overlapping text (TP95 and DCKB) on the Chopper PCB graphic.
160
Corrected the Preventive maintenance protocol checklist to remove HPR references and make it MAXPRO
specific.
161 through 163
Added Annual preventive maintenance kit part numbers, parts lists for the kits and the parts replacement
schedule.
167
Changed item 4 description from Replacement filter element to “Air” filter element. Changed item 6 description
from Replacement filter element to “Coolant” filter element.
169
Updated the graphic to show the new flow sensor and removed item 5 “Adapter: 1/2” push-in x 1/2 inch
push-in tube” because it is no longer necessary.
172
Added “(includes PCB) to the description for item 2.
179
Added a recommended spare parts lists
MAXPRO200 Instruction Manual 807700 Revision 1
205
Revision Changes
206
MAXPRO200 Instruction Manual 807700 Revision 1
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