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MAX100D
380-415V CE
Plasma Arc
Cutting System
Instruction Manual
802750 – Revision 0
EN50199
EN50192
®
MAX100D
380-415V CE
Instruction Manual
IM-275
(P/N 802750)
Revision 0 – December, 1996
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 1996 Hypertherm, Inc.
All Rights Reserved
Hypertherm and MAX are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
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)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm UK, Ltd.
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (ETSO – Technical Service)
00 800 49 73 7843 Tel (ETSO – Technical Service
toll-free in Europe)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
5/23/03
Hypertherm Brasil Ltda.
Rua Visconde de Santa Isabel, 20 – Sala 611
Vila Isabel, RJ
Brasil CEP 20560-120
55 21 2278 6162 Tel
55 21 2578 0947 Fax
ELECTROMAGNETIC COMPATIBILITY (EMC)
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built
in compliance with standard EN50199. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN50199 may not be
adequate to completely eliminate interference when the affected equipment is in
close proximity or has a high degree of
sensitivity. In such cases it may be necessary to use other measures to further
reduce interference.
This plasma equipment is designed for use
only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and
using the plasma equipment according to
the manufacturer's instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as
earthing the cutting circuit, see Earthing of
Workpiece. In other cases it could involve
constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all
cases electromagnetic disturbances must
be reduced to the point where they are no
longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user
shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into
account:
a. Other supply cables, control cables,
signalling and telephone cables; above,
below and adjacent to the cutting equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
e. Health of the people around, for
example the use of pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.
Hypertherm Plasma Systems
The size of the surrounding area to be
considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
METHODS OF REDUCING EMISSIONS
Mains Supply
Cutting equipment must be connected to the
mains supply according to the manufacturer's recommendations. If interference
occurs, it may be necessary to take
additional precautions such as filtering of
the mains supply. Consideration should be
given to shielding the supply cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding
should be electrically continuous throughout
its length. The shielding should be connected to the cutting mains supply so that good
electrical contact is maintained between the
conduit and the cutting power source
enclosure.
Maintenance of Cutting Equipment
The cutting equipment must be routinely
maintained according to the manufacturer's
recommendations. All access and service
doors and covers should be closed and
properly fastened when the cutting
equipment is in operation. The cutting
equipment should not be modified in any
way except for those changes and adjustments covered in the manufacturer's
instructions. In particular, the spark gaps of
arc striking and stabilizing devices should
be adjusted and maintained according to
the manufacturer's recommendations.
Earthing of Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of its size and position, for example,
ship's hull or building steelwork, a connection
bonding the workpiece to earth may reduce
emissions in some, but not all instances.
Care should be taken to prevent the earthing
of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the connection of
the workpiece to earth should be made by a
direct connection to the workpiece, but in
some countries where direct connection is
not permitted, the bonding should be
achieved by suitable capacitances selected
according to national regulations.
Note. The cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be authorized by a person who is competent to
assess whether the changes will increase
the risk of injury, for example, by allowing
parallel cutting current return paths which
may damage the earth circuits of other
equipment. Further guidance is given in IEC
TC26 (sec)94 and IEC TC26/108A/CD Arc
Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding
area may alleviate problems of interference.
Screening of the entire plasma cutting
installation may be considered for special
applications.
Cutting Cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor
level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should
be considered. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a
shock by touching these metallic
components and the electrode at the same
time. The operator should be insulated from
all such bonded metallic components.
i
WARRANTY
WARNING
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any damage
caused by the use of other than genuine Hypertherm parts may
not be covered by the Hypertherm warranty.
WARNING
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the Product in your
environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from
defects in materials and workmanship, if Hypertherm is notified
of a defect (i) with respect to the power supply within a period
of two (2) years from the date of its delivery to you, with the
exception of G3 Series power supplies, which shall be within a
period of three (3) years from the date of delivery to you, and
(ii) with respect to the torch and leads within a period of one (1)
year from its date of delivery to you. This warranty shall not
apply to any Product which has been incorrectly installed,
modified, or otherwise damaged. Hypertherm, at its sole
option, shall repair, replace, or adjust, free of charge, any
defective Products covered by this warranty which shall be
returned with Hypertherm’s prior authorization (which shall not
be unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance and
freight prepaid. Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph or with
Hypertherm’s prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express,
implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained
therefrom, and all implied warranties or conditions of
quality or of merchantability or fitness for a particular
purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach
by Hypertherm of its warranty. Distributors/OEMs may offer
different or additional warranties, but Distributors/OEMs are
not authorized to give any additional warranty protection to you
or make any representation to you purporting to be binding
upon Hypertherm.
Hypertherm, infringes any patent of any third party. You shall
notify Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement, and Hypertherm’s obligation to indemnify shall be
conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the defense
of the claim.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person or
entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranties, failure of
essential purpose or otherwise and even if advised of the
possibility of such damages.
LIABILITY CAP
In no event shall Hypertherm’s liability, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or
otherwise, for any claim action suit or proceeding arising
out of or relating to the use of the Products exceed in the
aggregate the amount paid for the Products that gave rise
to such claim.
INSURANCE
At all times you will have and maintain insurance in such
quantities and types, and with coverage sufficient and
appropriate to defend and to hold Hypertherm harmless in
the event of any cause of action arising from the use of the
Products.
NATIONAL AND LOCAL CODES
National and Local codes governing plumbing and electrical
installation shall take precedent over any instructions
contained in this manual. In no event shall Hypertherm be
liable for injury to persons or property damage by reason of any
code violation or poor work practices.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or substantially
all of your assets or capital stock to a successor in interest who
agrees to be bound by all of the terms and conditions of this
Warranty.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes, formulae, or
combinations not developed or purported to be developed by
Hypertherm, Hypertherm will defend or settle, at its own
expense, any suit or proceeding brought against you alleging
that the use of the Hypertherm product, alone and not in
combination with any other product not supplied by
ii
9-01
Hypertherm Plasma Systems
TABLE OF CONTENTS
Electromagnetic Compatibility (EMC) .......................................................................................................................i
Warranty .....................................................................................................................................................................ii
Section 1 SAFETY..................................................................................................................................................1-1
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions .........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4
Grounding Safety ......................................................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation ....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5
Additional Safety Information ....................................................................................................................................1-5
Section 1a SÉCURITÉ........................................................................................................................................1a-1
Identifier les consignes de sécurité.........................................................................................................................1a-2
Suivre les instructions de sécurité ..........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothéses auditives ........................................................................................................................1a-5
Section 2 SPECIFICATIONS................................................................................................................................2-1
General .....................................................................................................................................................................2-2
Product Specifications ..............................................................................................................................................2-3
MAX100D Power Supply ..................................................................................................................................2-3
MAX100D Machine Torch.................................................................................................................................2-4
PAC160 Hand Torch ........................................................................................................................................2-4
PAC160E Hand Torch......................................................................................................................................2-4
Dual Gas Mixer ................................................................................................................................................2-5
THC-2...............................................................................................................................................................2-5
MAX100D 380-415V CE Instruction Manual
iii
TABLE OF CONTENTS
Section 3 SETUP ..................................................................................................................................................3-1
Upon Receipt ............................................................................................................................................................3-2
Claims & Technical Questions ..................................................................................................................................3-2
Introduction ...............................................................................................................................................................3-3
Gas Supply Requirements ........................................................................................................................................3-4
Cylinder Compressed Air .................................................................................................................................3-4
Shop Compressed Air ......................................................................................................................................3-4
Plasma and Shield Gases................................................................................................................................3-5
Grounding Requirements..........................................................................................................................................3-5
Power Requirements ................................................................................................................................................3-6
Line Disconnect Switch ....................................................................................................................................3-6
Power Cables...................................................................................................................................................3-6
Power Supply Placement..........................................................................................................................................3-7
Power Supply Electrical Connections .......................................................................................................................3-7
380/415V Linkboard Configurations.................................................................................................................3-7
Power Cable Connection .................................................................................................................................3-8
Remote Start/Stop Switch ................................................................................................................................3-9
Machine Computer Interface............................................................................................................................3-9
Power Supply Gas Connections .............................................................................................................................3-10
Plasma Gas Connections...............................................................................................................................3-10
Shield Gas Connections.................................................................................................................................3-11
Connecting the Torch .............................................................................................................................................3-12
Torch Leads to Power Supply ........................................................................................................................3-12
Section 4 OPERATION ........................................................................................................................................4-1
Description of Controls and Indicators ......................................................................................................................4-2
Operating Instructions...............................................................................................................................................4-5
Operating Tips ........................................................................................................................................................4-10
Cut / Gouging Charts ..............................................................................................................................................4-20
Cut / Gouging Index................................................................................................................................................4-21
Mild Steel Cutting ...........................................................................................................................................4-22
Stainless Steel Cutting ...................................................................................................................................4-30
Aluminum Cutting...........................................................................................................................................4-39
Mild Steel Gouging.........................................................................................................................................4-49
Stainless Steel Gouging.................................................................................................................................4-51
Aluminum Gouging.........................................................................................................................................4-53
Section 5 MAINTENANCE ...................................................................................................................................5-1
Introduction ...............................................................................................................................................................5-2
Routine Maintenance ................................................................................................................................................5-3
Sequence of Events..................................................................................................................................................5-4
Initial Checks ..........................................................................................................................................................5-10
Troubleshooting ......................................................................................................................................................5-13
Test Procedure .......................................................................................................................................................5-20
Disassembly of Hand Torch....................................................................................................................................5-22
Disassembly of Machine Torch...............................................................................................................................5-24
iv
MAX100D 380-415V CE Instruction Manual
TABLE OF CONTENTS
Section 6 PARTS LIST .........................................................................................................................................6-1
Introduction ...............................................................................................................................................................6-2
MAX100D Power Supply
Front Panel Outside, Front Panel Inside, Control Panel ..................................................................................6-5
Plasma Gas Console .......................................................................................................................................6-7
Right Center Wall .............................................................................................................................................6-9
Base Plate Components ..................................................................................................................................6-9
Left Center Wall .............................................................................................................................................6-11
Rear Panel Outside, Rear Panel Inside .........................................................................................................6-13
MAX100D Machine Torch Assembly.......................................................................................................................6-15
MAX100D International Machine Torch Assembly ..................................................................................................6-15
PAC160 Hand Torch Assembly ..............................................................................................................................6-17
PAC160E Gouging Torch Assembly.......................................................................................................................6-19
MAX100D Lead Assemblies....................................................................................................................................6-20
MAX100D Consumable Parts Kits...........................................................................................................................6-21
Machine Torch Consumable Parts.................................................................................................................6-21
PAC160 Hand Torch Consumable Parts .......................................................................................................6-22
PAC160E Gouging Torch Consumable Parts ................................................................................................6-23
Dual Gas Mixer .......................................................................................................................................................6-25
Hose Package for Dual Gas Mixer .........................................................................................................................6-25
Recommended Spare Parts ...................................................................................................................................6-26
Section 7 WIRING DIAGRAMS ............................................................................................................................7-1
MAX100D Wiring Diagram ........................................................................................................................................7-2
Appendix A
FILTERS ...........................................................................................................................................a-1
Appendix B
IEC SYMBOLS USED ......................................................................................................................b-1
Appendix C
AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM .....................................................c-1
MAX100D 380-415V CE Instruction Manual
v
Section 1
SAFETY
In this section:
Recognize Safety Information...................................................................................................................................1-2
Follow Safety Instructions .........................................................................................................................................1-2
Cutting Can Cause Fire or Explosion .......................................................................................................................1-2
Electric Shock Can Kill..............................................................................................................................................1-3
Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3
A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4
Grounding Safety ......................................................................................................................................................1-4
Compressed Gas Equipment Safety ........................................................................................................................1-5
Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5
Noise Can Damage Hearing .....................................................................................................................................1-5
Pacemaker and Hearing Aid Operation ....................................................................................................................1-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................................1-5
Additional Safety Information ....................................................................................................................................1-5
Hypertherm Plasma Systems
1-1
SAFETY
RECOGNIZE SAFETY INFORMATION • Keep your machine in proper working condition.
The symbols shown in this section are used to identify
potential hazards. When you see a safety symbol in this
manual or on your machine, understand the potential
for personal injury, and follow the related instructions to
avoid the hazard.
FOLLOW SAFETY INSTRUCTIONS
Read carefully all safety messages in this manual and
safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
Unauthorized modifications to the machine may
affect safety and machine service life.
DANGER
WARNING
CAUTION
A signal word DANGER or WARNING is used with a
safety symbol. DANGER identifies the most serious
hazards.
• DANGER and WARNING safety labels are located
on your machine near specific hazards.
• WARNING safety messages precede related
instructions in this manual that may result in injury
or death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
damage to equipment if not followed correctly.
CUTTING CAN CAUSE FIRE OR EXPLOSION
Fire Prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of the
cutting area.
• Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres before
cutting.
• When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion Prevention
• Do not use the plasma system if explosive dust or
vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
1-2
11-98
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with Aluminum Cutting
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
Hypertherm Plasma Systems
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.
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage
or cracking of the cover. Replace a damaged power
cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch
leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
during the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
to allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
CUTTING CAN PRODUCE TOXIC FUMES
Cutting can produce toxic fumes and gases that
deplete oxygen and cause injury or death.
• Keep the cutting area well ventilated or use an
approved air-supplied respirator.
• Do not cut in locations near degreasing, cleaning or
spraying operations. The vapors from certain
chlorinated solvents decompose to form phosgene
gas when exposed to ultraviolet radiation.
• Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or
Hypertherm Plasma Systems
beryllium, unless the area is well ventilated and the
operator wears an air-supplied respirator. The
coatings and any metals containing these elements
can produce toxic fumes when cut.
• Never cut containers with potentially toxic materials
inside – they must be emptied and properly cleaned
first.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth
defects and, in some cases, cancer.
1-3
8-99
SAFETY
A PLASMA ARC CAN CAUSE INJURY AND BURNS
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
The plasma arc will cut quickly through gloves and
skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
ARC RAYS CAN BURN EYES AND SKIN
Eye Protection Plasma arc rays produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin.
• Use eye protection in accordance with applicable
national or local codes.
• Wear eye protection (safety glasses or goggles with
side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s
ultraviolet and infrared rays.
Arc Current
Up to 100 A
100-200 A
200-400 A
Over 400 A
Lens Shade
AWS (USA)
ISO 4850
No. 8
No. 11
No. 10
No. 11-12
No. 12
No. 13
No. 14
No. 14
GROUNDING SAFETY
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall
away when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or
local electrical codes.
1-4
5/6/02
Skin Protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and
slag.
• Remove any combustibles, such as a butane lighter
or matches, from your pockets before cutting.
Cutting Area Prepare the cutting area to reduce
reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to
reduce reflection.
• Use protective screens or barriers to protect others
from flash and glare.
• Warn others not to watch the arc. Use placards or
signs.
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.
Hypertherm Plasma Systems
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 or local codes.
NOISE CAN DAMAGE HEARING
Prolonged exposure to noise from cutting or gouging
can damage hearing.
• Use approved ear protection when using plasma
system.
• Warn others nearby about the noise hazard.
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.
ADDITIONAL SAFETY INFORMATION
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American
Welding Society, 550 LeJeune Road
P.O. Box 351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and
Welding Processes, American National Standards Institute
1430 Broadway, New York, NY 10018
3. ANSI Standard Z87.1, Safe Practices for Occupation and
Educational Eye and Face Protection, American National
Standards Institute, 1430 Broadway, New York, NY 10018
4. AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
Hypertherm Plasma Systems
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode.
• Handle and use compressed gas cylinders in
accordance with applicable national or local codes.
• Never use a cylinder that is not upright and secured
in place.
• Keep the protective cap in place over valve except
when the cylinder is in use or connected for use.
• Never allow electrical contact between the plasma
arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to open
a stuck cylinder valve.
PACEMAKER AND HEARING
AID OPERATION
Pacemaker and hearing aid operation can be affected
by magnetic fields from high currents.
Pacemaker and hearing aid wearers should consult a
doctor before going near any plasma arc cutting and
gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead to one
side, away from your body.
• Route the torch leads as close as possible to the
work cable.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as
possible.
5. AWS F5.2, Recommended Safe Practices for Plasma Arc
Cutting, American Welding Society
550 LeJeune Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Cylinders, Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202
7. CSA Standard W117.2, Code for Safety in Welding and Cutting,
Canadian Standards Association Standard Sales
178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
8. NFPA Standard 51B, Cutting and Welding Processes, National
Fire Protection Association
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code, National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C. 20402
1-5
11-98
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité.........................................................................................................................1a-2
Suivre les instructions de sécurité ..........................................................................................................................1a-2
Danger Avertissement Précaution ........................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2
Prévention des incendies, Prévention des explosions ...................................................................................1a-2
Risque d’explosion argon-hydrogène et méthane..........................................................................................1a-2
Détonation de l’hydrogène lors du coupage de l’aluminium...........................................................................1a-2
Les chocs électriques peuvent être fatals...............................................................................................................1a-3
Prévention des chocs électriques ..................................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4
Torches à allumage instantané ......................................................................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-4
Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4
Mise à la masse et à la terre...................................................................................................................................1a-4
Câble de retour, Table de travail, Alimentation ...............................................................................................1a-4
Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5
Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5
Pacemakers et prothèses auditives ........................................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-5
Hypertherm Systèmes plasma
1a-1
2/12/01
SÉCURITÉ
IDENTIFIER LES CONSIGNES
DE SÉCURITÉ
Les symboles indiqués dans cette section sont utilisés pour
identifier les risques éventuels. Si vous trouvez un symbole
de sécurité, que ce soit dans ce manuel ou sur
l’équipement, soyez conscient des risques de blessures et
suivez les instructions correspondantes afin d’éviter ces
risques.
SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité dans le
présent manuel et sur les étiquettes de sécurité se trouvant
sur la machine.
• Les étiquettes de sécurité doivent rester lisibles.
Remplacer immédiatement les étiquettes manquantes ou
abîmées.
• Apprendre à faire fonctionner la machine et à utiliser
correctement les commandes. Ne laisser personne utiliser
la machine sans connaître son fonctionnement.
• Garder la machine en bon état. Des modifications non
autorisées sur la machine peuvent engendrer des
problèmes de sécurité et raccourcir la durée d’utilisation
de l’équipement.
DANGER
AVERTISSEMENT
PRÉCAUTION
Les signaux DANGER ou AVERTISSEMENT sont utilisés
avec un symbole de sécurité, DANGER correspondant aux
risques les plus sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSEMENT
sont situées sur la machine pour signaler certains
dangers spécifiques.
• Les messages d’AVERTISSEMENT précèdent les
instructions d’utilisation expliquées dans ce manuel et
signalent les risques de blessures ou de mort au cas où
ces instructions ne seraient pas suivies correctement.
• Les messages de PRÉCAUTION précèdent les
instructions d’utilisation contenues dans ce manuel et
signalent que le matériel risque d’être endommagé si les
instructions ne sont pas suivies correctement.
LE COUPAGE PEUT PROVOQUER UN INCENDIE
OU UNE EXPLOSION
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage
ne présente aucun danger. Conserver un extincteur à
proximité.
• Éloigner toute matière inflammable à une distance d’au
moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant de
le manipuler ou avant de le mettre en contact avec des
matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir des
matières inflammables avant de les avoir vidés et
nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable
avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres
récipients fermés et pressurisés.
• Ne pas couper de récipients contenant des matières
combustibles.
1a-2
2/12/01
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables et
potentiellement explosifs. Conserver à l’écart de toute
flamme les bouteilles et tuyaux contenant des mélanges à
base d’hydrogène ou de méthane. Maintenir toute flamme
et étincelle à l’écart de la torche lors de l’utilisation d’un
plasma d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau
touche la partie inférieure de la pièce d’aluminium, de
l’hydrogène libre peut s’accumuler sous la pièce à couper
et détonner lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau
afin d’éliminer les risques de détonation de l’hydrogène.
Se référer à l’annexe du manuel pour plus de
renseignements sur les collecteurs d’aération.
Hypertherm Systèmes plasma
SÉCURITÉ
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
Toucher une pièce électrique sous tension peut provoquer
un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme un
circuit électrique entre la torche et la pièce à couper. La
pièce à couper et tout autre élément en contact avec cette
pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper
ou l’eau de la table à eau pendant le fonctionnement du
système plasma.
Prévention des chocs électriques
Tous les systèmes plasma Hypertherm utilisent des hautes
tensions pour le coupage (souvent de 200 à 400 V). On
doit prendre les précautions suivantes quand on utilise le
système plasma :
• Porter des bottes et des gants isolants et garder le corps
et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface
mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des
tapis isolants secs ou des couvertures assez grandes
pour éviter tout contact physique avec le travail ou le sol.
S’il s’avère nécessaire de travailler dans ou près d’un
endroit humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à
proximité de la source de courant. Ce dispositif permet à
l’opérateur d’arrêter rapidement la source de courant en
cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette
dernière est correctement mise à la terre.
• Installer et mettre à la terre l’équipement selon les
instructions du présent manuel et conformément aux
codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire
pour s’assurer qu’il n’est ni endommagé, ni fendu.
Remplacer immédiatement un cordon endommagé.
Un câble dénudé peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont
usés ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du
coupage. Laisser la pièce à couper en place ou sur la
table de travail, le câble de retour connecté lors du
coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces
de la torche, couper l’alimentation ou débrancher la prise
de courant.
• Ne jamais contourner ou court-circuiter les verrouillages
de sécurité.
• Avant d’enlever le capot du système ou de la source de
courant, couper l’alimentation électrique. Attendre ensuite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que
les capots de la source de courant ne soient en place.
Les raccords exposés de la source de courant sont
extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout d’abord
la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour être
utilisé uniquement avec des torches Hypertherm
spécifiques. Ne pas utiliser des torches inappropriées qui
pourraient surchauffer et présenter des risques pour la
sécurité.
LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES
Le coupage peut produire des vapeurs et des gaz toxiques
qui réduisent le niveau d’oxygène dans l’air et peuvent
provoquer des blessures, voire la mort.
• Conserver le poste de coupage bien aéré ou utiliser un
masque respiratoire homologué.
• Ne pas procéder au coupage près d’endroits où
s’effectuent le dégraissage, le nettoyage ou la vaporisation. Certains solvants chlorés se décomposent sous
l’effet des rayons ultraviolets et forment du phosgène.
• Ne pas couper des métaux peints ou contenant des
matières toxiques comme le zinc (galvanisé), le plomb, le
cadmium ou le béryllium, à moins que la zone de travail
Hypertherm Systèmes plasma
soit très bien ventilée et que l’opérateur porte un masque
respiratoire. Les revêtements et métaux contenant ces
matières peuvent produire des vapeurs toxiques lors du
coupage.
• Ne jamais couper de récipients pouvant contenir des
matières inflammables avant de les avoir vidés et
nettoyés correctement.
• Quand on utilise ce produit pour le soudage ou le
coupage, il dégage des fumées et des gaz qui
contiennent des produits chimiques qui, selon l’État de
Californie, provoquent des anomalies congénitales et,
dans certains cas, le cancer.
1a-3
2/12/01
SÉCURITÉ
L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
Protection des yeux Les rayons de l’arc plasma
produisent de puissants rayons visibles ou invisibles
(ultraviolets et infrarouges) qui peuvent brûler les yeux et la
peau.
• Utiliser des lunettes de sécurité conformément aux codes
locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque
muni d’écrans latéraux et encore masque de soudure)
avec des verres teintés appropriés pour protéger les yeux
des rayons ultraviolets et infrarouges de l’arc.
Courant de l’arc
Jusqu’à 100 A
100-200 A
200-400 A
Plus de 400 A
Puissance des verres teintés
AWS (É.-U.)
ISO 4850
No 8
No 11
o
N 10
No 11-12
o
No 13
N 12
o
N 14
No 14
Protection de la peau Porter des vêtements de sécurité
pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :
MISE À LA MASSE ET À LA TERRE
Câble de retour Bien fixer le câble de retour (ou de
masse) à la pièce à couper ou à la table de travail de façon
à assurer un bon contact métal-métal. Ne pas fixer le câble
de retour à la partie de la pièce qui doit se détacher.
Table de travail Raccorder la table de travail à la terre,
conformément aux codes de sécurité locaux ou nationaux
appropriés.
1a-4
5/6/02
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées
du corps.
• Pantalon sans revers pour éviter que des étincelles ou
des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet
combustible comme les briquets au butane ou les
allumettes.
Zone de coupage Préparer la zone de coupage afin de
réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre
pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin
de protéger les autres personnes de la lumière et de la
réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc.
Utiliser des affiches ou des panneaux.
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est
connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation à
la source de courant lors de l’installation du système,
s’assurer que le fil de terre est correctement branché.
• Placer tout d’abord le fil de terre du cordon d’alimentation
sur le plot de mise à la terre puis placer les autres fils de
terre par-dessus. Bien serrer l’écrou de retenue.
• S’assurer que toutes les connexions sont bien serrées
pour éviter la surchauffe.
Hypertherm Systèmes plasma
SÉCURITÉ
SÉCURITÉ DES BOUTEILLES DE
GAZ COMPRIMÉ
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse.
• Utiliser uniquement les bouteilles, régulateurs, tuyaux et
accessoires appropriés et conçus pour chaque application
spécifique.
• Entretenir l’équipement et les pièces d’équipement à gaz
comprimé afin de les garder en bon état.
• Étiqueter et coder avec des couleurs tous les tuyaux de
gaz afin d’identifier le type de gaz contenu dans chaque
tuyau. Se référer aux codes locaux ou nationaux en
vigueur.
LE BRUIT PEUT PROVOQUER DES
PROBLÈMES AUDITIFS
Une exposition prolongée au bruit du coupage ou du
gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de
l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques
encourus en cas d’exposition au bruit.
UN ARC PLASMA
PEUT ENDOMMAGER
LES TUYAUX GELÉS
LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES
Les bouteilles de gaz contiennent du gaz à haute pression.
Si une bouteille est endommagée, elle peut exploser.
• Manipuler et utiliser les bouteilles de gaz comprimé
conformément aux codes locaux ou nationaux.
• Ne jamais utiliser une bouteille qui n’est pas placée à la
verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet
sauf si la bouteille est en cours d’utilisation ou connectée
pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma et
une bouteille.
• Ne jamais exposer des bouteilles à une chaleur
excessive, aux étincelles, aux scories ou aux flammes
nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres
outils pour débloquer le robinet des bouteilles.
PACEMAKERS ET
PROTHÈSES AUDITIVES
Les champs magnétiques produits par les courants à haute
tension peuvent affecter le fonctionnement des prothèses
auditives et des pacemakers. Les personnes portant ce
type d’appareil doivent consulter un médecin avant de
s’approcher d’un lieu où s’effectue le coupage ou le
gougeage plasma.
Pour réduire les risques associés aux champs magnétiques :
• Garder loin de soi et du même côté du corps le câble de
retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près possible
du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble de
retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
Les tuyaux gelés peuvent être endommagés ou éclater
si l'on essaie de les dégeler avec une torche plasma.
Hypertherm Systèmes plasma
1a-5
2/12/01
Section 2
SPECIFICATIONS
In this section:
General .....................................................................................................................................................................2-2
Product Specifications ..............................................................................................................................................2-3
MAX100D Power Supply ..................................................................................................................................2-3
MAX100D Machine Torch .................................................................................................................................2-4
PAC160 Hand Torch.........................................................................................................................................2-4
PAC160E Hand Torch ......................................................................................................................................2-4
Dual Gas Mixer ................................................................................................................................................2-5
THC-2...............................................................................................................................................................2-5
MAX100D 380-415V CE Instruction Manual
2-1
SPECIFICATIONS
General
Hypertherm’s MAX100D is a dual-gas system designed for cutting most metals from gauge to 32 mm thick. In
addition to hand cutting, it can be used with a machine torch and a THC-2 Torch Height Control system for highspeed mechanized cutting.
The MAX100D provides continuously variable current output from 30 to 100 Amps for optimum performance on all
thicknesses of metal up to 32 mm thick. This allows the operator wide variations in cutting speeds on the same
thickness of metal. Two nozzle sizes (60-Amp and 100-Amp) provide high-quality cuts throughout its range of cut
thicknesses.
The system can also provide a continuous pilot arc which allows high-quality cutting of perforated or expanded
metal without any appreciable deterioration in parts life. This feature is only available for use with the 60-Amp
nozzle.
The unique MAX100D power supply design uses transistor technology to produce a very smooth constant current
DC output.
Air can be used as the primary plasma gas, providing low operating costs combined with high-speed performance.
Cylinder air or shop air is acceptable as long as it is free of moisture, oil, and particulate matter contamination.
For better cut quality on metals such as stainless steel, aluminum, and other non-ferrous materials, use either
nitrogen, argon/hydrogen (Hypertherm recommends a mixture of 35% hydrogen and 65% argon), or a mixture of
argon/hydrogen and nitrogen as the plasma gas. Air, nitrogen, and carbon dioxide are the shield gases that can
be used.
In addition to cutting, the MAX100D can be used for plasma arc gouging. Both mechanized and hand gouging
capabilities are provided. Air and H35 are the plasma gases for the gouging application. When H35 is used as the
plasma gas, high gouging efficiency is achieved. Air gouging has lower efficiency but is economical on gas
consumption.
2-2
MAX100D 380-415V CE Instruction Manual
SPECIFICATIONS
Product Specifications
MAX100D Power Supply
The MAX100D is a constant current, secondary converter chopper power supply providing continuously variable
amperage from 30 Amps to 100 Amps. It conforms to the following specifications:
Maximum OCV (U0) .............................................280 VDC
Output Current (I2)................................................30-100 A
Output Voltage (U2) .............................................90-150 VDC
Duty Cycle Rating (X) ..........................................800% @ 15 KW, 40° C (104° F)
Ambient Temperatures/Duty Cycle.......................Power supplies will operate between +14° and 104° F
(-10° and +40° C). Power supplies operated in an ambient
temperature above 86° F (30° C) may show some
decrease in duty cycle.
Input Power (Input Voltage (U1) x Input Current (I1):
#059199 ...............................................................380/415V, CE/LVD, 3PH, 50/60 Hz, 28/26 Amps
Dimensions and Weight:
Width ....................................................................673 mm
Height...................................................................1092 mm
Depth....................................................................806 mm
Weight ..................................................................205 kg
Gas Requirements:
Plasma Gas Types ..............................................Air, Nitrogen (N2), Argon/Hydrogen
(H35 = 35% hydrogen and 65% argon),
Argon/Hydrogen-Nitrogen mixture.
Shield Gas Types .................................................Air, Carbon Dioxide (CO2), Nitrogen (N2)
Gas Quality .......................................................... Clean, dry, oil-free
Plasma Gas Flow ................................................58 l/min
Shield Gas Flow ...................................................208 l/min
Plasma Gas Inlet Pressure ..................................5.4 bar to 8.5 bar dynamic (flowing) pressure.
Shield Gas Inlet Pressure ....................................5.4 bar to 8.5 bar dynamic (flowing) pressure.
Plasma Gas and Shield Gas Pressures in
Test and Operate modes......................................See Cut / Gouging Chart data in Section 4
MAX100D 380-415V CE Instruction Manual
2-3
3-99
SPECIFICATIONS
MAX100D Machine Torch
Maximum mechanized cutting..............................16 mm
Maximum current at 80% duty cycle ....................100 Amps
Maximum temperature at torch head ...................149° C
Gouging capability (metal removal rate):
H35 as plasma gas ..............................................6.8 kg/hour
Air as plasma gas.................................................3.6 kg/hour
Gas Flow ..............................................................208 l/min at 4.1 bar with 100 amp consumables
Weight ..................................................................0.79 kg
WARNING
The voltage between the tip of the torch and the workpiece will exceed 113 VDC if shielded
consumable parts are not installed in the hand torches. The hand torches must be operated with
shielded parts to maintain the S mark and CE low voltage compliance for hand held applications.
This requirement does not apply to machine torch applications.
PAC160 Hand Torch
Maximum cutting thickness range........................32 mm
Maximum current at 80% duty cycle ....................100 Amps
Maximum temperature at torch head ...................149° C
Gas Flow ..............................................................208 l/min at 4.1 bar with 100 amp consumables
Weight ..................................................................0.68 kg
PAC160E Hand Torch
Maximum cutting thickness range........................32 mm
Maximum current at 80% duty cycle ....................100 Amps
Maximum temperature at torch head ...................149° C
Maximum temperature at torch handle ................60° C with hand heat shield
Gouging capability (metal removal rate):
H35 as plasma gas ..............................................6.8 kg/hour
Air as plasma gas.................................................3.6 kg/hour
Gas Flow ..............................................................208 l/min at 4.1 bar with 100 amp consumables
Weight ..................................................................1.14 kg with hand heat shield
2-4
3-99
MAX100D 380-415V CE Instruction Manual
SPECIFICATIONS
Dual Gas Mixer – Optional
The MAX100D gas mixer is used to provide an H35 - Nitrogen gas mixture for high-quality stainless-steel cutting
(See Cut / Gouging Chart data in Section 4)
Plasma inlet pressure (dynamic)..........................6.8 bar
Plasma outlet pressure (dynamic)........................4.1 bar
Percentage of mixture ..........................................0 to 100%
Plasma flow rate...................................................35 l/min
Dimensions and Weight:
Width ....................................................................292 mm
Height...................................................................371 mm
Depth....................................................................102 mm
Weight ..................................................................7.3 kg
THC-2 – Optional
See IM20 (#800200) for details and instructions for the THC-2 Torch Height Control system.
MAX100D 380-415V CE Instruction Manual
2-5
3-99
Section 3
SETUP
In this section:
Upon Receipt ............................................................................................................................................................3-2
Claims & Technical Questions ..................................................................................................................................3-2
Introduction ...............................................................................................................................................................3-3
Gas Supply Requirements ........................................................................................................................................3-4
Cylinder Compressed Air .................................................................................................................................3-4
Shop Compressed Air ......................................................................................................................................3-4
Plasma and Shield Gases................................................................................................................................3-5
Grounding Requirements..........................................................................................................................................3-5
Power Requirements ................................................................................................................................................3-6
Line Disconnect Switch ....................................................................................................................................3-6
Power Cables...................................................................................................................................................3-6
Power Supply Placement..........................................................................................................................................3-7
Power Supply Electrical Connections .......................................................................................................................3-7
380/415V Linkboard Configurations.................................................................................................................3-7
Power Cable Connection .................................................................................................................................3-8
Remote Start/Stop Switch ................................................................................................................................3-9
Machine Computer Interface............................................................................................................................3-9
Power Supply Gas Connections .............................................................................................................................3-10
Plasma Gas Connections...............................................................................................................................3-10
Shield Gas Connections .................................................................................................................................3-11
Connecting the Torch ..............................................................................................................................................3-12
Torch Leads to Power Supply ........................................................................................................................3-12
MAX100D 380-415V CE Instruction Manual
3-1
SETUP
Upon Receipt
Verify that all components listed below are present. Alert your distributor if any parts are missing. All communications regarding this equipment must include the model number and serial number (located on the back of the
MAX100D).
PAC160 System – Hand Torch Configuration:
• MAX100D power supply with 7.6 meter work cable (ground) and clamp
• PAC160 hand torch with torch lead assembly
• Consumable spare parts kit (#028649)
PAC160E System – Extended Hand Torch Configuration:
•
•
•
•
MAX100D power supply with 7.6 meter work cable (ground) and clamp
PAC160E hand torch with torch lead assembly
Consumable spare parts kit (#028665)
Hand heat shield (#020711)
MAX100D System – Machine Torch Configuration:
• MAX100D power supply with 7.6 meter work cable (ground) and clamp
• MAX100D machine torch and torch lead assembly
• Consumable spare parts kit (#028650)
• Dual Gas Mixer – optional (#059123)
• THC-2 Torch Height Control – optional (#052002)
Note:
For detailed part number information, see the Parts List (Section 6).
Claims and Technical Questions
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier. When requested, Hypertherm will furnish you with a copy of the bill of lading.
Claims for defective merchandise – All units shipped from Hypertherm undergo rigorous quality control testing.
However, if your unit does not function correctly:
1. Read Troubleshooting in the Maintenance section (Section 5) of this manual. You may find the problem is quite
easy to fix, such a loose connection.
2. If you are unable to solve the problem, call your distributor. He will be able to help you, or refer you to an
authorized Hypertherm repair facility.
3. If you need additional assistance, contact the nearest Hypertherm Technical Service Department listed at the
front of this manual.
3-2
MAX100D 380-415V CE Instruction Manual
SETUP
Introduction
The following requirements must be fulfilled prior to the installation of the MAX100D plasma cutting system. Please
read these requirements carefully. Their purpose is to aid you in the installation of your plasma cutting system and
to allow maximum performance.
Installation and service of the electrical and plumbing systems must conform to national or local electrical and
plumbing codes. This work should be performed only by qualified, licensed personnel.
For installation, operation or service questions or problems, contact the nearest Hypertherm Technical Service
Department listed at the front of this manual.
MAX100D 380-415V CE Instruction Manual
3-3
SETUP
Gas Supply Requirements
Two different sources of air can be used to supply the MAX100D. The setting should be flowing (dynamic):
Cylinder Compressed Air
The cylinder air supply must be clean, dry and oil-free. The cylinder regulator must be used only for compressed air
and must be capable of delivering at least 208 liters/minute of air at 5.4 bar to 8.5 bar output pressure.
Caution:
Do not exceed 8.5 bar delivery pressure to the system. Exceeding this pressure
will cause shortened torch parts life.
Pressures in excess of 8.5 bar can also damage the pressure gauge that is located
on top of the MAX100D filter. If delivery pressure is greater than 8.5 bar, turn
regulator on top of the MAX100D filter counterclockwise to decrease the pressure
to the system.
Shop Compressed Air
Shop compressed air must be clean, dry and oil-free if used to supply the MAX100D. Poor quality air reduces cut
speeds, produces poor cut quality, and reduces parts life. Shop air must be available at a minimum dynamic
pressure of 5.4 bar and must be routed through the regulator and filter supplied with the system. The regulator and
filter are mounted at the top rear of the MAX100D power supply.
If the shop air is not clean, refer to Appendix A for recommended filter specifications. These filters are available
from any industrial supplier.
Caution:
Note:
Do not exceed 8.5 bar delivery to the system. Exceeding this pressure will cause
shortened torch parts life.
Whether you use a compressed air cylinder or shop compressed air:
– Use an inert gas hose to connect the gas supply to the input connection on the air regulator
mounted at the rear of the power supply.
– Use a filter to maintain a high air purity level. All moisture, oil and other contaminants must be
removed.
3-4
MAX100D 380-415V CE Instruction Manual
SETUP
Plasma and Shield Gases
When nitrogen, argon/hydrogen, or an argon/hydrogen-nitrogen mixture is used as the plasma gas, and nitrogen or
carbon dioxide is used as the shield gas, they must be supplied to the MAX100D at 99.995% purity. The source can
be compressed gas cylinders or liquid containers. The gas supply source must be capable of delivering a minimum
of 208 liters/minute at a delivery pressure of 5.4 bar. Refer to the Cut / Gouging Charts in Section 4 for detailed
information.
Hoses
To obtain the proper plasma and shield gas flow rates and pressures, use hose that meets the following
specifications:
I.D.:
9.5 mm minimum
Length: 30 m maximum
Purity
If the purity level of the plasma gas is too low, cut speeds decrease, cut quality deteriorates, cutting thickness
capability decreases, and parts life shortens.
Note:
These conditions also occur if there are leaks in the gas supply hoses or connections.
Grounding Requirements
The plasma system must be properly grounded to ensure personal safety, and to reduce emission of radio
frequency interference.
• Connect the work table to a high-quality earth ground within 6 m of the table. A suitable ground consists of a
solid copper rod of at least 13 mm diameter driven to a depth of at least 2.5 m into the earth below the
permanent moisture level.
• For more information, refer to applicable national and local electrical codes.
MAX100D 380-415V CE Instruction Manual
3-5
SETUP
Power Requirements
Line Disconnect Switch
• Use a primary line disconnect switch for each power supply. This disconnect switch allows you to turn the
power supply off quickly in an emergency situation. The switch should be located on a wall near the power
supply, and be easily accessible to the operator. The interrupt level of the switch must be equal to or exceed
the continuous rating of the fuses. The line disconnect fuses should be sized according to the table below:
Input
Voltage
Rated Input
Current
Time Lag
type gG
Fuse Size
380 VAC
415 VAC
28 A
26 A
40 A
40 A
Recommended Power Cord Gauge Size (mm2)
to 25 m
25-50 m
50-75 m
75-100 m
4 mm2
4 mm2
6 mm2
6 mm2
10 mm2
10 mm2
16 mm2
16 mm2
Power Cables
• Power cables are supplied by the customer.
• Cable sizes vary based on the distance of the receptacle from the main box – see table above. In Europe,
use a 4-conductor Harmonized (“HAR”) type cord. Final specification and installation of the power cord
should be made by a licensed electrician and according to applicable national or local codes. See also
Mains Supply on page i in the front part of this manual for further power (supply) cable shielding
recommendations.
• To connect power cable to power supply, see Power Cable Connection later in this section.
3-6
MAX100D 380-415V CE Instruction Manual
SETUP
Power Supply Placement
• Place the power supply in an area that is free of excessive moisture, is relatively clean, and has proper
ventilation so that air flow is not blocked in any way. (Cooling air is drawn in through the front panel grating,
and is exhausted through the rear of the unit by a cooling fan.)
• Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE
WARRANTY..
Power Supply Electrical Connections
380/415V Linkboard Configurations
The 380/415-volt power supply is shipped from the factory linked for 380-volt operation. The links must be moved
for 415-volt operation. See Figure 3-1.
WARNING
Danger: High Voltage. Line voltage may be present on this linkboard. Disconnect input power before
servicing.
1. Remove the left-side cover of the power supply, and locate the linkboard on the inside front wall.
2. Ensure that the linkboard is configured for the proper line voltage.
Figure 3-1
Dual Voltage 380/415-Volt Linkboard
MAX100D 380-415V CE Instruction Manual
3-7
SETUP
Power Cable Connection
Power Cable to MAX100D Power Supply
1. Locate the EMI filter box on the rear of the power supply.
2. Unscrew the filter cover screws and remove the cover for access to the input voltage connections.
3. Insert the power cable through the strain relief.
4. Connect leads L1 to U, L2 to V, and L3 to W terminals of the filter (see Fig. 3-2). Ensure that all connections are
tight to avoid excessive heating.
5. Connect the ground lead to rear terminal of filter marked.
Strain Relief
GND
Power Cable
L1
EMI Filter Box
L2
L3
Figure 3-2
MAX100D Primary Power Connections
WARNING
There is line voltage at the filter even if the I (ON) pushbutton on the MAX100D power supply has not
been pressed. As a common safety practice, ALWAYS verify that the line disconnect switch is in the
OFF position before installing, disconnecting or servicing in this area. In the U.S., use a "lock-out /
tag out" procedure until the service or maintenance work is complete. In other countries, follow
appropriate national or local safety procedures.
3-8
MAX100D 380-415V CE Instruction Manual
SETUP
Power Cable Connection (Continued)
Power Cable from MAX100D Power Supply to Power Source
1. Be certain that the line disconnect switch is in the OFF position.
2. Connect the power cord leads to the line disconnect switch. Follow applicable national or local electrical codes.
3. Be certain that the line disconnect switch remains in the OFF position during the rest of the setup of the
MAX100D system.
Remote Start/Stop Switch (Optional)
To connect the remote start/stop switch:
1. Pass the remote start/stop switch cable assembly through the strain relief at the rear of the MAX100D.
2. Connect wires 33 and 34 to TB1-5 and TB1-6 for machine “start.” (See Figure 6-5 for location of TB1, and
Figure 3-3 for detail of TB1.)
3. Connect wires 37 and 38 to TB1-7 and TB1-8 for “auxiliary 24-volt AC input.”
TB1
Figure 3-3
Remote Start/Stop Switch Connections
Machine Computer Interface (Optional)
The customer must supply 2-pair twisted 22 AWG (American Wire Gauge) cable (or equivalent).
Refer to TB1 on page 7-2 in the Wiring Diagrams for machine interface connections.
MAX100D 380-415V CE Instruction Manual
3-9
SETUP
Power Supply Gas Connections
Plasma Gas Connections
1. When using nitrogen or argon/hydrogen as the plasma gas, connect hose from source to
the connector on the rear of the plasma gas console located on the top of the power supply
labeled PLASMA GAS. (Fig. 3-4)
2. When using air as the plasma gas, connect hose from SOURCE SUPPLY to the connector
located on the left of the regulator on the rear of the power supply. (Fig. 3-6) Remove TEE
PLUG on right side of regulator, and connect 0.5 m hose (#024373) from the tee to the
PLASMA GAS inlet on the plasma gas console. (Fig. 3-6, 3-4)
3. If you are not cutting with an H35-N2 mixture, skip this step (3).
When using a nitrogen and argon/hydrogen mixture as the plasma gas, the optional Dual
Gas Mixer must be used. The mixer is secured to the rear and top of the Plasma Gas
Console with four 8-32 screws.
#015230
• Attach the left-handed adapter (#015230) included in the Dual Gas Mixer hose package
(#028721) to the argon/hydrogen (H35) tank. Find the red 7.6 meter left-hand threaded
hose (#024384) from the package and connect the hose from the argon/hydrogen tank to
INLET1 of the Dual Gas Mixer.
#015009
#015230
(remove from hose)
• Attach the right-handed adapter (#015009) included in the Dual Gas Mixer hose package
(#028721) to the nitrogen tank. Find the blue 7.6 meter right-hand threaded hose
(#024205) from the package and connect the hose from the nitrogen tank to INLET2 of
the Dual Gas Mixer.
• Find the 610 mm red hose (#024374) from the hose package and remove the left-hand
connector (#015230). Attach this connector to the PLASMA GAS inlet on the rear of the
Gas Console. Connect the hose from the Dual Gas Mixer OUTLET to the PLASMA GAS
inlet at the rear of the plasma gas console.
8-32 screw holes
Figure 3-4
3-10
Plasma Gas Console Connections and Torch Connection
MAX100D 380-415V CE Instruction Manual
SETUP
Outlet
Inlet1
Inlet2
Figure 3-5
Dual Gas Mixer Connections
Shield Gas Connections
1. When using air, nitrogen or carbon dioxide as the shield gas, connect hose from SOURCE SUPPLY to the
connector on the left of the regulator on the rear of the power supply. (Fig. 3-6)
Source
supply
Figure 3-6
Tee Plug
Shield Gas Power Supply Connections and Air Plasma Gas Connection
MAX100D 380-415V CE Instruction Manual
3-11
SETUP
Connecting the Torch
Torch Leads to Power Supply
1. Align the TORCH CONNECTOR Key Plug with the 2X1 RECEPTACLE Key Slot (on the plasma gas console)
and push in until the pins seat. (Figure 3-7)
2. Turn the connector Securing Ring 1/4 turn counterclockwise to ensure that the securing ring threads and the
receptacle threads are aligned prior to tightening.
Caution:
The connector securing ring and 2X1 receptacle are fine-threaded. Thread
damage could occur if cross-threaded.
3. Turn the connector securing ring clockwise to tighten.
TORCH CONNECTOR
2X1 RECEPTACLE
Key Plug
Key Slot
Securing Ring
Figure 3-7
3-12
Quick Disconnect Alignment
MAX100D 380-415V CE Instruction Manual
Section 4
OPERATION
In this section:
Description of Controls and Indicators ......................................................................................................................4-2
Plasma Gas Console Panel .............................................................................................................................4-2
MAX100D Control Panel ..................................................................................................................................4-2
Dual Gas Mixer ................................................................................................................................................4-4
Operating Instructions...............................................................................................................................................4-5
Operating Tips ........................................................................................................................................................4-10
Changing Consumable Parts .........................................................................................................................4-10
Cutting with Hand Torch .................................................................................................................................4-12
Piercing with Hand Torch ...............................................................................................................................4-15
Gouging with Hand Torch ...............................................................................................................................4-16
Common Cutting Faults .................................................................................................................................4-18
Duty Cycle......................................................................................................................................................4-18
Gas Pressure .................................................................................................................................................4-18
Cut / Gouging Charts ..............................................................................................................................................4-20
Cut / Gouging Index................................................................................................................................................4-21
Mild Steel Cutting ...........................................................................................................................................4-22
Stainless Steel Cutting ...................................................................................................................................4-30
Aluminum Cutting...........................................................................................................................................4-39
Mild Steel Gouging.........................................................................................................................................4-49
Stainless Steel Gouging.................................................................................................................................4-51
Aluminum Gouging.........................................................................................................................................4-53
MAX100D 380-415V CE Instruction Manual
4-1
OPERATION
Description of Controls and Indicators
Plasma Gas Console Panel (Figure 4-1)
• GOUGING / CUTTING Application Switch
Changes pilot arc current for gouging or cutting operations.
• PLASMA Gas Adjustment Valve
Adjusts plasma gas pressure in TEST position.
• PLASMA Gas Pressure Gauge
Indicates dynamic (flowing) plasma gas pressure.
MAX100D Control Panel (Figure 4-2)
• Green I (ON) button
Activates the power supply and its control circuits.
• Red O (OFF) button
Shuts the power supply down.
• White POWER ON light
Illuminates after the I (ON) button is released to indicate that all control circuits are activated, safety
interlocks are satisfied, and the system is ready for operation.
• Green GAS PRESSURE light
Illuminates after the I (ON) button is released to indicate that the gas pressure is adequate. If power supply
shuts down and light is not illuminated when the I (ON) button is pushed, then the gas pressure is
inadequate.
• Yellow OVER-TEMPERATURE light
Normally not illuminated. If power supply shuts down and light is illuminated when the I (ON) button is
pushed, then the power transformer and/or the chopper has overheated.
• AMPS output adjustment knob
Adjusts output current between 30 and 100 amps. (Increase the amperage to cut thicker material.)
• PLATE – EXPANDED/NORMAL switch
In EXPANDED (up) position, a continuous pilot arc remains on. This setting is recommended for cutting
expanded plate. Never exceed 40 amps while in this position.
Use in NORMAL (down) position when cutting normal plate.
4-2
MAX100D 380-415V CE Instruction Manual
OPERATION
Description of Controls and Indicators (cont.)
• GAS TEST/RUN switch
In TEST position, gases flow so that adjustments to both shield and plasma gas pressures can be made.
RUN position is used after gases have been set in TEST position, and cut is about to be made.
• SHIELD Gas Adjustment Valve
Adjusts shield gas pressure in TEST position.
• SHIELD Gas Pressure Gauge
Indicates dynamic (flowing) plasma gas pressure.
PLASMA Gas
Adjustment Valve
PLASMA Gas
Pressure Gauge
Figure 4-1
Plasma Gas Console Panel
SHIELD Gas
Adjustment Valve
SHIELD Gas
Pressure Gauge
Figure 4-2
MAX100D 380-415V CE Instruction Manual
MAX100D Control Panel
4-3
OPERATION
Description of Controls and Indicators (cont.)
Dual Gas Mixer (Figure 4-3)
Note:
If you are not cutting with an H35-N2 mixture, skip this page.
• GAS1 Adjustment Valve
Adjusts plasma flow for gas component #1 that is plugged into INLET1.
• GAS1 Flowmeter
Indicates flow rate of gas component #1 that is sent to the Plasma Gas Console.
• GAS1 Pressure Gauge
Indicates plasma GAS1 inlet pressure.
• GAS2 Adjustment Valve
Adjusts plasma flow for gas component #2 that is plugged into INLET2.
• GAS2 Flowmeter
Indicates flow rate of gas component #2 that is sent to the Plasma Gas Console.
• GAS2 Pressure Gauge
Indicates plasma GAS2 inlet pressure.
• OUTLET Pressure Gauge
Indicates plasma gas mixture outlet pressure.
HYPERTHERM
OUTLET
Outlet
Inlet1
Inlet2
GAS1
GAS2
Dual Gas Mixer
Figure 4-3
4-4
Gas Mixer
MAX100D 380-415V CE Instruction Manual
OPERATION
Operating Instructions
WARNING
Before operating this system, you must read the Safety section of this manual thoroughly!
1. Ensure that the work environment and your clothing meet the safety requirements outlined in the Safety section.
2. Follow the system installation instructions in the Setup section.
3. Be sure that the correct consumable parts are in the MAX100D torch. See Cut / Gouging Charts later in this
section for correct consumables.
4. Turn on the facility gas supply. Adjust incoming plasma and shield gas pressures to a minimum of 5.4 bar.
5. Apply 3-phase power to the MAX100D.
6. Press the green I (ON) button to power up the system. Hold it down until the white POWER ON light and the
green GAS PRESSURE light both illuminate.
➠
7. Place the GAS TEST/RUN switch in the TEST position. Gases will flow through the system.
➠
TEST
MAX100D 380-415V CE Instruction Manual
4-5
OPERATION
8. If you are not cutting with an H35-N2 mixture, skip this step (8).
8.1. At the Plasma Gas Console Panel, choose CUTTING.
8.2. Fully open PLASMA Gas Adjustment Valve on the Plasma Gas
Console Panel.
OUTLET
8.3. Be certain that incoming flowing (dynamic) pressures to the Dual
Gas Mixer are equal.
8.4. Adjust the H35 (GAS1) and N2 (GAS2) mixture % at the Dual Gas
Mixer by referring to Plasma Gas Mix H35 GAS1 and N2 Gas2 in
the Cut / Gouging Charts (pg.4-32 for 100 amp cutting).
➠
➠
GAS1
GAS2
Note: When adjusting the H35-N2 mixture at the Dual Gas Mixer,
be careful not to let the mixer OUTLET pressure go below 20 psi
(1.4 bar). (A pressure switch inside the power supply will shut down
the system if the incoming pressure drops below 20 psi (1.4 bar).)
8.5. Go to step 10.
9. At the Plasma Gas Console Panel, choose CUTTING or GOUGING application, and then, with the PLASMA
Gas Adjustment Valve, set the plasma gas pressure for the particular metal you are cutting. Refer to the Plasma
Gas Pressure in TEST position in the Cut / Gouging Charts later in this section.
➠
Plasma gas pressure in RUN position is always higher than the set TEST pressure. No
adjustment is necessary for RUN position.
➠
Note:
➠
10. Using the SHIELD Gas Adjustment Valve on the MAX100D Control Panel, set the shield gas pressure
according to the Shield Gas Pressure in the Cut / Gouging Charts later in this section.
4-6
MAX100D 380-415V CE Instruction Manual
OPERATION
➠
11. After gases have been set, switch to the RUN position. Gases will stop flowing through the system.
RUN
➠
12. Adjust the AMPS potentiometer to the desired current. Refer to the Arc Current Setting in the Cut / Gouging
Charts later in this section
13. Place the PLATE EXPANDED/NORMAL switch in the NORMAL position.
Note: If you are cutting metal grate, place the PLATE EXPANDED/NORMAL switch in the EXPANDED
position.
➠
14. If you are using a torch height control system, adjust the Arc Voltage Setting on the torch height control
according to the specifications in the Cut / Gouging Charts later in this section.
MAX100D 380-415V CE Instruction Manual
4-7
OPERATION
15. Adjust the work clamp to the work table or workpiece. Do not attach the work clamp to the portion of the
workpiece that will fall away. See Figure 4-4.
16. Position the torch the appropriate distance from the workpiece. Refer to the Torch-to-work Distance in the
Cut / Gouging Charts later in this section.
17. Set the machine travel speed. Refer to Travel Speed in the Cut / Gouging Charts later in this section.
Figure 4-4
Proper Work Clamp Connection
18. Hand Torch:
Press the torch start button and hold it down.
Machine Torch: Press the START button.
After a two-second delay, the pilot arc will activate, and transfer will occur if the Torch-to-work Distance is set
properly.
Notes:
Hand Torch:
The arc will extinguish if the torch switch is released or if no material remains under the arc.
Machine Torch: The arc will extinguish if the STOP button is pressed or if no material remains under the arc.
Postflow of gas will continue for ten seconds after arc is extinguished.
4-8
MAX100D 380-415V CE Instruction Manual
OPERATION
Operating Tips
Changing Consumable Parts
WARNING
Always unplug the power supply before inspecting or changing the torch parts.
The consumable parts in the torch need to be inspected periodically for signs of wear. A good rule of thumb is to
check the parts after every 100 starts (pierces, edge starts, parts cut, etc.).
To remove the consumables (Fig. 4-5):
1. Machine torch. Bring the torch to the edge of the machine with the lifter raised to its highest point. Hold your
hand under the retaining cap – the nozzle and swirl ring may fall when you remove the retaining cap. Unscrew
and remove the retaining cap. If the nozzle and swirl ring remain inside the cap, take them out and set them
aside.
Hand torch. Unscrew and remove the retaining cap. The nozzle and swirl ring will come out; set them aside.
2. Inspect the retaining cap. It should be undamaged.
3. Check the shield for external signs of wear. The shield should be clean and clear of metal debris. (Debris will
cause arcing.) The gas holes along the edge of the shield should not be blocked with debris. The center hole
should not have any nicks or gouges, and should show no signs of arcing activity.
4. Unscrew the shield. Inspect the gas holes from the inside. The holes should be clear of metal or other debris. If
the gas holes are blocked by debris, try to open them by pushing a pin through each one from the outside of
the shield to the inside. If the shield is still good, screw it back on to the retaining cap. If it is damaged, replace
it with a new one.
5. Inspect the O-rings on the torch. They should be lubricated and undamaged. If they are dry, lubricate them with
a thin film of the lubricant provided in the spare parts kit. If they are damaged, replace them.
6. Inspect the nozzle for damage or signs of wear. The inside of the nozzle should be clean and bright, with no
deposits from the electrode. You can clean the inside of the nozzle with steel wool, but be sure to remove any
remnants of the steel wool afterward. The hole in the nozzle should not be worn or oval-shaped. If the nozzle is
damaged, replace it with a new one.
7. Inspect the swirl ring. It should be clean, and the holes along the side should not be plugged. If the swirl ring is
damaged, replace it with a new one.
8. Remove the electrode with the wrench supplied in the spare parts kit. Inspect it. If the center of the electrode
has a pit more than 1 mm deep, replace it. If the electrode is still good, inspect its O-ring; it should be lubricated
and undamaged. If the O-ring is dry, lubricate it with a thin film of the lubricant supplied in the consumable parts
kit. If it is damaged, replace it.
4-10
MAX100D 380-415V CE Instruction Manual
OPERATION
9. Inspect the inside of the torch body. It should be clean and undamaged.
10. Replace the electrode and tighten it with the wrench. Do not overtighten it.
11. Install the swirl ring on the electrode with the word “front” facing away from the torch body – it won't fit in
properly if it is installed in the wrong direction. Place the nozzle on top of the swirl ring. Be certain that the
nozzle is inserted far enough into the torch so that the O-ring is not visible, and is not pinched.
12. Replace the retaining cap and shield. Make sure that it is tightened snugly; if it is loose, it can affect the cut (or
gouge) quality.
Shield
Retaining Cap
Nozzle
Swirl
Ring
Electrode
Torch
O-Rings
Figure 4-5
MAX100D 380-415V CE Instruction Manual
Consumable Parts
4-11
OPERATION
Cutting with Hand Torch
• Set APPLICATION switch to CUTTING.
• Do not fire the pilot arc into the air needlessly – doing so causes a drastic reduction of the nozzle and
electrode life.
• Start cutting from the edge of the workpiece (Fig. 4-6) unless you must pierce. For tips on piercing, see
Piercing later in this section.
• When cutting, make sure that the sparks are coming out of the bottom of the workpiece. If they are spraying
on top of the workpiece, you are moving the torch too fast, or you do not have sufficient power to fully
penetrate the workpiece.
• Hold the torch lightly on the metal or just off the metal. Holding the torch firmly to the workpiece causes the
nozzle to stick and makes smooth cutting difficult. The arc transfers once the torch is within 3 mmof the
workpiece.
• To cut circles use a template or a radius cutter attachment (Fig. 4-7).
• Pull the torch through the cut. Pulling it is easier than pushing it.
• Hold the torch nozzle (tip) at a vertical position and watch the arc as it cuts along the line (Fig. 4-8). By
lightly dragging the nozzle on the workpiece, you can maintain a steady cut. For straight-line cuts, use a
straight edge as a guide.
4-12
MAX100D 380-415V CE Instruction Manual
OPERATION
Figure 4-6
Figure 4-7
MAX100D 380-415V CE Instruction Manual
Starting a Cut
Cutting a Circle
4-13
OPERATION
Figure 4-8
4-14
Dragging the Torch
MAX100D 380-415V CE Instruction Manual
OPERATION
Piercing with Hand Torch
Note:
Consumable life will be shortened when piercing metal greater than 15 mm thick.
• Hold the torch so that the nozzle is approximately 1.5 mm away from the workpiece before pressing the
start button. This method maximizes the life of the nozzle.
• Hold the torch at an angle to the workpiece 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.
• Start the cut at an angle rather than in an upright position. This method permits the hot metal to escape to
one side rather than splashing back against the nozzle, protecting the operator from the sparks and
extending the torch nozzle life (Fig. 4-9).
• When the pierce is complete, proceed with the cut.
1. Tilt the torch and push the start button.
2. Rotate the torch to an upright position.
Figure 4-9
MAX100D 380-415V CE Instruction Manual
Piercing
4-15
OPERATION
Gouging with Hand Torch
The MAX100D can be used for gouging mild steel, stainless steel, or aluminum by using the gouging consumables
(See Cut / Gouging Charts later in this section). Use the following guidelines to assist you with the gouging
process:
• Set APPLICATION switch to GOUGING.
• When gouging, it is absolutely necessary to wear full protection – a welding helmet with at least a #6 glass,
welding gloves and a welding jacket. The arc is fully exposed and will cause serious burns if skin is not
covered.
• An optional hand heat shield (#020711) is available and should be used for hand gouging. The hand heat
shield guards the hand and the plastic torch handle from excessive heat.
• Install the gouging consumables just as you would install the standard cutting consumables.
• Adjust the gas pressures according to Cut / Gouging Chart data.
• Tilt the torch approximately 40-45° from the surface to be gouged and feed into the gouge. Try not to allow
the shield to come in contact with the plate since this can cause premature wear. Multiple passes or
“weaving” may be necessary to gouge wider and deeper sections. (See Fig. 4-10.)
4-16
MAX100D 380-415V CE Instruction Manual
OPERATION
40°
Direction of Travel
Figure 4-10
MAX100D 380-415V CE Instruction Manual
Gouging
4-17
OPERATION
Common Cutting Faults
• The workpiece is not totally penetrated. Causes can be:
–
–
–
–
The current is too low.
The cut speed is too high.
The torch parts are worn.
The metal being cut is too thick.
• Dross forms on the bottom of the cut. Causes can be:
– The cutting speed is too slow.
– The torch parts are worn.
Duty Cycle
The duty cycle, or the amount of time the pilot or plasma arc can remain “on” in minutes within a 10-minute
period, is affected by many factors. When the current is set at 100 amps, the MAX100D has an 80% duty cycle.
During normal operation, the plasma arc can remain on 8 minutes out of every 10 minutes without causing the
temperature sensors to disable the unit. The duty cycle increases to 100% when the current is set at or below
80 amps.
The duty cycle is reduced if:
• The input line voltage is less than nominal, due to a long power cord, poor utility supply, etc.
• You are cutting material greater than 25 mm thick.
• The work clamp is not making a good electrical contact with the workpiece due to paint, rust, etc.
Gas Pressure
The plasma gas, compressed air or nitrogen, must be available at a flow rate of 208 liters/minute and a minimum
pressure of 5.4 bar. If the pressure is below 4.1 bar, the torch will extinguish.
4-18
MAX100D 380-415V CE Instruction Manual
OPERATION
Cut / Gouging Charts
The cut and gouging chart information on the following pages will enable you to successfully cut or gouge using the
MAX100D system.
Caution:
Note:
Before cutting, check all settings and adjustments. Also, check for damaged torch
parts and worn consumable parts.
If the metal thickness that you are cutting is not listed in the cut charts, make an
appropriate interpolation for Arc Voltage, Travel Speed and Approx. Motion Delay Time.
WARNING
The voltage between the tip of the torch and the workpiece may exceed 113 VDC if shielded
consumable parts are not installed in the torch. Cut charts that specify non-shielded consumables
are for machine torch applications only. The PAC160 hand torch must be operated with shielded
parts to maintain the S mark and CE low voltage compliance.
4-20
MAX100D 380-415V CE Instruction Manual
OPERATION
Cut / Gouging Index
CUT / GOUGING INDEX
Metal
Current
Mild Steel
100 Amp
100 Amp
100 Amp
100 Amp**
60 Amp
60 Amp
60 Amp
60 Amp†
Stainless
100 Amp
100 Amp
100 Amp*
100 Amp
100 Amp**
60 Amp
60 Amp
60 Amp†
30/40 Amp
Plasma Gas
Shield Gas
Page
Air
N2
N2
Air
Air
N2
N2
Air
Air
Air
CO2
Air
Air
Air
CO2
Air
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
N2
N2
H35-N2
H35
N2
N2
N2
N2
Air
Air
CO2
N2
N2
Air
Air
CO2
Air
Air
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
Aluminum
100 Amp
100 Amp
100 Amp
100 Amp
100 Amp
100 Amp**
60 Amp
60 Amp
60 Amp
60 Amp†
Air
N2
N2
H35
H35
Air
Air
N2
N2
Air
Air
Air
CO2
Air
N2
Air
Air
Air
CO2
Air
4-39
4-40
4-41
4-42
4-43
4-44
4-45
4-46
4-47
4-48
Mild Steel
100 Amp
100 Amp
Air
H35
Air
Air
4-49
4-50
Stainless
100 Amp
100 Amp
H35
H35
Air
N2
4-51
4-52
Aluminum
100 Amp
100 Amp
H35
H35
Air
N2
4-53
4-54
* Dual Gas Mixer required
** Extended Consumables Cut Chart
† Unshielded Consumable Parts
MAX100D 380-415V CE Instruction Manual
4-21
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting
Plasma Gas: Air
Shield Gas: Air
Current Setting: 100 Amp
This gas combination gives good cut speed, low dross levels and is very economical. Some surface
nitriding can occur.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
120433
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
4.8†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
135
80
3048
0.8
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
10
140
2032
1.0
12
145
1143
1.2
15
150
762
1.5
19*
155
432
25*
165
279
32*
170
152
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
4-22
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 100 Amp
This gas combination is used when cut edge quality and surface nitriding are less important. Electrode life
is extended when this combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bari)
6
3.4
5.5†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
140
80
1651
1.,0
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
145
1270
1.0
12
150
1016
1.5
15
155
508
1.5
19*
165
254
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-23
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting
Plasma Gas: N2
Shield Gas: CO2
Current Setting: 100 Amp
This gas combination is used when cut edge quality and surface nitriding are less important. Electrode life
is extended when this combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
5.9†
Shield
Gas (CO2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(CO2) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
140
80
2159
1.0
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
145
1270
1.0
12
145
1016
1.2
15
150
762
1.5
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-24
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Extended Consumables
Mild Steel Cutting
Plasma Gas: Air
Shield Gas: Air
Current Setting: 100 Amp
This gas combination gives good cut speed, low dross levels and is very economical. Some surface
nitriding can occur. The extended consumables allow the user greater accessibility for some cutting
applications.
020333
Deflector
020846
Retaining Cap
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
3
3.4
5.5†
020754
020706
Nozzle Swirl Ring
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
120444
Electrode
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
120
80
4572
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
6
120
3175
0.8
10
125
2286
1.0
12
135
1270
1.2
1.5
15
135
889
19*
145
559
25*
150
356
32*
150
254
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-25
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting
Plasma Gas: Air
Shield Gas: Air
Current Setting: 60 Amp
This gas combination gives good cut speed, low dross levels and is very economical. Some surface
nitriding can occur.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
120433
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1
3.4
5.2†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
120
100
7620
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.3
120
7620
0.5
1.5
125
7620
0.5
2
130
6096
0.5
2.5
130
5080
0.5
3
130
4445
0.5
3.5
130
4318
0.6
6
135
1397
0.8
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-26
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 60 Amp
This gas combination is used when cut edge quality and surface nitriding are less important. Electrode life
is extended when this combination is used.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1
3.4
5.2†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
100
7620
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.3
125
7620
0.5
1.5
125
7620
0.5
2
130
5334
0.5
2.5
130
3556
0.5
3
135
3048
0.5
3.5
135
2159
0.6
6
145
762
0.8
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-27
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting
Plasma Gas: N2
Shield Gas: CO2
Current Setting: 60 Amp
This gas combination is used when cut edge quality and surface nitriding are less important. Electrode life
is extended when this combination is used.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1
3.4
5.2†
Shield
Gas (CO2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(CO2) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
100
7620
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.3
125
7620
0.5
1.5
125
7620
0.5
2
130
5334
0.5
2.5
130
4064
0.5
3
135
3048
0.8
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-28
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Mild Steel Cutting – Unshielded Parts
Plasma Gas: Air
Shield Gas: Air
Current Setting: 60 Amp
This gas combination gives good cut speed, low dross levels and is very economical. Some surface
nitriding can occur.
020333
Deflector
020756
Retaining Cap
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1
2.8
5.5†
020922
Nozzle
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
60
020706
Swirl Ring
120433
Electrode
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
110
100
10160
0.2
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.3
115
8636
0.2
1.5
120
7620
0.2
2
120
6096
0.5
2.5
125
5080
0.5
3
125
3810
0.8
3.4
125
3556
1.0
6
130
1651
1.0
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-29
OPERATION
MAX100D Machine/PAC160 Hand Torch
Stainless Steel Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 100 Amp
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying
elements are less important. Electrode life is extended when this combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.5
3.4
5.5†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
130
80
5588
0.2
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
2.5
140
4191
0.5
4
145
1778
0.8
6
150
1397
0.8
9
150
1016
1.0
12
155
762
1.2
15
155
559
19*
155
559
25*
165
279
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
4-30
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Stainless Steel Cutting
Plasma Gas: N2
Shield Gas: CO2
Current Setting: 100 Amp
This gas combination is used when surface nitriding and surface oxidation of alloying elements is less
important. Electrode life is extended when using this gas combination.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.5
3.4
5.9†
Shield
Gas (CO2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(CO2) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
80
5588
0.2
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
2.5
140
4318
0.5
4
145
1778
1.0
6
150
1397
1.0
9
150
1016
1.0
12
155
762
1.5
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-31
OPERATION
MAX100D Machine/PAC160 Hand Torch
Stainless Steel Cutting
Plasma Gas: H35-N2
Shield Gas: N2
Current Setting: 100 Amp
Dual Gas Mixer (#059123) required
This gas combination is used when good surface quality and long consumable life are desired.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Dual Gas
Mixer
Shield Gas
(H35&N2) Inlet (N2) Inlet
Pressures
Pressure
Material
Thickness
H35
N2
Shield
Gas (N2)
Pressure
Travel Speed
Approx.
Motion
Delay
Time
(mm)
GAS1*
GAS1*
(bar)
(mm)
(amps)
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
3
10
90
4
3
100
150
80
3429
0.5
6.9
6.9
4
20
80
150
2540
0.5
6
60
40
150
1651
1.0
9
80
20
155
1016
1.5
12
90
10
155
762
1.5
15
90
10
160
762
2.0
Plasma
Gas Mix
Torch-to-work
Distance
Arc
Current
Setting
Arc
Voltage
Setting
Duty
Cycle
Note: • To get good cut quality, dynamic (flowing) input pressure to Dual Gas Mixer should be equal (6.9 bar).
• When cutting stainless steel with the H35-N2 mixture, dross may form on the bottom of the cut if the N2
flow rate is too low.
• When the Dual Gas Mixer is properly set, the plasma gas pressure gauge on the gas console should read
approximately 3.8 bar.
* Align flowmeter scale with middle of flowmeter float ball when setting mix ratios.
* Full scale = 100. Flow rate at full scale (100) of the flow meter is about 35.4 liters/minute.
1 bar = 6.895 KPa
4-32
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Stainless Steel Cutting
Plasma Gas: H35
Shield Gas: N2
Current Setting: 100 Amp
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
H35
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
9
3.4
5.2†
Shield
Gas (N2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
155
80
1016
1.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
12
155
762
1.5
15
160
762
2.0
Plasma
Shield Gas
Gas
(H35) Inlet
(N2) Inlet
Pressure
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-33
OPERATION
MAX100D Machine/PAC160 Hand Torch
Extended Consumables
Stainless Steel Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 100 Amp
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying
elements are less important. Electrode life is increased when this combination is used. The extended
consumables allow the user greater accessibility for some cutting applications.
020333
Deflector
020846
Retaining Cap
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
2.5
3.4
5.5†
020754
Nozzle
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
020706
Swirl Ring
020887
Electrode
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
130
80
4445
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
3
130
4064
0.5
4
135
2032
0.8
6
135
1524
0.8
9
140
1016
1.0
12
145
889
1.2
15
150
457
1.5
19*
155
381
25*
160
254
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
4-34
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Stainless Steel Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 60 Amp
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying
elements are less important. Electrode life is extended when this combination is used.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1
3.4
5.2†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
100
7620
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.5
125
7620
0.5
2
130
6096
0.5
2.5
130
4572
0.5
3
140
3810
1.0
4
145
1651
1.0
6
150
1143
1.0
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-35
OPERATION
MAX100D Machine/PAC160 Hand Torch
Stainless Steel Cutting
Plasma Gas: N2
Shield Gas: CO2
Current Setting: 60 Amp
This gas combination is used when surface nitriding and surface oxidation of alloying elements is less
important. Electrode life is extended when using this gas combination.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1
3.4
5.2†
Shield
Gas (CO2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(CO2) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
100
9144
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.5
125
9144
0.5
2
130
6096
0.5
2.5
130
3810
0.8
3
135
3048
1.0
4
140
1397
1.0
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-36
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine Torch
Stainless Steel Cutting – Unshielded Parts
Plasma Gas: N2
Shield Gas: Air
Current Setting: 60 Amp
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying
elements are less important. Electrode life is extended when this combination is used.
020333
Deflector
020756
Retaining Cap
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.3
2.8
5.5†
020922
Nozzle
020706
Swirl Ring
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
Arc
Arc
Current Voltage
Setting Setting
(bar)
(mm)
(amps)
4
3
60
020193
Electrode
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
120
100
9144
0.2
6.9†
6.9
1.5
120
7620
0.2
2
125
6096
0.5
2.5
125
4572
0.5
3
135
3556
1.0
4
140
1524
1.0
6
145
1016
1.0
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-37
OPERATION
MAX100D Machine Torch
Stainless Steel Cutting*
Plasma Gas: Air
Shield Gas: Air
Current Setting: 30/40 Amp
This gas combination is used when cut edge quality, surface nitriding and surface oxidation of alloying
elements are less important.
020333
Deflector
020756
Retaining Cap
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
0.5
2.8
4†
020921
Nozzle
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
0.5
30**
020950
Swirl Ring
020951
Electrode
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
65-75***
100
6350
0
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
0.6
30**
5842
0
0.7
30**
5588
0
0.9
30**
5080
0
1.2
40
3810
0.1
1.5
40
3048
0.1
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
* Some stainless steel plate comes with a plastic film attached to it. Because of the close torch-to-work distance
required for 30/40 amp cutting, this film must be removed before cutting begins.
** Turn AMPS knob totally counterclockwise for 30 Amp setting
*** To maintain the 0.5 mm Torch-to-work Distance as the electrode wears, increase arc voltage in this range to
avoid having the torch dive into the plate.
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-38
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: Air
Shield Gas: Air
Current Setting: 100 Amp
This gas combination gives good cut speed, low dross levels and is very economical.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
120433
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
5.2†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
140
80
2413
0.8
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
140
1778
1.0
12
145
1397
1.2
15
150
1143
1.5
19*
155
838
25*
160
559
32*
170
279
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-39
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 100 Amp
This gas combination is used when cut edge quality is less important. Electrode life is extended when this
combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
5.9†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
145
80
2413
1.0
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
150
1778
1.0
12
155
1397
1.5
15
155
1143
1.5
19*
160
889
25*
165
559
32*
175
279
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
4-40
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: N2
Shield Gas: CO2
Current Setting: 100 Amp
This gas combination is used when cut edge quality is less important. Electrode life is extended when this
combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
5.9†
Shield
Gas (CO2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(CO2) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
145
80
2413
0.8
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
145
1778
1.0
12
150
1397
1.2
15
155
1143
1.5
19*
160
889
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-41
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: H35
Shield Gas: Air
Current Setting: 100 Amp
This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma
gas) gives maximum thickness cutting capability, good cut quality and weldability. Electrode life is
extended when this combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
H35
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
5.5†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
130
80
2413
0.8
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
130
1778
1.0
12
135
1397
1.2
15
135
1143
1.5
19*
140
889
Plasma
Gas
Shield Gas
(H35) Inlet (Air) Inlet
Pressure
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
4-42
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: H35
Shield Gas: N2
Current Setting: 100 Amp
This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma
gas) gives maximum thickness cutting capability, excellent cut quality and excellent weldability. Electrode
life is extended when this combination is used.
020846
Retaining Cap
020335
Hand Shield
020705
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
H35
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
6
3.4
5.5†
Shield
Gas (N2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
130
80
2413
0.8
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
9
135
1778
1.0
12
135
1397
1.2
15
140
1143
1.5
19*
145
889
Plasma
Shield Gas
Gas
(H35) Inlet
(N2) Inlet
Pressure
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-43
OPERATION
MAX100D Machine Torch
Extended Consumables
Aluminum Cutting
Plasma Gas: Air
Shield Gas: Air
Current Setting: 100 Amp
This gas combination gives good cut speed, low dross levels and is very economical. The extended
consumables allow the user greater accessibility for some cutting applications.
020333
Deflector
020846
Retaining Cap
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.5
3.4
5.5†
020754
Nozzle
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
100
020706
Swirl Ring
120444
Electrode
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
130
80
4445
0.2
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
2
130
4064
0.2
2.5
130
3683
0.5
3
130
3683
0.5
3
135
3429
0.5
4
135
3175
0.8
6
135
2921
0.8
9
140
2286
1.0
12
140
1524
1.2
1.5
15
145
1143
19*
145
762
25*
155
508
32*
160
304
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
* Piercing not recommended
1 bar = 6.895 KPa
4-44
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: Air
Shield Gas: Air
Current Setting: 60 Amp
This gas combination gives good cut speed, low dross levels and is very economical.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
120433
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.3
3.4
5.5†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
120
100
7620
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.5
125
6096
0.5
2
125
5080
0.5
2.5
130
4064
0.5
3
130
3048
0.8
6
135
2286
1.0
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-45
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: N2
Shield Gas: Air
Current Setting: 60 Amp
This gas combination is used when cut edge quality is less important. Electrode life is extended when this
combination is used.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.3
3.4
5.9†
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
100
6096
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.5
125
4572
0.5
2
135
4064
0.5
2.5
140
3302
0.5
3
145
2159
0.8
6
155
1016
1.0
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-46
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160 Hand Torch
Aluminum Cutting
Plasma Gas: N2
Shield Gas: CO2
Current Setting: 60 Amp
This gas combination is used when cut edge quality is less important. Electrode life is extended when this
combination is used.
020756
Retaining Cap
020335
Hand Shield
120336
Nozzle
020706
020193
Swirl Ring Electrode
020334
Machine Shield
Plasma Gas Pressure
Nitrogen
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.3
3.4
5.9†
Shield
Gas (CO2)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
1.5
60
Plasma
Gas
(N2) Inlet
Pressure
Shield Gas
(CO2) Inlet
Pressure
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
125
100
6096
0.5
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.5
125
4572
0.5
2
135
4064
0.5
2.5
140
3302
0.5
3
145
2159
0.8
6
155
1016
1.0
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-47
OPERATION
MAX100D Machine Torch
Aluminum Cutting – Unshielded Parts
Plasma Gas: Air
Shield Gas: Air
Current Setting: 60 Amp
This gas combination gives good cut speed, low dross levels and is very economical.
020333
Deflector
020756
Retaining Cap
Plasma Gas Pressure
Air
Material
Thickness
(mm)
TEST
(bar)
RUN
(bar)
1.3
2.8
5.5†
020922
Nozzle
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
(bar)
(mm)
(amps)
4
3
60
020706
Swirl Ring
120433
Electrode
Duty
Cycle
Travel Speed
Approx.
Motion
Delay
Time
(volts)
(%)
(mm/min)
(sec)
(bar)
(bar)
115
100
7620
0.2
6.9†
6.9
Arc
Arc
Current Voltage
Setting Setting
1.5
120
6096
0.2
2
120
5080
0.5
2.5
125
4064
0.5
3
125
3048
0.8
6
130
2286
1.0
Plasma
Gas
(Air) Inlet
Pressure
Shield Gas
(Air) Inlet
Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-48
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160E Hand Torch
Mild Steel Gouging
Plasma Gas: Air
Shield Gas: Air
Current Setting: 100 Amp
This combination is very economical on gas.
020712
Shield
Torch-to-work
Angle of
inclination
020669
Retaining Cap
Plasma Gas Pressure
Air
Θ (Degrees)
TEST
(bar)
RUN
(bar)
40°
3.4
3.7†
020745
Nozzle
020750
Swirl Ring
020744
Electrode
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
Arc
Current
Setting
Duty
Cycle
Approx. Plasma Gas Shield Gas
Motion
(Air) Inlet
(Air) Inlet
Travel Speed Delay Time Pressure
Pressure
(bar)
(mm)
(amps)
(%)
(mm/min)
(sec)
(bar)
(bar)
4
1.5
100
80
381
1.0
6.9†
6.9
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-49
OPERATION
MAX100D Machine/PAC160E Hand Torch
Mild Steel Gouging
Plasma Gas: H35
Shield Gas: Air
Current Setting: 100 Amp
Hypertherm recommends a plasma gas mixture of 35% hydrogen, and 65% argon. This gas combination is
highly efficient and yields long consumable life.
020712
Shield
Torch-to-work
Angle of
inclination
020669
Retaining Cap
Plasma Gas Pressure
H35
Θ (Degrees)
TEST
(bar)
RUN
(bar)
40°
3.4
3.7†
020704
Nozzle
020750
Swirl Ring
020703
Electrode
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
Arc
Current
Setting
Duty
Cycle
Approx. Plasma Gas Shield Gas
Motion
(H35) Inlet (Air) Inlet
Travel Speed Delay Time Pressure
Pressure
(bar)
(mm)
(amps)
(%)
(mm/min)
(sec)
(bar)
(bar)
4
3
100
80
508
1.0
6.9†
6.9
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-50
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160E Hand Torch
Stainless Steel Gouging
Plasma Gas: H35
Shield Gas: Air
Current Setting: 100 Amp
Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. This gas
combination is highly efficient and yields long consumable life.
020712
Shield
Torch-to-work
Angle of
inclination
020669
Retaining Cap
Plasma Gas Pressure
H35
Θ (Degrees)
TEST
(bar)
RUN
(bar)
40°
3.4
3.7†
020704
Nozzle
020750
Swirl Ring
020703
Electrode
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
Arc
Current
Setting
Duty
Cycle
Approx. Plasma Gas Shield Gas
Motion
(H35) Inlet (Air) Inlet
Travel Speed Delay Time Pressure
Pressure
(bar)
(mm)
(amps)
(%)
(mm/min)
(sec)
(bar)
(bar)
4
3
100
80
508
1.0
6.9†
6.9
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-51
OPERATION
MAX100D Machine/PAC160E Hand Torch
Stainless Steel Gouging
Plasma Gas: H35
Shield Gas: N2
Current Setting: 100 Amp
Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. This gas
combination is highly efficient, yields long consumable life, and leaves a superior work surface.
020712
Shield
Torch-to-work
Angle of
inclination
020669
Retaining Cap
Plasma Gas Pressure
H35
Θ (Degrees)
TEST
(bar)
RUN
(bar)
40°
3.4
3.7†
020704
Nozzle
020750
Swirl Ring
020703
Electrode
Shield
Gas (N2)
Pressure
Torch-to-work
Distance
Arc
Current
Setting
Duty
Cycle
(bar)
(mm)
(amps)
(%)
(mm/min)
(sec)
(bar)
(bar)
4
3
100
80
508
1.0
6.9†
6.9
Approx. Plasma Gas Shield Gas
Motion
(H35) Inlet
(N2) Inlet
Pressure
Travel Speed Delay Time Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-52
MAX100D 380-415V CE Instruction Manual
OPERATION
MAX100D Machine/PAC160E Hand Torch
Aluminum Gouging
Plasma Gas: H35
Shield Gas: Air
Current Setting: 100 Amp
Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. This gas
combination is highly efficient and yields long consumable life.
020712
Shield
Torch-to-work
Angle of
inclination
020669
Retaining Cap
Plasma Gas Pressure
H35
Θ (Degrees)
TEST
(bar)
RUN
(bar)
40°
3.4
3.7†
020704
Nozzle
020750
Swirl Ring
020703
Electrode
Shield
Gas (Air)
Pressure
Torch-to-work
Distance
Arc
Current
Setting
Duty
Cycle
Approx. Plasma Gas Shield Gas
Motion
(H35) Inlet (Air) Inlet
Travel Speed Delay Time Pressure
Pressure
(bar)
(mm)
(amps)
(%)
(mm/min)
(sec)
(bar)
(bar)
4
3
100
80
508
1.0
6.9†
6.9
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
MAX100D 380-415V CE Instruction Manual
4-53
OPERATION
MAX100D Machine/PAC160E Hand Torch
Aluminum Gouging
Plasma Gas: H35
Shield Gas: N2
Current Setting: 100 Amp
Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. This gas
combination is highly efficient, yields long consumable life, and leaves a superior work surface.
020712
Shield
Torch-to-work
Angle of
inclination
020669
Retaining Cap
Plasma Gas Pressure
H35
Θ (Degrees)
TEST
(bar)
RUN
(bar)
40°
3.4
3.7†
020704
Nozzle
020750
Swirl Ring
020703
Electrode
Shield
Gas (N2)
Pressure
Torch-to-work
Distance
Arc
Current
Setting
Duty
Cycle
(bar)
(mm)
(amps)
(%)
(mm/min)
(sec)
(bar)
(bar)
4
3
100
80
508
1.0
6.9†
6.9
Approx. Plasma Gas Shield Gas
Motion
(H35) Inlet
(N2) Inlet
Pressure
Travel Speed Delay Time Pressure
† If RUN pressure is higher than recommended, lower Plasma Gas Inlet Pressure
1 bar = 6.895 KPa
4-54
MAX100D 380-415V CE Instruction Manual
Section 5
MAINTENANCE
In this section:
Introduction ...............................................................................................................................................................5-2
Routine Maintenance ................................................................................................................................................5-3
Torch and Torch Leads .....................................................................................................................................5-3
Power Supply ...................................................................................................................................................5-3
Sequence of Events..................................................................................................................................................5-4
Initial Checks ..........................................................................................................................................................5-10
Troubleshooting ......................................................................................................................................................5-13
Test Procedure........................................................................................................................................................5-20
Chopper Module Test Procedure ...................................................................................................................5-20
Disassembly of Hand Torch ....................................................................................................................................5-22
Removal .........................................................................................................................................................5-22
Replacement ..................................................................................................................................................5-22
Disassembly of Machine Torch ...............................................................................................................................5-24
Removal .........................................................................................................................................................5-24
Replacement ..................................................................................................................................................5-24
MAX100D 380-415V CE Instruction Manual
5-1
MAINTENANCE
Introduction
The MAX100D, and all Hypertherm plasma systems, undergo rigorous testing prior to shipment and should require
little maintenance if proper setup and operation procedures as outlined in Sections 3 and 4 are followed.
If a problem does arise, this section will familiarize qualified service personnel with the proper operation of the
MAX100D system, and will provide guides to troubleshoot problems that may occur during operation. The intent of
this section is to isolate problems at a modular level. PC board component level troubleshooting is not addressed.
This section begins with a detailed sequence of events flowchart, an initial checks procedure, a troubleshooting
guide, test procedures and instructions to remove and replace the torch and torch leads.
The service personnel performing the troubleshooting testing must be high-level electronic service
technicians that have worked with high voltage electro-mechanical systems. Knowledge of final isolation
troubleshooting techniques is assumed.
In addition to being technically qualified, service personnel must perform all testing with safety in mind.
Refer to the Safety section for operating precautions and warning formats.
For service questions or problems, contact the nearest Hypertherm Technical Service Department listed at the front
of this manual.
WARNING
SHOCK HAZARD: The large electrolytic capacitor(s) (blue-cased cylinder(s)) store 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 the capacitor(s) with a screwdriver or other
implement…explosion, property damage and/or personal injury will result. Wait at least five minutes after
turning the power supply off before touching the chopper or the capacitor(s).
5-2
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Routine Maintenance
Hypertherm systems are designed to require little regular maintenance under normal use and conditions. The
routine maintenance suggestions in this section will allow the operator to keep the system in peak operating
condition.
Torch and Torch Leads
Inspect the torch and torch leads on a regular basis:
• Always inspect the torch's consumable parts and main body before cutting. Worn or damaged parts can
cause gas leaks which can cause cut quality to deteriorate. Inspect consumables for indications of arcing,
overheating or pitting, and replace any parts that appear worn or damaged. See Changing Consumable
Parts in Section 4.
• The torch leads should be checked occasionally for cracking or other damage.
Power Supply
Inspect the power supply on a regular basis:
• Check the exterior for any damage that might affect safe operation of the power supply.
• Remove the power supply cover and inspect the interior. Check wiring harnesses and connections for wear
or damage. Check for loose connections and areas of discoloration which may indicate overheating.
• Clean the power supply periodically: use compressed air to blow dust and dirt that may have accumulated
inside the unit. In an excessively dirty environment, do this weekly.
MAX100D 380-415V CE Instruction Manual
5-3
MAINTENANCE
Sequence of Events
On the following pages is a detailed flow chart outlining the sequence of events during proper MAX100D operation
with a hand or machine torch. Shaded boxes represent action taken by the operator.
The following symbols used in the flowchart are ANSI standard flowcharting symbols. Their names and definitions
are as follows:
5-4
Terminus
The terminus is used to indicate the beginning
or ending point of a flowchart.
Task/Process
Box
The process or task box is used to
indicate any process or task other than an
input/output operation or a decision.
Decision
Diamond
The decision diamond is used to indicate
a decision or branching point.
Preparation
The preparation symbol is used to indicate an
instruction modification.
Off-page
Connector
The off-page connector is used to indicate
exit or entry from another page to the
flowchart.
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Push ON button
(1PB)
1. 120V relay CR4 on
PCB2 closes
2. Fans on
3. V6 activated
All interlocks
satisfied?
No
1. 24VAC relay CR3 on PCB2
remains open
2. Control Panel lights not
illuminated
3. LEDs on PCB4 not illuminated
Yes
1. CR1 and CR2 on PCB2 close
2. 24VAC relay CR3 on PCB2 closes
3. POWER ON LT1 and GAS PRESSURE
LT2 illuminate
4. 120V to PCB4
5. D5 on PCB4 illuminates
6. 12VDC activates CS1 on PCB3
Switch to TEST
(SW2 opens)
1. 120 volts activates V1 (gas start),
V2 (gas step), and V5 (pre flow/post flow gas)
2. Gases flow through system
To
page 5-6
MAX100D 380-415V CE Instruction Manual
5-5
MAINTENANCE
From
page 5-5
Adjust flow
rates
THC-2
installed?
Yes
Set machine
delay, set voltage
No
Switch to RUN
(SW2 closes)
1. V1, V2, and V5
deactivated
2. Gases stop flowing
Plate switch to NORMAL
(SW1 closes)
CR1 opens (pilot arc off)
5-6
To
page 5-7
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
From
page 5-6
Adjust current
(R6)
Press START
button
1.
2.
3.
4.
5.
D6 on PCB4 illuminates
V1, V5 activated
V4 on momentarily
Gases flow
Chopper output activated
2 seconds of
gas preflow
To
page 5-8
MAX100D 380-415V CE Instruction Manual
5-7
MAINTENANCE
From
page 5-7
1.
2.
3.
4.
Main Contactor CON2 closes, power to T2
Pilot arc relay (CR1) closes
Power to high-voltage transformer T3
High frequency sparking and pilot arc
initiated
Move torch
closer to plate
Transfer
of arc?
No
Yes
1.
2.
3.
4.
5.
Arc transfer sensed by CS1
D8 Xfer on PCB4 illuminates
D17 on PCB4 illuminates
Pilot arc relay CR1 opens, pilot arc off
Power off to high-voltage transformer T3,
high frequency off
6. V3 on momentarily
7. V2 activated, step gas on
THC
installed?
Yes
Machine
motion
delay
No
1. D4 on PCB4 illuminates
2. Machine motion starts
(machine torch only)
3. Cutting begins
5-8
From
page 5-9
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
From
page 5-8
THC-2
installed?
Yes
UP / DOWN lights
active on THC-2
No
STOP pressed (machine torch),
START button released (hand torch)
Plate overrun
1.
2.
3.
4.
5.
Machine motion stops (machine torch only)
Main contactor CON2 opens
Chopper output deactivated
D4, D6, D8, D17 on PCB4 off
V1, V2 deactivated
10 seconds
of gas
post-flow
1. V5 deactivated
2. Gases stop flowing
3. Cut sequence complete
MAX100D 380-415V CE Instruction Manual
5-9
MAINTENANCE
Initial Checks
Before tracking down specific problems, it is good practice to do a visual check, and verify proper voltages are
present at the power source, transformer and power distribution board.
WARNING
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 main disconnect switch off.
2. Using a Phillips head screwdriver, remove top plate, two side plates, front plate, and rear plate.
3. Inspect interior of unit for discoloration on pc boards, or other apparent damage. If a component or module is
obviously defective upon visual inspection, remove and replace it before doing any testing. Refer to the Parts
List section (6) to identify parts and part numbers.
4. If no damage is apparent, apply power by turning on the main disconnect switch.
5. Measure the voltage between the U, V and W terminals on the EMI filter located on the rear of the MAX100D
power supply. Refer to Figure 5-1. The voltage between any two of the three terminals should be equal to the
supply voltage (380 or 415 VAC). If there is a problem at this point, disconnect main power and check
connections, power cable, and fuses at line disconnect switch. Repair and/or replace defective component(s) if
necessary.
(continued on page 5-12)
5-10
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Power
Cable
Ground
Figure 5-1
Primary Power Measurement Location – MAX100D
MAX100D 380-415V CE Instruction Manual
5-11
MAINTENANCE
F3
RECP2
RECP1
CR1
CR2
CR3
CR4
RECP3
RECP4
Figure 5-2
Power Distribution Board PCB2
6. Measure voltage at power distribution board PCB2. See Figure 5-2 for detail of PCB2. Look on the board for
fuses F3 and F4. Measurements between each fuse and chassis ground are as follows:
F3:
F4:
115 VAC
24 VAC
If voltages are not present, or incorrect at one or more of these points, disconnect power and troubleshoot
PCB2 fuses and associated pins, connectors and wiring between power distribution board connector RECP1
and transformer secondary T1. See Figure 6-5 for location of T1.
Also, check main power fuses F1 and F2 (located in Figure 6-1), and associated wiring and connections
between T1 and L1 and L2.
Repair and/or replace defective component(s) if necessary.
5-12
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Troubleshooting
The troubleshooting section is presented by following normal operational sequence. Shaded boxes with operator
action correspond to action outlined in Sequence of Events. Before troubleshooting for specific problems, be sure
that unit passes Initial Checks as outlined earlier in this section.
WARNING
SHOCK HAZARD: Always use caution when servicing a power supply when the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death. If questions or problems
arise during servicing, call the nearest Hypertherm Technical Services Department listed at the front of this
manual.
Push ON button
(PB1)
Problem
Possible Causes and Solutions
1.
1.1. The green I (ON) PB1 pushbutton is defective.
Check switch. The ON switch is normally open
The fans are not operating and
the POWER ON indicator does
not illuminate.
1.2. The red O (OFF) PB2 pushbutton is defective.
Check switch. The OFF switch is normally closed.
1.3. Associated wiring not making good contact.
Check wiring and repair or replace, if necessary.
2.
POWER ON indicator
illuminates, but the fans are
not operating.
2.1. CR4 on the Power Distribution Board is defective.
Check that CR4 switches when ON pushbutton is pressed.
See Figure 5-2 for location of CR4. If CR4 is defective,
replace PCB2.
2.2. Terminals to fans are not seated together securely and/or
not getting 120VAC from Power Distribution Board.
Check terminals and associated wiring for good continuity.
Check for 120VAC at terminals.
2.3. PL2 and RECP2 on Power Distribution Board (see Figure
5-2 for location of RECP2) are not seated well.
Check pins, connectors and associated wiring for good
continuity. Repair or replace, if necessary.
MAX100D 380-415V CE Instruction Manual
5-13
MAINTENANCE
Problem
Possible Causes and Solutions
3.
3.1.
The fans are operating, but the
POWER ON indicator does not
illuminate.
Note:
Indicator On = Indicator Off = The I (ON) PB1 pushbutton was not held down for a long
enough time.
Press and hold the I (ON) button for a minimum of 5
seconds. If the POWER ON indicator will not illuminate
after holding down the I (ON) button for 5 seconds, check
the safety “interlock” indicators while holding down the I
(ON) button. Refer to the control panel indicator
conditions and possible causes and solutions listed
opposite.
3.2.1. Gas is not on or is set too low.
Control panel indicator GAS PRESSURE will not
illuminate if the pressure to the MAX100D is set too low.
Be certain that the plasma supply gas is on and is set to a
minimum of 6.2 bar.
3.2.2. There is a gas leak somewhere in the system.
Be certain that there is no hissing sound coming from the
torch, or anywhere between the torch and the gas supply.
3.2.3. Pressure switch PS1 not functioning.
PS1 is normally open, and closes when gas pressure of
2.7 bar or greater is sensed. It is powered by 24VAC from
the Power Distribution Board. After PS1 is closed, 24VAC
illuminates the GAS PRESSURE indicator. Use wiring
diagram in Section 7 to troubleshoot.
5-14
3.3.
Main Transformer T2 and/or chopper has overheated.
Temperature switch TS1 will open when the transformer
overheats. Temperature switch TS2 will open when the
chopper overheats. If transformer T2 or chopper are
excessively hot, leave the MAX100D off with fans running
for 1 hour to cool down. If transformer and chopper are
not hot, take TS1 connector apart and check for
continuity. TS1 and TS2 are normally closed. Also, check
TS2 for continuity. Check pins, connectors and associated
wiring from TS1 and TS2 to PL3 of power distribution
board PCB2.
3.4.
There are problems with the gas pressure and the
transformer or chopper.
See 3.2. to 3.3. above
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Switch to TEST
Problem
Possible Causes and Solutions
4.
4.1. TEST/RUN switch no functioning.
SW2 is open in the TEST position. Make a continuity check.
Gas flow is weak, or not
flowing.
4.2. Plasma Gas or Shield Gas adjustment valves are closed.
Open plasma gas valve on plasma gas console and shield
gas valve on front control panel.
4.3. Valves V5, or V2 not getting 120VAC from Control Board
PCB4.
Check for 120VAC at V5 and V2 after switch is in TEST
position. If V5 and/or V2 are not getting 120VAC from
PCB4, check to see if PCB4 is functioning.
Repair and/or replace defective component(s).
4.4. Gas line(s) from valves to adjustment valves to torch are
blocked or leaking.
Check hoses and repair or replace if necessary.
Adjust flow rates
Problem
Possible Causes and Solutions
5.
5.1. Source gas pressures not on or set too low.
Set incoming pressure to a minimum of 6.2 bar at
59 liters/minute for plasma gas, and 6.2 bar at
208 liters/minute for shield gas.
Flow rates cannot be adjusted
to specifications suggested in
Cut / Gouging charts.
5.2. Gas line(s) from valves to adjustment valves to torch are
blocked or leaking.
Check hoses and repair or replace if necessary.
MAX100D 380-415V CE Instruction Manual
5-15
MAINTENANCE
Switch to
RUN
Problem
Possible Causes and Solutions
6.
6.1. TEST/RUN switch not functioning.
SW2 is closed in RUN position. Make a continuity check.
Gas continues to flow.
6.2. Solenoid valves V2 and V5 not getting 0VAC from Control
Board PCB4.
Disconnect terminals to V2 and V5, and check for 0VAC
from Control Board PCB4 after SW2 is in the RUN position.
If there is 120VAC replace Control Board PCB4.
6.3. Solenoid valves V2 and V5 not functioning.
If valves are getting 0VAC from PCB4, verify that valves are
opening correctly. If not, replace them.
Press START
button
Problem
Possible Causes and Solutions
7.
7.1. There is no spark between the spark gap electrodes.
Clean (with emery cloth), align, and/or regap (.5 mm per
gap) the electrodes, if necessary. Ensure that the electrode
surfaces between the gaps are flat. If surfaces are rounded,
replace and regap.
There is no high frequency and
no pilot arc.
7.2. High voltage transformer T3 is overheating.
Check T3 for leaking or overheating. Replace, if necessary.
7.3. High voltage transformer T3 not getting 120VAC from
Control Board PCB4.
Check pins, connectors and associated wiring from T3 to
PCB4.
7.4. T3 or capacitor pair C6, C7 in spark gap assembly
defective.
Shut down system and remove capacitors C6 and C7.
Restart system and see if a faint spark is now observed
across the gaps. If a spark is not observed at the gaps,
replace T3. If there is a spark, replace capacitor pair C6,
C7. Always replace the capacitors in pairs.
5-16
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Problem
Possible Causes and Solutions
7.5. There is no high frequency at the torch.
Check for a shorted torch, a damaged pilot arc lead, or
loose lead connections. Replace the torch or pilot arc lead
or tighten the lead connections.
7.6. Pilot arc relay CR1 is not functioning or not getting 120VAC
from the Control Board PCB4.
See if the CR1 relay contacts close after the START
command is given. If CR1 does not close check to see if
CR1 is getting 120VAC from PCB4. If it is, replace CR1. If
there is no 120VAC from PCB4, replace Control Board
PCB4.
8.
There is high frequency, but
there is no pilot arc.
8.1. Torch parts are worn.
Check consumable parts and replace, if necessary. See
Changing Consumable Parts in Section 4.
8.2. Torch leads are loose or worn.
Replace torch leads as required.
8.3. Pilot arc relay CR1 not functioning.
See solution 7.6.
8.4. Main contactor CON2 or PCB4 is defective.
Check to see if CON2 is getting 24VAC after START
command is given. If there is no 24VAC, check pins,
connections, and associated wiring from CON2 to PCB4.
If wiring is O.K., replace PCB4.
If there is 24VAC at CON2 after START command is given,
measure for 200 VAC between terminals A, B and C of main
transformer T2. If there is no voltage between these points,
replace CON2.
8.5. Surge injection circuit is defective.
Check capacitor C3 and resistor R3. Replace as required.
8.6. Chopper defective or not functioning.
See Chopper Module Test Procedure later in this section to
troubleshoot.
MAX100D 380-415V CE Instruction Manual
5-17
MAINTENANCE
Move torch
close to plate
Problem
Possible Causes and Solutions
9.
9.1. The work clamp is not connected or it is broken.
Connect or repair the work clamp.
Arc not transferring to
workpiece.
9.2. The PLATE switch is in the EXPANDED position.
Verify that PLATE is in the NORMAL position.
9.3. Torch Height Control receiving incorrect voltage for correct
standoff distance (for machine torches with THC).
Check the arc voltage setting for the type and thickness of
metal you are cutting from the Cut / Gouging Charts in
Section 4.
9.4. Transfer of arc not sensed by MAX100D.
See Arc Transfer Test Procedure later in this section.
9.5. Chopper defective or not functioning.
See Chopper Module Test Procedure later in this section.
10.
The unit stops cutting during
cut, or cuts poorly.
10.1. There is insufficient gas pressure.
Check gas inlet pressure specifications under Cut /
Gouging Charts in Section 4.
Check plasma and shield gas pressures in TEST and RUN
positions as specified under Cut / Gouging Charts in
Section 4.
10.2. Torch is getting insufficient current.
Check the arc current setting for the type and thickness of
metal you are cutting from the Cut / Gouging Charts in
Section 4.
10.3. Torch consumable parts are worn.
Check consumables and replace if necessary. See
Changing Consumable Parts in Section 4.
10.4. The PLATE switch is in the EXPANDED position.
When cutting most metals, place the PLATE switch in the
NORMAL position. Switch to EXPANDED position only
when cutting metal grate (see Description of Controls and
Operating Instructions in Section 4).
5-18
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Problem
Possible Causes and Solutions
10.5. The power supply has overheated.
Shut down system and wait for unit to cool down. If unit
will not restart, see interlock troubleshooting guide earlier
in this section (3.2).
10.6. Chopper defective or not functioning.
See Chopper Module Test Procedure later in this section.
Plate overrun
STOP pressed (machine torch),
START button released (hand torch)
or
Problem
Possible Causes and Solutions
11.
11.1. Defective or miswired machine START switch.
Check switch and wiring diagrams for correct hookup of
PLASMA START and MACHINE START.
Machine motion continues
(machine torch only).
11.2. Arc transfer signal not changing.
Check to see if D8 on Control Board PCB4 remains
illuminated after torch moves away from plate. See Figure
5-7 for location of D8.
•
If D8 remains illuminated, check to see if CS1 is
sending a 0 volt signal to PCB4. If there is 0 volts at
PCB4, replace sensor CS1. If voltage at PCB4 is
greater than 0 volts, replace Control Board PCB4.
•
If D8 is extinguished, replace Control Board PCB4.
12.
Gas continues to flow after
10 seconds.
12.1. Gas TEST/RUN switch is in the TEST position.
Be certain that Gas switch is in the RUN position when
cutting.
13.
No post-flow of gas.
13.1. Defective Control Board PCB4.
See step 4.3. If valves are working in TEST mode, but not
in post-flow mode, replace Control Board PCB4.
13.2. Defective valves.
See solution 4.4.
14.
Short torch consumables life.
14.1. Plate is in the Expanded position.
See solution 10.4.
14.2. Pilot arc relay CR1 not opening after transfer of arc.
Check to see if contacts on relay CR1 are stuck shut.
Replace if necessary.
If relay is OK, check to see if CR1 is receiving 120VAC
fromthe Control Board PCB4 after transfer of arc. If
Control Board PCB4 continues to send 120VAC to CR1
after arc transfer, replace Control Board PCB4.
MAX100D 380-415V CE Instruction Manual
5-19
\
MAINTENANCE
Test Procedures
WARNING
SHOCK HAZARD: Always use caution when servicing a power supply when the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death. If questions or problems
arise during servicing, contact the nearest Hypertherm Technical Service Department listed at the front of this
manual.
Arc Transfer Test Procedure
The “transfer” of arc refers to the arc being made between the electrode of the torch and the workpiece. The pilot
arc is made between the torch electrode and the torch nozzle and precedes transfer in normal operation. When
transfer is made, it is sensed by a Hall effect device (CS1) on the I/O board and the signal is sent to the Control
Board PCB4. To check for proper functioning of the arc transfer sensing system, perform the following procedure:
1. Observe D8 on PCB4 (see Figure 5-6) and see if it illuminates after main contactor closes (see sequence
flowchart earlier in this section). If it does not illuminate, continue to next step. If it does illuminate, return to
Troubleshooting section.
2. Disconnect connector from CS1 (see Figure 6-3 for location of CS1) and check for +12VDC. If there is +12VDC,
go to step 5.
3. If there is no +12VDC, power down and check connectors, pins and associated wiring between PL4 and PL6
(connected to S2 on Control Board PCB4). Repair and/or replace defective component(s) if necessary.
4. If wiring is OK, replace Control Board PCB4.
5. If there is +12VDC at CS1, reconnect PL4 and take voltage between pins 13&14 of PL6 on Control Board PCB4
after arc is established. This should read 0 volts.
If there is no 0 volts, replace CS1.
5-20
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Test Procedures (cont.)
Chopper Module Test Procedure
Note:
Take voltages with a digital multimeter capable of storing min. and max. readings.
WARNING
SHOCK HAZARD: Use extreme care when working near the chopper modules. The large electrolytic
capacitor(s) (blue-cased cylinder(s)) store 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 the capacitor(s) with a screwdriver or other implement…explosion, property damage and/or
personal injury will result. Wait at least five minutes after turning the power supply off before touching the
chopper or the capacitor(s).
1. Turn all power to the MAX100D OFF.
Disconnect terminals labeled 21&22 from their mating receptacles to disable the high frequency transformer.
Terminals 21&22 are located near the high voltage transformer T3. See Fig. 6-2 for location of T3.
2. Remove large fuse F5. Check to see if fuse is open. See Fig. 6-3 for location of F5.
3. Place the positive lead to the + side of the bridge and the negative lead to the – side of the bridge. See Fig. 5-3.
Note that actual connection points are hidden by cap support bracket in Fig. 5-3.
4. Turn power to the MAX100 ON, and start system up. After the START command has been given, check voltage.
The input to the chopper at these points should be about +280 VDC. If the input is OK and F5 was blown,
replace the chopper module.
If there is no +280 VDC input, check input to bridge for shorts. Also, check contactor (CON2), connections and
associated wiring to the contactor. Repair and/or replace defective component(s) if necessary.
5. If voltage from above step is +280 VDC and F5 is not blown, check output of chopper by putting the positive
lead of the voltmeter at point (+) WORK and placing the negative lead on point (-) TORCH. See Fig. 5-3.
6. Turn the system on and press the START command. After the START command has been given, check the
voltage. If the output from the chopper at these points is +280 VDC, chopper is OK.
7. If the chopper does not output +280 VDC, check to see if LED1 logic power light is illuminated. If LED1 is not
illuminated, check if 120V is going to JP6. If there is no 120V at JP6, check wiring back to power distribution
board. Repair or replace defective component(s), if necessary.
Also check to see if LED3 is turning green when enabled (normal condition). If LED1 is illuminated and LED3 is
red when enabled (fault condition), then make sure that JP9 is seated properly.
MAX100D 380-415V CE Instruction Manual
5-21
MAINTENANCE
Test Procedures (cont.)
8. If chopper still does not output 280V after completing step 7, there may be a problem with the control signal or
the chopper module. The chopper drive signal comes from the control board PCB4 as an analog level from 0 to
+12 VDC, which varies the duty cycle and subsequent output current of the chopper. This analog signal is on
pins 10&11 of S3 on PCB4.
To determine if there is a problem with the chopper module or with control board PCB4, proceed as follows:
• Ensure that high frequency is still disabled (see step 1).
• Disconnect PL7 from S3 on PCB4.
• Place voltmeter across output of chopper and press the START command.
• If the voltmeter reads +280 VDC, then there is a problem with PCB4.
• If the voltmeter reads 0 volts, then replace chopper module.
Bridge (–)
Bridge (+)
LED1
LED3
(-) TORCH
JP9
(+) WORK
JP6
Figure 5-3
5-22
4-00
Chopper Module – Front View
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Disassembly of Hand Torch
To remove and replace the hand torch main body from the lead, perform the following procedure and see Figure 5-4.
Removal
1. Remove the 5 screws and separate the two handle halves.
2. Remove the torch switch from the handle switch holder and allow it to hang freely.
3. For the shield gas lead, use a 3/8" open-end wrench to hold the torch main body fitting and a 1/2" open-end
wrench to loosen the torch lead fitting.
4. For the plasma gas lead, use a 5/16" open-end wrench to hold the torch main body fitting and a 7/16" open-end
wrench to loosen the torch lead fitting.
5. For the cap-on gas lead, use a 5/16" open-end wrench to hold the torch main body fitting, and a 3/8" open-end
wrench to loosen the torch lead fitting.
6. Remove the torch main body.
Replacement
Reverse the above steps to replace the new torch body onto the torch leads.
Handle
Shield
Switch Holder
Torch Leads
Cap-On
Switch
Plasma
Shield
Cap-On
Plasma
Main Body
Handle
Figure 5-4
PAC160 or PAC160E Hand Torch Assembly
MAX100D 380-415V CE Instruction Manual
5-23
MAINTENANCE
Disassembly of Machine Torch
Refer to Figure 5-5 and follow the instructions below.
Removal
1. Unscrew the torch sleeve from the torch main body and slide it over the torch leads.
2. For the shield gas lead, use a 3/8" open-end wrench to hold the torch main body fitting and a 1/2" open-end
wrench to loosen the torch lead fitting.
3. For the plasma gas lead, use a 5/16" open-end wrench to hold the torch main body fitting and a 7/16" open-end
wrench to loosen the torch lead fitting.
4. For the cap-on gas lead, use a 5/16" open-end wrench to hold the torch main body fitting, and a 3/8" open-end
wrench to loosen the torch lead fitting.
5. Remove the torch main body.
Replacement
Reverse the above steps to replace the new torch body onto the torch leads.
Sleeve
Shield
Plasma
Shield
Leads
Plasma
Cap-On
Main Body
Cap-On
Figure 5-5 Machine Torch Assembly
5-24
MAX100D 380-415V CE Instruction Manual
MAINTENANCE
Plasma Gas Console
PG1
V1
CO2
Plasma Gas
In
To Torch
PS1
(NO set to
close @
20 PSI)
MV1
V2
Plasma
Connection
PS3 (NC set to open @ 50 PSI)
V3
PS4 (NC set to open @ 10 PSI)
V4
MAX100D Power Supply
PG2
PS2 (NO set to close @ 60 PSI)
Shield Gas
In
To Torch
V5
MV2
CO1
PS5
(NO set to close @ 60 PSI)
V6
Figure 5-6
Shield
Connection
To Torch
Cap Sensor
MAX100D System Plasma and Shield Gas Flow Schematic
MAX100D 380-415V CE Instruction Manual
5-25
MAINTENANCE
(PIN 1)
D6
Start Command
PL5
S1
(PIN 1)
D8 Arc
Transfer
PL6
D5
+12 VDC
S2
(PIN 1)
D4
Mach. Motion
D17
Current
(shunt)
PL7
S3
Figure 5-7
5-26
PCB4 Control Board
MAX100D 380-415V CE Instruction Manual
Section 6
PARTS LIST
In this section:
Introduction ...............................................................................................................................................................6-2
MAX100D Power Supply
Front Panel Outside, Front Panel Inside, Control Panel ..................................................................................6-5
Plasma Gas Console .......................................................................................................................................6-7
Right Center Wall .............................................................................................................................................6-9
Base Plate Components ..................................................................................................................................6-9
Left Center Wall..............................................................................................................................................6-11
Rear Panel Outside, Rear Panel Inside .........................................................................................................6-13
MAX100D Machine Torch Assembly .......................................................................................................................6-15
MAX100D International Machine Torch Assembly...................................................................................................6-15
PAC160 Hand Torch Assembly ...............................................................................................................................6-17
PAC160E Gouging Torch Assembly........................................................................................................................6-19
MAX100D Lead Assemblies ....................................................................................................................................6-20
MAX100D Consumable Parts Kits...........................................................................................................................6-21
Machine Torch Consumable Parts .................................................................................................................6-21
PAC160 Hand Torch Consumable Parts ........................................................................................................6-22
PAC160E Gouging Torch Consumable Parts.................................................................................................6-23
Dual Gas Mixer .......................................................................................................................................................6-25
Hose Package for Dual Gas Mixer .........................................................................................................................6-25
Recommended Spare Parts ...................................................................................................................................6-26
MAX100D 380-415V CE Instruction Manual
6-1
PARTS LIST
Introduction
In this section is a parts list breakdown with accompanying drawings for the MAX100D plasma torch system.
The format to list and call out Hypertherm parts is as follows:
Item
Part
Number
Description
1
12
14
129153
001611
005092
008328
Cont Pnl SA: MAX100D-CE/LVD
Pnl: MAX100D-CE/LVD Cont
PB Sw: Grn NO Full Gd
Knob: .930 Dia 1/4 SFT Blk/Nat
Item:
Part
Number:
Designator
Qty.
PB1
1
1
1
Refers to item call out on opposing page.
Number (Ex. 1) refers to numbered call out 1 on opposing page.
Refers to Hypertherm part numbers.
Bold part numbers (Ex. 129153) signify parent or subassemblies that contain
additional items.
Normal-style part numbers (Ex. 001611) signify items under parent or subassembly.
Description:
Describes the item.
Bold descriptions not indented (Ex. Cont Pnl SA: MAX100D) signify parent assemblies
that contain additional items.
Normal-style part numbers that are indented (Ex. Pnl: MAX100D CE/LVD Cont) signify
items under parent or subassembly.
Normal-style part numbers that are not indented (Ex. Knob: .930 Dia 1/4 SFT Blk/Nat)
represent subassemblies that are not under the parent assembly.
Designator:
Represents a cross reference to wiring diagrams or pneumatic diagrams.
(Ex. PB1 refers to pushbutton PB1 shown in wiring diagrams)
Qty.:
Refers to the number of items in the parent or subassembly.
6-2
MAX100D 380-415V CE Instruction Manual
PARTS LIST
11
12
6
6
4 5
4 7
13 14
3
2
10
1
6
4 8
9
20
17
18
19
15
16
Figure 6-1
6-4
MAX100D: Front Panel Outside, Front Panel Inside, and Control Panel
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D: Front Panel Outside, Front Panel Inside and Control Panel
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part
Number
Description
129153
001611
005105
005041
005088
005089
005168
005177
005197
006002
022008
005121
005122
009483
008328
027079
027080
041313
129118
005199
129075
008997
001574
Cont Pnl SA: MAX100D-CE/LVD
Pnl: MAX100D-CE/LVD Cont
Tgl Sw: 3PDT
Tgl Sw: DP Maint ON/ON
Lamp Hldr: Use T3-1/4 LTBULB
Lens: Wht For 005088
Lightbulb: 28VDC 40ma T3-1/4
Lens: Green for 005088
Lens: Amber for 005088
Meter Valve: 1/4 FPT .125 Orf
Gauge, Press 2 1/2" Dia. 1-100
PB Sw: Grn NO Full Gd
PB Sw: Red NC
Pot: 1K-Ohm 1W 10%
Knob: .930 Dia 1/4 SFT Blk/Nat
Fan 450-550 CFM 120VAC 50/60 Hz
Fan 225 CFM 120VAC 50/60 Hz
PC BD Assy Ctrl MAX100D
CH130-CE/LVD Chopper SA
Temperature Switch 82°C
Linkboard SA: 100/D-CE/LVD 380-415
Fuse: 2A 500V 10mmX38mm GI Slo
Panel:MAX100-CE/LVD Front
MAX100D 380-415V CE Instruction Manual
Designator
SW2
SW1
LT1, LT2, LT3
PB1
PB2
R6
M1
M2
PCB4
TS2
F1, F2
Qty.
1
1
1
1
3
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
6-5
PARTS LIST
13
13
1
14
2
Figure 6-2
6-6
12
11
9
10
3
4
5
6
8
7
MAX100D: Plasma Gas Console
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D: Plasma Gas Console
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
Number
129163
001612
029793
004566
006093
006093
006093
006093
005093
005093
005093
006002
004117
022008
005044
028559
Description
MAX100D Gas Cont SA
Gas Console Enclosure
Manf SA: MAX100D Gas Cont
Manf: MAX100D Plasma Gas
Sol Valve: 150# Manif Mnt 120V NC
Sol Valve: 150# Manif Mnt 120V NC
Sol Valve: 150# Manif Mnt 120V NC
Sol Valve: 150# Manif Mnt 120V NC
Press Sw: 0-90 psi 1/8 NPT
Press Sw: 0-90 psi 1/8 NPT
Press Sw: 0-90 psi 1/8 NPT
Meter Valve:1/4 FPT .125 Orifice
Cap: Ndl Valve
Pressure Gauge:100#/Bar 2.5" 1/8CBM
Tgl Sw: SPDT Maint ON/ON
Rcpt Assy: MAX100D Qdisc
MAX100D 380-415V CE Instruction Manual
Designator
V1
V2
V3
V4
PS1
PS3
PS4
MV1
PG1
10TGS
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
6-7
1-98
PARTS LIST
4
12
1
7
6
8
2
11
10
5
9
3
Figure 6-3
6-8
MAX100D: Right Center Wall
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D: Right Center Wall
Item
1
2
3
4
5
6
7
8
9
10
11
12
Part
Number
003021
007022
008317
014021
029190
009350
004061
004140
009280
009371
041120
029202
129164
001578
001575
Description
Designator
Relay: 120VAC SPST NO
Shunt: 100A 100 mv
Fuse: 125A 250V Semicond
Transformer, 5000VAC, 20ma
Hi Freq/IO Panel SA, MAX100
Spark Gap Assy: 40-20/2000/HD
Electrd:Spk Gap 1/8 x 1.6
Base:40/80/100/200/HD Spk Gap
Cap: .022uF 15kV
Coil Assy:80-100A HF
PC BD Assy I/O MAX100
Current Sensor SA, MAX100
Capacitor SA:MAX100/D-CE/LVD Filter
Cover: MAX100-CE/LVD Side
Cover: MAX100-CE/LVD Top
CR1
1MSH
F5
T3
PCB3
SG1
C6,C7
T4
CS1
Qty.
1
1
1
1
1
1
3
1
2
1
1
1
1
1
1
MAX100D: Base Plate Components
Item
1
2
Part
Number
014043
014065
Description
Designator
Inductor, 4mh, 100ADC, MAX100
Transformer 15kW 220-380-415/3/50
L1
T2
Qty.
1
1
2
1
Figure 6-4
MAX100D: Base Plate Components
MAX100D 380-415V CE Instruction Manual
6-9
PARTS LIST
See Figure 6-2 for detail of Plasma Gas Console
3
4
12
2
7
14
11
13
6
8
1
10
5
9A
9
Figure 6-5
6-10
MAX100D: Left Center Wall
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D: Left Center Wall
Item
1
2
3
4
5
6
7
8
9
9A
10
11
12
13
14
Part
Number
003021
004261
001601
001602
008079
009015
009296
009622
003153
003154
014028
041530
003173
003174
108000
001578
Description
Designator
Relay: 120VAC SPST NO
Lifting Eye: 80/100 Pwr Unit
Plate: MAX100-CE/LVD Lifting Eye
Gasket: MAX100-CE/LVD Lifting Eye
Term Bd: 12-Term
Res: 10K ohm 10W 5% VIT
Cap: 100uF 350WV +50-10%
Res: 10 ohm, 50W 5% W/L Brk
Contactor, MAX100 60A 3P, 24VAC
Cont: MAX100 NO Aux
Transformer, 40/100 220-380-415V
PC Bd Assy Power Dist. MAX100-CE/LVD
Relay: 24VAC 7A DPDT Mini
Relay: 115VAC 7A DPDT Mini
Fuse: 2A 250V 6.3mmX32mm
Cover: MAX100-CE/LVD Side
CR3
MAX100D 380-415V CE Instruction Manual
TB1
R4
C3
R3
CON2
T1
PCB2
CR1,CR2,CR3
CR4
F3,F4
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
1
6-11
PARTS LIST
1
4
2
3
6
5
8
9
10
9
15
16
17
18
7
20 19
12 13 14
11
21
Figure 6-6
6-12
MAX100D: Rear Panel Outside, Rear Panel Inside
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D: Rear Panel Outside, Rear Panel Inside
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
Number
Description
001182
001577
029772
004264
011025
011027
015532
024162
028559
008415
008944
008070
001549
001556
129024
009625
009625
029771
005093
006014
005093
006014
023209
Handle: MAX80/MAX100
Panel: MAX100-CE/LVD Rear
Air Regulator SA: MAX100D
Bracket: 80/100/200 Air Regulator
Filter Regulator: 0-120 psi 1/4NPT Air
Gauge,0-120 psig for 011025
Street Elbow, 1/4", 90°
Hose Assy #6 x 19 1/2" Air Reg
Rcpt Assy: MAX100D Qdisc
Strain Relief: 3/4 NPT x .310-.560
Strain Relief: 3/4 NPT .530 X .750
Strain Relief: 1/2 NPT x .312-.375
Enclosure:MAX100-CE Filter
Cover:MAX100-CE Filter Enclosure
Line Filter SA:MAX100-CE
Resistor: 2.0 ohm, 395W
Resistor: 2.0 ohm, 395W
Gas Sply SA: MAX100D
Press Sw: 0-90 PSI 1/8 NPT
Sol Valve: 90# 1/4 FPT 120V NC
Press Sw: 0-90 PSI 1/8 NPT
Sol Valve: 90# 1/4 FPT 120V NC
Cable, Ground #4 W/Clamp 25'
MAX100D 380-415V CE Instruction Manual
Designator
R2
R1
PS2
V6
PS5
V5
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6-13
PARTS LIST
8
9
10
11
7
2
3
Figure 6-7
6-14
6
4
5
1
Machine Torch Assembly
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D Machine Torch Assembly
Item
Part
Number
Description
1
2
3
4
5
6
7
8
9
10
11
9
10
11
9
10
11
059115
059116
059117
028596
120433
020334
020846
020705
020706
020713
058019
020243
028555
028910
002190
028556
028910
002190
028557
028910
002190
MAX100D Machine Torch Assy 25'
MAX100D Machine Torch Assy 50'
MAX100D Machine Torch Assy 75'
MAX100D Machine Torch Assy
Electrode: PAC130/160/MAX100/D Air
Shield: MAX80/100/C/D 100A
Shield Cap: PAC160/100D 100A, Cutting
Nozzle: PAC160/MAX100D 100A Cut
Swirl Ring: PAC160/MAX100D Cut
MAX100D Machine Torch Main Body
O-Ring: Viton .801 x .070
Torch Pos Sleeve MAX100
Leads: MAX100D Machine Torch 25'
Plug Assy:PAC160 Mach Qdisc
Boot: 80A/100A QDisc PL
Leads: MAX100D Machine Torch 50'
Plug Assy:PAC160 Mach Qdisc
Boot: 80A/100A QDisc PL
Leads: MAX100D Machine Torch 75'
Plug Assy:PAC160 Mach Qdisc
Boot: 80A/100A QDisc PL
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MAX100D International Machine Torch Assembly
Item
Part
Number
Description
1
2
3
4
5
6
7
8*
9
10
11
9
10
11
9
10
11
059163
059164
059165
028752
120433
020334
020846
020705
020706
020713
058019
020245
028555
028910
002190
028556
028910
002190
028557
028910
002190
MAX100D Intl. Machine Torch Assy 25'
MAX100D Intl. Machine Torch Assy 50'
MAX100D Intl. Machine Torch Assy 75'
MAX100D Intl. Machine Torch Assy
Electrode: PAC130/160/MAX100/D Air
Shield: MAX80/100/C/D 100A
Shield Cap: PAC160/100D 100A, Cutting
Nozzle: PAC160/MAX100D 100A Cut
Swirl Ring: PAC160/MAX100D Cut
MAX100D Machine Torch Main Body
O-Ring: Viton .801 x .070
Torch Mntg Sleeve MAX100 Intl.
Leads: MAX100D Machine Torch 25'
Plug Assy:PAC160 Mach Qdisc
Boot: 80A/100A QDisc PL
Leads: MAX100D Machine Torch 50'
Plug Assy:PAC160 Mach Qdisc
Boot: 80A/100A QDisc PL
Leads: MAX100D Machine Torch 75'
Plug Assy:PAC160 Mach Qdisc
Boot: 80A/100A QDisc PL
Designator
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* No rack with 020245 sleeve
MAX100D 380-415V CE Instruction Manual
6-15
PARTS LIST
10
9
2
1
9
3
11
12
5
6
Figure 6-8
6-16
7
8
4
PAC160 Hand Torch Assembly
MAX100D 380-415V CE Instruction Manual
PARTS LIST
PAC160 Hand Torch Assembly
Item
Part
Number
Description
1
2
3
4
5
6
7
8
9
10
9
10
9
10
11
12
059124
059125
059126
001214
001217
005094
120433
020335
020846
020705
020706
029730
028558
029731
028558
029732
028558
020761
075365
PAC160 Torch Assy 25'
PAC160 Torch Assy 50'
PAC160 Torch Assy 75'
Handle: PAC130/PAC140 Tch
Boot: PAC130 Tch
PB Switch: Tch
Electrode: PAC130/160/MAX100/D Air
Shield: MAX80/100/C/D 100A
Shield Cap: PAC160/100D 100A, Cutting
Nozzle: PAC160/MAX100D 100A Cut
Swirl Ring: PAC160/MAX100D Cut
Leads: PAC160/160E Torch 25'
PL Assy: PAC160/100D QDisc
Leads: PAC160/160E Torch 50'
PL Assy: PAC160/100D QDisc
Leads: PAC160/160E Torch 75'
PL Assy: PAC160/100D QDisc
PAC160 Tch Main Body
P/S, #6 x 3/4, PH, Rnd, S/B
MAX100D 380-415V CE Instruction Manual
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
6-17
PARTS LIST
10
9
2
1
9
3
12
11
5
6
Figure 6-9
6-18
7
8
4
PAC160 Hand Torch Assembly
MAX100D 380-415V CE Instruction Manual
PARTS LIST
PAC160E Gouging Torch Assembly
Item
1
2
3
4
5
6
7
8
9
10
9
10
9
10
11
12
Part
Number
Description
059112
059113
059114
001214
001217
005094
020703
020712
020699
020704
020750
029730
028558
029731
028558
029732
028558
020693
075365
020711
PAC160E Torch Assy 25'
PAC160E Torch Assy 50'
PAC160E Torch Assy 75'
Handle: PAC130/PAC140 Tch
Boot: PAC130 Tch
PB Switch: Tch
Electrode: PAC160E H35 Gouge
Shield: PAC160E Gouge
Shield Cap: PAC160/100D 100A, Gouging
Nozzle: PAC160E H35 Gouge
Swirl Ring: PAC160/MAX100D Cut
Leads: PAC160/160E Torch 25'
PL Assy: PAC160/100D QDisc
Leads: PAC160/160E Torch 50'
PL Assy: PAC160/100D QDisc
Leads: PAC160/160E Torch 75'
PL Assy: PAC160/100D QDisc
PAC160E Ext Tch Main Body
P/S, #6 x 3/4, PH, Rnd, S/B
Hand Heat Shield
MAX100D 380-415V CE Instruction Manual
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PARTS LIST
MAX100D Lead Assemblies
MAX100D Machine Torch Lead Assemblies
Part Number
028555
028556
028557
Description
Leads: MAX100D Machine Torch 25'
Leads: MAX100D Machine Torch 50'
Leads: MAX100D Machine Torch 75'
PAC160/160E Hand Torch Lead Assemblies
Part Number
029730
029731
029732
6-20
Description
Leads: PAC160/160E Torch 25'
Leads: PAC160/160E Torch 50'
Leads: PAC160/160E Torch 75'
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D Consumable Parts Kits
Machine Torch Consumable Parts (#028650)
Item
1
2
3
4
5
6
6
7
8
3
Part
Number
Description
120433
020193
020334
020846
020756
020705
120336
020706
058019
027055
027322
001067
Electrode, PAC130/160/MAX100/D Air
Electrode, PAC130/160/MAX100/D N2, H35
Shield: MAX80/100/C/D 100A
Shield Cap: PAC160/100D 100A, Cutting
Shield Cap: PAC160/MAX100D 60A
Nozzle: PAC160/MAX100D 100A Cut
Nozzle: MAX100D 60A Shield
Swirl Ring: PAC160/MAX100D Cut
O-Ring: Viton .801 x .070
Lubricant, Silicon, 1/4 Oz Tube
Wrench: 3/8 Hex Electrode
Box: Gray Plastic
4
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6
5
7
1
10
5
4
1
1
5
5
2
2
1
1
1
8
2
Figure 6-10
Machine Torch Consumable Parts
MAX100D 380-415V CE Instruction Manual
6-21
PARTS LIST
MAX100D Consumable Parts Kits (cont.)
PAC160 Hand Torch Consumable Parts (#028649)
Item
1
2
3
4
5
6
6
7
8
3
Part
Number
Description
120433
020193
020335
020846
020756
020705
120336
020706
058019
027055
027322
001067
Electrode, PAC130/160/MAX100/D Air
Electrode, PAC130/160/MAX100/D N2, H35
Shield: PAC130/160 100A
Shield Cap: PAC160/100D 100A, Cutting
Shield Cap: PAC160/MAX100D 60A
Nozzle: PAC160/MAX100D 100A Cut
Nozzle: MAX100D 60A Shield
Swirl Ring: PAC160/MAX100D Cut
O-Ring: Viton .801 x .070
Lubricant, Silicon, 1/4 Oz Tube
Wrench: 3/8 Hex Electrode
Box: Gray Plastic
4
6
5
7
1
10
5
2
1
1
5
5
2
2
1
1
1
8
2
Figure 6-11
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PAC160 Hand Torch Consumable Parts
MAX100D 380-415V CE Instruction Manual
PARTS LIST
MAX100D Consumable Parts Kits (cont.)
PAC160E Gouging Torch Consumable Parts (#028665)
Item
1
2
3
4
5
6
7
8
3
Part
Number
Description
020744
020703
020712
020699
020745
020704
020750
058019
027055
027322
001067
Electrode, PAC160E Air Gouge
Electrode, PAC160E H35 Gouge
Shield: PAC160E Gouge
Shield Cap: PAC160/100D 100A, Gouging
Nozzle: PAC160E Air Gouge
Nozzle: PAC160E H35 Gouge
Swirl Ring: PAC160E Gouge
O-Ring: Viton .801 x .070
Lubricant, Silicon, 1/4 Oz Tube
Wrench: 3/8 Hex Electrode
Box: Gray Plastic
4
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Figure 6-12
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1
10
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2
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5
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1
1
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8
2
PAC160E Gouging Torch Consumable Parts
MAX100D 380-415V CE Instruction Manual
6-23
PARTS LIST
2
HYPERTHERM
4
4
OUTLET
13
GAS1
GAS2
3
3
Dual Gas Mixer
19
11 6 7 8
1
7
8
9
6 12
14
17
13
5
12
6
15
16
6
7
8
10
7
8
7
8
18
5
12
3
11
11
Figure 6-13
6-24
7
8
3
Dual Gas Mixer
MAX100D 380-415V CE Instruction Manual
PARTS LIST
Dual Gas Mixer
Item
Part
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
059123
001408
001410
006062
011051
015001
015570
015608
015609
015610
015611
015612
015613
022020
046077
006074
015551
015230
015009
001409
MAX100D Dual Gas Mixer
Encl: Dual Gas Mixer
Panel: Dual Gas Mixer Front
Motor Valve: 1/8 FPT .062 Orf
Flowmeter: 27SCFH NO Valve
Adapter, Bulkhead, 1/4 NPTF
Reducer Bushing 1/4 x 1/8
Sleeve, Delrin 1/4"
Insert, Brass (1/4 OD)
Connector Female 1/4
Connector Male 1/4 Tube x 1/8
Elbow, Male 1/4 Tube x 1/8 NPT
Male Running Tee
Gauge: Pressure, 160 PSI/BAR
Tubing, 1/4 OD x .040 Blu Nyl
Check Valve, 1/4 NPT
Coupling:1/4 Brass
Adapter:1/4NPT X LH'B' Brass
Adapter:1/4NPT X RH'B' Male Brass
Panel:Dual Gas Mixer Rear
Designation
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6 ft
2
2
2
1
1
Hose Package for Dual Gas Mixer
Part
Number
Description
028721
015230
015009
024205
024373
024374
024384
Hose Package: MAX100D Dual Gas Mixer
Adapter: 1/4NPT x LH 'B'
Adapter: 1/4NPT x RH 'B'
Hose Assy: 3/8 Blue RH 25 ft
Hose Assy: 3/8 Blue RH 1.5 ft
Hose Assy: 3/8 Red LH 2 ft
Hose Assy: 3/8 Red LH 25 ft
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6-25
PARTS LIST
Recommended Spare Parts
Part
Number
Description
Designator
022008
011025
011031
005168
005121
005122
005093
006093
006014
003021
003066
003054
008997
005102
014021
027079
027080
041313
129118
041530
020761
020693
020713
Gauge, 0-100 psig
Filter Regulator: 0-120 psi 1/4NPT Air
Replacement filter
LTBULB:28VDC 40ma T3-1/4
PB Sw: Grn NO Full Gd
PB Sw: Red NC
Press Sw: 0-90 psi 1/8 NPT
Sol Valve:150#
Sol Valve:90#
Relay: 120VAC SPST NO
Contactor, MAX100 60A
Sw:MAX40/100/HT40C Aux Contactor
Fuse: 2A 500V 10mmX38mm Slo
Thermostat, 75°C
Transformer, 5000VAC, 20ma
Fan 450-550 CFM 120VAC 50/60 Hz
Fan 225 CFM 120VAC 50/60 Hz
PC BD Assy Ctrl MAX100D
CH130 Chopper Module
PC Bd Assy Power Dist. MAX100
PAC160 Torch Main Body
PAC160E Torch Main Body
MAX100D Machine Torch Main Body
PG1,2
6-4,6-6
6-12
LT1,LT2,LT3
PB1
PB2
PS1,2,3,4,5
V1,2,3,4
V5,6
CR1,CR2
CON2
6-4
6-4
6-4
6-6,6-12
6-6
6-12
6-8,6-10
6-10
6-10
6-4
6-26
F1,F2
TS1
T3
M1
M2
PCB4
PCB2
Page Number
Showing Item
6-8
6-4
6-4
6-4
6-4
6-10
6-16
6-18
6-14
MAX100D 380-415V CE Instruction Manual
Section 7
WIRING DIAGRAMS
In this section:
MAX100D Wiring Diagram ........................................................................................................................................7-2
MAX100D 380-415V CE Instruction Manual
7-1
Appendix A
AIR FILTERS
Air Filters
Gas purity is critical for maximizing consumable parts life, as well as for producing the highest quality cutting which
Hypertherm plasma equipment can achieve. Plasma air must be clean, dry and oil-free, and air must be delivered
at the pressure and flow rate specified for each plasma system. If the air supply contains moisture, oil or dirt
particles, cut quality will be lowered and consumable parts life will be shortened, which increase production costs.
To optimize both consumables life and cut quality, Hypertherm recommends a three-stage filtering process for
compressor air for removing contaminants from the air supply.
1. The first stage of filtering should remove at least 99% of all particles and liquids 5 microns and larger in size.
2. The second stage should be a coalescing-type filter to remove oil. This filter should remove 99.99% of particles
0.025 micron and larger in size.
3. The third and final stage of filtration should be an activated carbon adsorbent filter that removes 99.999% of oil
or hydrocarbons that have not been trapped by the previous stages.
MAX100D 380-415V CE Instruction Manual
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Appendix B
IEC SYMBOLS USED
IEC Symbols Used
Direct Current (DC).
Alternating current (AC).
Plasma cutting torch.
AC input power connection.
The terminal for the external protective (earthed) conductor.
A chopper-based power source.
Anode (+) work clamp.
Temperature switch.
Pressure switch.
Plasma torch in the TEST position (cooling and cutting gas exiting nozzle).
The power is on.
The power is off.
Volt/amp curve.
MAX100D 380-415V CE Instruction Manual
b-1
Appendix C
AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM
Aeration Manifold for Plasma Cutting Aluminum
Introduction
When plasma arc cutting aluminum at the water table surface or below water, free hydrogen gas may be generated
by the cutting process. The high temperature of the plasma process causes disassociation of oxygen and hydrogen
from the water in the water table. The hot aluminum, which has a high affinity for oxygen, then combines with the
oxygen leaving free hydrogen.
An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the floor of the water
table to replenish the oxygen content of the water.
Making an Aeration Manifold – Figure c-1
Make an Aeration Manifold with two-inch (50 mm) PVC tubing with one-inch (25 mm) Distribution Lines
connected to it. Drill 1/8 inch (3 mm) holes every six inches (150 mm) in the distribution lines. Cap the ends of the
distribution lines and install the lines so that oxygen is delivered to all parts of the cutting area.
Connect the manifold to a shop air line. Set a pressure regulator to obtain a steady stream of bubbles.
Aeration Manifold
Distribution Lines
Regulated air in
Figure c-1 Aeration Manifold
MAX100D 380-415V CE Instruction Manual
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