Hypertherm MAX200 Machine Torch Plasma Arc Cutting System User Manual Page 1

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Summary of Contents

Page 1 - Cutting System

Machine Torch Plasma Arc Cutting SystemInstruction Manual 800980 – Revision 16MAX200®EN50199EN60974-1

Page 2

TABLE OF CONTENTSMAX200 Instruction Manual iii15Electromagnetic Compatibility (EMC)...

Page 3

MAX200 Instruction Manual 4-3515OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 4 - 800980 Rev 11 to 12

4-36 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 5

MAX200 Instruction Manual 4-3715OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 6 - Instruction Manual

4-38 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 7

MAX200 Instruction Manual 4-3915OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 8 - Hypertherm Plasma Systems i

4-40 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 9 - WARRANTY

MAX200 Instruction Manual 4-4115OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 10 - MAX200 Instruction Manual iii

4-42 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 11

MAX200 Instruction Manual 4-4315OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 12 - MAX200 Instruction Manual v

4-44 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 13 - Section 1

TABLE OF CONTENTSiv MAX200 Instruction Manual15Adjusting the Filter/Pressure Regulator ...

Page 14

MAX200 Instruction Manual 4-4515OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 15 - Hypertherm Plasma Systems 1-3

4-46 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 16

MAX200 Instruction Manual 5-115Section 5MAINTENANCEIn this section:Routine Maintenance...

Page 17

5-2 MAX200 Instruction Manual15MAINTENANCEWARNINGSHOCK HAZARD: The large electrolytic capacitor(s) (blue-cased cylinder(s)) store large amounts ofener

Page 18 - WARNING LABEL

MAX200 Instruction Manual 5-315MAINTENANCEProblem: The green POWER ON pushbutton switch PB1 is pressed, but the fans are not operatingand the green PO

Page 19 - SÉCURITÉ

5-4 MAX200 Instruction Manual15MAINTENANCEProblem: The green POWER ON pushbutton switch PB1 is pressed, the green POWER ONindicator illuminates, but t

Page 20

MAX200 Instruction Manual 5-515MAINTENANCEProblem: The green POWER ON indicator is illuminated, the torch switch is pressed and the DC ONindicator ill

Page 21

5-6 MAX200 Instruction Manual15MAINTENANCERemoval and Replacement of TorchTo remove and replace the torch main body from the torch lead, perform the f

Page 22 - MISE À LA MASSE ET À LA TERRE

MAX200 Instruction Manual 5-715MAINTENANCERemoval and Replacement of Torch LeadTo remove and replace the torch lead, perform the following procedures.

Page 23

5-8 MAX200 Instruction Manual15MAINTENANCEReplacement1. Replace the repaired or replacement lead(s) with the other leads.2. Ensure the lead lengths (1

Page 24 - Étiquette de sécurité

TABLE OF CONTENTSMAX200 Instruction Manual v15Cut Charts...

Page 25 - SPECIFICATIONS

MAX200 Instruction Manual 6-115Section 6PARTS LISTIn this section:MAX200 Power Supply...

Page 26 - Product Specifications

6-2 MAX200 Instruction Manual15PARTS LISTFigure 6-1 Power Supply – Control Panel SA, Front2006 SEC30MACHINE DELAYAMPS1 23456710119812131415

Page 27 - CE Power Supplies

MAX200 Instruction Manual 6-315PARTS LISTPartItemNumber Description Designator Qty.029319 Panel, Control SA1 041536 PCB, interlock display SA 1009063

Page 28 - MAX200 Machine Torch

6-4 MAX200 Instruction Manual15PARTS LISTFigure 6-2 Power Supply – Front View12345678

Page 29 - Section 3

MAX200 Instruction Manual 6-515PARTS LISTPartItemNumber Description Designator Qty.029315 P/O Shield Gas Supply SA1 006032 Valve, solenoid, shield gas

Page 30 - Upon Receipt

6-6 MAX200 Instruction Manual15PARTS LISTFigure 6-3 Power Supply – Right Side, Front View121111023976854

Page 31 - Pre-Installation

MAX200 Instruction Manual 6-715PARTS LISTPartItemNumber Description Designator Qty.*, ** P/O Power Supply Assy1 029359 Linkboard SA (240/480V models o

Page 32 - Air Supply

6-8 MAX200 Instruction Manual15PARTS LISTFigure 6-4 Power Supply – Right Side, Rear View1 239456871112171413151619182010

Page 33 - Gas Supply

MAX200 Instruction Manual 6-915PARTS LISTPartItemNumber Description Designator Qty.*,** P/O Power Supply Assy1 029359 Linkboard SA (240/480V models on

Page 34 - Torch Coolant Requirements

6-10 MAX200 Instruction Manual15PARTS LISTFigure 6-5 Power Supply – Left Side, Front View12345678

Page 35 - Routing the Torch Lead

Hypertherm Plasma Systems 1-1Section 1SAFETYIn this section:Recognize Safety Information...

Page 36 - Power Requirements

MAX200 Instruction Manual 6-1115PARTS LISTPartItemNumber Description Designator Qty.1 129118 Chopper SA, CH130 CE/LVD CH2 1005199 Switch, temperature

Page 37 - MAX200 Instruction Manual 3-9

6-12 MAX200 Instruction Manual15PARTS LISTFigure 6-6 Power Supply – Left Side, Rear View12456781112109131415 1618173

Page 38

MAX200 Instruction Manual 6-1315PARTS LISTPartItemNumber Description Designator Qty.*,** P/O Power Supply Assy1 008317 Fuse, semiconductor, 125 Amp, 2

Page 39

6-14 MAX200 Instruction Manual15PARTS LISTFigure 6-7 Power Supply – Rear View32451131214151611109867

Page 40 - AC POWER CABLE

MAX200 Instruction Manual 6-1515PARTS LISTPartItemNumber Description Designator Qty.129252 Pump Motor Subassembly 11 128385 Kit, Replacement Motor, 1/

Page 41 - Connect the Air and Gas Hoses

6-16 MAX200 Instruction Manual15PARTS LISTRecommended Spare PartsPower SupplyPartNumber Description Designator005044 Switch, toggle SPDT S1005121 Push

Page 42

MAX200 Instruction Manual 6-1715PARTS LISTRecommended Spare Parts (cont.)Machine Torch and Torch LeadsPartNumber Description Designator120584 Torch Ma

Page 43 - Shield Gas

6-18 MAX200 Instruction Manual15PARTS LISTPart NumbersPlasma Gas/ Nozzle Type RetainingShield Gas (Amps) Shield Cap Nozzle Swirl Ring ElectrodeAir/Air

Page 44 - Grounding

MAX200 Instruction Manual 6-1915PARTS LIST120837220021020415120547020604020617020605020616020566020618020607020613020608020611020612020424020448020514

Page 45

6-20 MAX200 Instruction Manual15PARTS LISTConsumable Parts KitsConsumable Parts Kit (028392)Part # Description Quantity001067 Enclosure, Consumable Pa

Page 46

SAFETY1-2 Hypertherm Plasma Systems11-98SAFETYRECOGNIZE SAFETY INFORMATIONThe symbols shown in this section are used toidentify potential hazards. Whe

Page 47

MAX200 Instruction Manual 6-2115PARTS LISTFigure 6-9 MAX200 Machine Torch Assembly (Standard)MAX200 Machine Torch Assembly with 1.75" diameter To

Page 48 - Cable (Fig. 3-10)

6-22 MAX200 Instruction Manual15PARTS LISTFigure 6-9.1 MAX200 Machine Torch Assembly (Optional)MAX200 Machine Torch Assembly with 2" Stainless St

Page 49 - Part No. Length

MAX200 Instruction Manual 6-2315PARTS LISTFigure 6-9.2 MAX200 Machine Torch Assembly (Optional)MAX200 Machine Torch Assembly with 1.75" diameter

Page 50

6-24 MAX200 Instruction Manual15PARTS LISTMachine Torch Lead AssembliesSee Figure 6-10PartItem Number Description Qty.028454 Shield Torch Lead, 10 Ft.

Page 51

MAX200 Instruction Manual 6-2515PARTS LISTMachine Torch Lead Assemblies (continued)See Figure 6-10PartItem Number Description Qty.028383 Shield Torch

Page 52

6-26 MAX200 Instruction Manual15PARTS LISTMachine Torch Lead Assemblies (continued)See Figure 6-10PartItem Number Description Qty.028459 Shield Torch

Page 53

MAX200 Instruction Manual 6-2715PARTS LISTMachine Torch Lead Assemblies (continued)See Figure 6-10PartItem Number Description Qty.028773 Shield Torch

Page 54

6-28 MAX200 Instruction Manual15PARTS LISTMachine Torch Lead Assemblies (continued)Note: Hypertherm does not recommend using torch leads longer than 7

Page 55

MAX200 Instruction Manual 7-115Section 7WIRING DIAGRAMSIntroductionThis section contains the wiring diagrams for the MAX200 system. When tracing a sig

Page 56

WIRING DIAGRAMS7-2 MAX200 Instruction Manual15BatteryCap, polarizedCap, non-polarizedCap, feed-thruCircuit breakerCoax shieldCurrent SensorCurrent sen

Page 57

Touching live electrical parts can cause a fatal shockor severe burn.• Operating the plasma system completes anelectrical circuit between the torch an

Page 58

WIRING DIAGRAMSMAX200 Instruction Manual 7-315Switch, Level,Normally ClosedTime Delay Closed,NO/OffTransformerElectrodeTorch SymbolsNozzleShieldTorchT

Page 59

A1ABCD4 3 2 1DCB234ITEM NO.DRAWN BYAPP. BYCHECKED BYUNLESS OTHERWISE SPECIFIED: TOLERANCES ARE: DIMENSIONS ARE IN INCHES. PART MUST BE FREE OF BURRS A

Page 60 - Part No

NOTE: SEE SHEETS 7 & 8PEL1BoxCustomerSuppliedDisconnectL2TB1L3PEL1L3L2YELYELREDORNORNRED202119181617L1L1F2F1T14T21480 VAC500 VACC4T22C2B2C2B240-48

Page 61

F1H192M1106PL2121BLKV7PL19106REC5WHT1071071232311REDRED/BLKREDRED/BLKPB143PB2124PL234REC23787 8RED/BLKRED/BLKREDM2CH1T212 15 1626252019HX1RED/BLKRED/B

Page 62

V9S171 RED/BLK70 RED69 RED/BLK68 REDRED 68PS4181 RED/BLK69 RED/BLKV1TESTV3RUN182 REDON LightDC PowerInterlockedSTARTPlasmaControl PCBContactor24 V

Page 63

154 BLK153 WHT6514117Torch Height ControlPCB10REC1Divide4CommonHeight7Complete56IHS120 VACCH1+CH2 CurrentR3 ShuntREC5START9PL18128111413DOWNAutoRela

Page 64 - Adjust the Torch Position

ORORPower Supply #4Machine HOLDWHT80toHOLDMachineTB3TrandformerHIGH VOLTAGEADVVANCED DELAYMachine Motion8678797978606061618786878485848580YEL/BLKYEL/B

Page 65

WIRED FOR 415 VAC220-380-415/50BRNWHTVIOBLUEBLKT1400 VAC380 VAC240 VACF2PEUL1VL2TB1WL3F11413L1LT3220 VAC4C41L25B42CON163A43 Phase415 VAC50 HertzL1E-St

Page 66 - OPERATION

073036 & 073039480-500/50WIRED FOR 500 VACT1073002 & 073020240-480/60WIRED FOR 480 VACCON1L1PEGRY15BLKWHT1314L2UL1VL2LT345WL3TB1Fuse63 Phase48

Page 67 - Front Panel Controls

PLASMAGASSHIELDGASGASPLASMATORCHCAPNOZZLECAPGASSHIELDV1V3V5V9PS160psiV5V2PS34psiPS426psiPG1V4PG2CO1CO3CO2PS270psiGAS FLOW DIAGRAMPLASMA STEP GAS SOLEN

Page 68 - MAX200 Instruction Manual 4-3

SAFETY1-4 Hypertherm Plasma Systems5/6/02SAFETYInstant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.A PLASMA ARC CAN CA

Page 69 - Operation

Box-5010 Hanover, NH 03755-5010 603/643-3441ITEM NO.FROM HYPERTHERM, INC.FOR MANUFACTURING OR FABRICATIONCONTAINED THEREON IS CONSIDEREDPROPRIETARY AN

Page 70 - Operating Tips

MAX200 Instruction Manual a-114Appendix AFILTERSIn this section:Hankison® Centriflex® Filters...

Page 79

SAFETYHypertherm Plasma Systems 1-511-98SAFETY• Never lubricate cylinder valves or regulators with oilor grease.• Use only correct gas cylinders, regu

Page 80

In this appendix:Propylene Glycol Safety DataSection 1 Chemical Product and Company Identification ... b

Page 85

b-6Figure b-1 Freezing Point of Propylene Glycol Solution% of Propylene GlycolTemperature, °F-70-60-50-40-30-20-100102030400 102030405060

Page 90

SAFETY1-6 Hypertherm Plasma Systems8-99SAFETYWARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and m

Page 91

MAX200 Instruction Manual c-114Appendix CAERATION MANIFOLDIn this section:Aeration Manifold for Plasma Cutting Aluminum...

Page 92

c-2 MAX200 Instruction Manual14APPENDIX C – AERATION MANIFOLDFigure c-1 Aeration ManifoldRegulated air inDistribution LinesAeration ManifoldAeration M

Page 93

MAX200 Instruction Manual d-114Appendix DELECTROMAGNETIC COMPABILITY (EMC)In this section:EMC Introduction ...

Page 94

d-2 MAX200 Instruction Manual14APPENDIX D – ELECTROMAGNETIC COMPABILITY (EMC)EMC INTRODUCTIONThis plasma cutting equipment has beenbuilt in compliance

Page 95

MAX200 Instruction Manual d-314APPENDIX D – ELECTROMAGNETIC COMPABILITY (EMC)GeneralThis appendix will enable a qualified electrician to install the p

Page 96 - 3.4-3.5 3.4-3.6 3.4 6.2 6.2

010297 REVACAUTIONFill Coolant Reservoirwith Hypertherm Coolant!Hypertherm Nr. 028393Liquide De RefroidisseurRemplir Le Reservoir AvecATTENTION!010177

Page 97 - 3.4-3.5 3.4-3.6 3.4 8.3 8.3

MAX200 Instruction Manual d-514APPENDIX D – ELECTROMAGNETIC COMPABILITY (EMC)Line Disconnect SwitchConnecting the power cable to the line disconnect s

Page 98

010297 REVACAUTIONFill Coolant Reservoirwith Hypertherm Coolant!Hypertherm Nr. 028393Liquide De RefroidisseurRemplir Le Reservoir AvecATTENTION!010177

Page 99

Hypertherm Systèmes plasma 1a-12/12/01Section 1aSÉCURITÉDans cette section :Identifier les consignes de sécurité...

Page 100 - 3/8 inch (10 mm)

1Changed Page Description800980 Rev 14 to 155/10/023.21 Added part numbers for cable lengths 25 ft-200 ft3.27Call-outs for ends of cable changed. Powe

Page 101

SÉCURITÉ1a-2 Hypertherm Systèmes plasma2/12/01IDENTIFIER LES CONSIGNES DE SÉCURITÉLes symboles indiqués dans cette section sont utilisés pouridentifie

Page 102

SÉCURITÉHypertherm Systèmes plasma 1a-32/12/01Toucher une pièce électrique sous tension peut provoquerun choc électrique fatal ou des brûlures graves.

Page 103

SÉCURITÉ1a-4 Hypertherm Systèmes plasma5/6/02Torches à allumage instantanéL’arc plasma s’allume immédiatement après que la torchesoit mise en marche.L

Page 104

SÉCURITÉHypertherm Systèmes plasma 1a-52/12/01• Ne jamais lubrifier les robinets des bouteilles ou lesrégulateurs avec de l’huile ou de la graisse.• U

Page 105

SÉCURITÉ1a-6 Hypertherm Systèmes plasma2/12/01Étiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilis

Page 106

MAX200 Instruction Manual 2-114Section 2SPECIFICATIONSIn this section:General ...

Page 107

2-2 MAX200 Instruction Manual14SPECIFICATIONSGeneralMAX200s are normally shipped from the factory (configured for mild steel cutting) with air supplie

Page 108

MAX200 Instruction Manual 2-314SPECIFICATIONSDimensions:Width ...28-1/4" (71 cm)

Page 109

2-4 MAX200 Instruction Manual14SPECIFICATIONSMAX200 Machine TorchThe MAX200 machine torch conforms to the following specifications:Maximum cutting thi

Page 110

MAX200 Instruction Manual 3-115Section 3SETUPIn this section:Upon Receipt ...

Page 111 - Water Tube

2Changed Page Description800980 Rev 12 to 137/99CoverNew RevisionTitle PageNew RevisioniAdded plumbing/electrical code statement to warranty page1.1-1

Page 112 - MAINTENANCE

3-2 MAX200 Instruction Manual14SETUPUpon ReceiptThe MAX200 power supply is shipped mounted to a skid and protected by a heavy carton cover. Before unp

Page 113 - Troubleshooting

MAX200 Instruction Manual 3-314SETUPClaims and Technical QuestionsClaims for damage during shipment – If your unit was damaged during shipment, you mu

Page 114 - MAX200 Instruction Manual 5-3

3-4 MAX200 Instruction Manual14SETUPAir and Gas Supply RequirementsIf making hard plumbing connections, avoid using iron pipe. Never use PTFE tape o

Page 115 - 5-4 MAX200 Instruction Manual

MAX200 Instruction Manual 3-514SETUPAdjusting the Filter/Pressure RegulatorTo adjust the filter/pressure regulator for the required air pressure (90 p

Page 116 - MAX200 Instruction Manual 5-5

3-6 MAX200 Instruction Manual14SETUPTorch Coolant RequirementsThe power supply is shipped without any coolant in the tank. A standard mixture of propy

Page 117 - Replacement

MAX200 Instruction Manual 3-714SETUPCaution: Do not route the torch lead with the torch connected. Damage to the torch couldresult from dropping, bang

Page 118 - MAX200 Instruction Manual 5-7

3-8 MAX200 Instruction Manual14SETUPPower RequirementsA separate line disconnect switch should be provided for each MAX200 power supply. The disconnec

Page 119 - 5-8 MAX200 Instruction Manual

MAX200 Instruction Manual 3-914SETUP240/480V Linkboard Configurations• The 240/480-volt unit (# 073002 and # 073020) is shipped from the factory linke

Page 120 - PARTS LIST

3-10 MAX200 Instruction Manual14SETUP220/380/400/415V Transformer T1 and T2 Configurations• The 220/380/400/415-volt, 3Ø, 50 Hz power supply is normal

Page 121 - 6-2 MAX200 Instruction Manual

MAX200 Instruction Manual 3-1114SETUP400T1T2415 T2T1Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations (2 of 2)

Page 122 - MAX200 Instruction Manual 6-3

3Page Changed Description800980 Rev 11 to 12CoverNew RevisionTitle PageNew Revision2.2Revised duty cycle rating2.3Added 073036 & 073039 power supp

Page 123 - 6-4 MAX200 Instruction Manual

3-12 MAX200 Instruction Manual14SETUPPower, Gas, and Torch Lead ConnectionsConnect the Power CableTo connect the power cable to the 400V CE power supp

Page 124 - MAX200 Instruction Manual 6-5

MAX200 Instruction Manual 3-1314SETUPConnect the Air and Gas HosesWhen connecting pipeline shop air or compressed gas cylinders, use inert gas hoses f

Page 125 - 6-6 MAX200 Instruction Manual

3-14 MAX200 Instruction Manual14SETUP Figure 3-5 Plasma Gas and Shield Air ConnectionsPlasma GasSupply HoseShieldAir HoseFilter/PressureRegulatorAir S

Page 126 - MAX200 Instruction Manual 6-7

MAX200 Instruction Manual 3-1514SETUPFigure 3-6 Plasma Gas and Shield Gas ConnectionsPlasma GasSupply HoseShield GasSupply HosePlasma (Gas) and Shield

Page 127 - 6-8 MAX200 Instruction Manual

3-16 MAX200 Instruction Manual14SETUPConnect the Torch LeadTo connect the machine torch lead to the MAX200, proceed as follows (see Figure 3-7 ):1. Co

Page 128 - MAX200 Instruction Manual 6-9

MAX200 Instruction Manual 3-1714SETUPFigure 3-7 Machine Torch Lead Connections to MAX200

Page 129

3-18 MAX200 Instruction Manual14SETUPFigure 3-8 Proper Work Clamp Connection

Page 130

MAX200 Instruction Manual 3-1914SETUPMachine Torch System InstallationsThe MAX200 machine torch system can be installed in any of the following system

Page 131

3-20 MAX200 Instruction Manual14SETUPFigure 3-9 Machine Torch System Interconnection Diagram without THC OptionRemote SwitchAssemblyMachine InterfaceC

Page 132

MAX200 Instruction Manual 3-2115SETUPRefer to Machine Interface CableSignal List on next page.Figure 3-10 MAX200 to Machine Interface Cable Diagram (1

Page 133

4Changed Page Description800980 Rev 8 to 9Cover Uprevved manual due to LVD complianceTitle Page Uprevved manual due to LVD compliance0.01 Changed refe

Page 134

3-22 MAX200 Instruction Manual14SETUPMachine Interface Cable Signal List* Signals are AC relays. DC relays are available as an option from Hypertherm

Page 135 - Recommended Spare Parts

MAX200 Instruction Manual 3-2314SETUPInstall the MAX200 with THC OptionThe THC option consists of:• The THC Subassembly (located in the MAX200)• The R

Page 136 - Machine Torch and Torch Leads

3-24 MAX200 Instruction Manual14SETUPSR Interface Cable(Fig. 3-12)PR/DR InterfaceCable (Fig. 3-13)PR to ComputerInterface Cable(used with PRonly) (Fig

Page 137

MAX200 Instruction Manual 3-2514SETUPFUNCTION COLOR 1X4 5X1PLASMA START-SIG BLU 1 2PLASMA START-COM BLK 5 4SHIELD N/A 10 —INITIAL HEIGHT-SIG YEL 2 1IN

Page 138 - Consumable Configurations

MAX200 Instruction Manual 3-2715SETUPPower Supply – 1X2 DR/PR Remote – 5X2LEGEND – POWER SUPPLY END LEGEND – DR/PR REMOTE ENDPIN COLOR FUNCTION PIN CO

Page 139 - Consumable Parts Kits

MAX200 Instruction Manual 3-2914SETUPLEGEND – DR/PR REMOTE ENDSOCKET COLOR FUNCTION1 Blk Current Program I202 Blu " " I403 Grn " "

Page 140 - Sleeve (Standard)

MAX200 Instruction Manual 3-3114SETUPInstall the MAX200 with IHS OptionThe IHS option can only be used when the THC option has been installed as descr

Page 141 - Sleeve (Optional)

3-32 MAX200 Instruction Manual14SETUP2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now ar

Page 142

MAX200 Instruction Manual 3-3314SETUPUpper Limit Switchand Cable (customersupplied)Inductive ProbeAssy (Fig. 3-17)Air HoseAssyTorch Mounting SATorch L

Page 143 - Machine Torch Lead Assemblies

MAX200 Instruction Manual 3-3514SETUPLEGEND – POWER SUPPLY END – 1X3 LEGEND – IHS ENDPIN COLOR FUNCTION SOCKET COLOR FUNCTION1 Red IHS Complete Sig. 1

Page 144

MAX200Machine TorchInstruction ManualRevision 16 – November, 2013for Serial Numbers beginning with 200-003654© Copyright 2013 Hypertherm, Inc. All Rig

Page 145

3-36 MAX200 Instruction Manual14SETUPLEGEND – IHS END LEGEND – INDUCTIVE SENSOR ENDPIN COLOR FUNCTION SOCKET COLOR FUNCTION1 Clear Signal A Red Power

Page 146

MAX200 Instruction Manual 3-3714SETUPConnect to the Inductor Sensor Assembly1. At the Torch Mounting Subassembly, connect the two (2) 40-foot IHS/Sens

Page 147

3-38 MAX200 Instruction Manual14SETUP6. Connect the common wire (black) to 1TB-11 (#4).7. Connect the signal wire (clear) to 1TB-12 (#67).Note: If the

Page 148 - Wiring Diagram Symbols

MAX200 Instruction Manual 3-3914SETUPRedX FT, 047125, Belden #9320–20 AWG,1 Pair Overall Shielded, CSA CertifiedQty 6, 074027 Terminal–Insulated Locki

Page 149 - 7-2 MAX200 Instruction Manual

3-40 MAX200 Instruction Manual14SETUPWARNINGDisconnect all power to the MAX200 before adjusting the torch. Failure to do so could result ineye or bodi

Page 150 - Torch Symbols

MAX200 Instruction Manual 3-4114SETUPInstall the Water Muffler OptionThe Water Muffler option can be used with the 1.75 inch (44.5 mm) diameter torch

Page 151 - BC 5-9-96

MAX200 Instruction Manual 4-114Section 4OPERATIONIn this section:Front Panel Controls...

Page 152 - N/A MAX200 2 OF 9

4-2 MAX200 Instruction Manual14OPERATIONFront Panel ControlsPower• ON (1) pusbutton/indicator switchActivates the power supply and its control circuit

Page 153 - PCB ASSY: 041534

MAX200 Instruction Manual 4-315OPERATIONGas• TEST/RUN switchSets dynamic (flowing) gas flow.• PLASMA pressure gauge/plasma gas needle valveAdjusts and

Page 154 - N/A MAX200 4 OF 9

4-4 MAX200 Instruction Manual14OPERATIONPre-operation1. Ensure that your cutting environment and your clothing meet the safety requirements outlined i

Page 155 - N/A MAX200 5 OF 9

Hypertherm, Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)800-643-9878 Tel (Tech

Page 156 - N/A MAX200 6 OF 9

MAX200 Instruction Manual 4-514OPERATION1. Refer to the cutting charts (page 4-10) to find the required operating parameters for the metal you plan to

Page 157 - ELEC/GAS SCHEM: MAX200

4-6 MAX200 Instruction Manual15OPERATION4. Using the 7/8" side of the wrench (supplied in the spare parts kit), remove the shield. Inspect the ga

Page 158 - 380-415/50 CE

MAX200 Instruction Manual 4-714OPERATIONCutting TechniquesTorch AlignmentPrior to cutting with a machine torch, ensure that the torch is at right angl

Page 159 - 013179 013-2-179 013179B9

4-8 MAX200 Instruction Manual14OPERATIONCutting• Start cutting from the edge of the workpiece, unless you must pierce. For tips on piercing, refer to

Page 160 - ITEM NO

MAX200 Instruction Manual 4-914OPERATIONCommon Cutting Faults• The workpiece is not totally penetrated. Causes can be:– The current is too low.– The c

Page 161 - Appendix A

4-10 MAX200 Instruction Manual15OPERATIONCut ChartsThe following Cut Charts provide the necessary information in order for the operator using the MAX2

Page 162

Shield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay TimeTest (psi)Run (psi)(psi) (Inc

Page 163

4-12 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 164

MAX200 Instruction Manual 4-1315OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 165

4-14 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 166

ELECTROMAGNETIC COMPATIBILITY (EMC)EMC INTRODUCTIONHypertherm's CE-marked equipment is builtin compliance with standard EN50199. Theequipment sho

Page 167

MAX200 Instruction Manual 4-1514OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 168

4-16 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 169

MAX200 Instruction Manual 4-1714OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 170 - BENZOTRIAZOLE SAFETY DATA

4-18 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 171

MAX200 Instruction Manual 4-1915OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 172

4-20 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 173

MAX200 Instruction Manual 4-2114OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 174

4-22 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 175

MAX200 Instruction Manual 4-2314OPERATIONSet plasma gas inlet pressure to 120 psi (8.3 bar)Set shield gas inlet pressure to 90 psi (6.2 bar)Note: Maxi

Page 176

4-24 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 177

WARRANTYii Hypertherm Plasma Systems9-01WARNINGGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system. Any d

Page 178

MAX200 Instruction Manual 4-2514OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 179

4-26 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 180 - AERATION MANIFOLD

MAX200 Instruction Manual 4-2714OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 181

4-28 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 182 - Appendix D

MAX200 Instruction Manual 4-2914OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 183

4-30 MAX200 Instruction Manual14OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

Page 184 - Connect power cable

MAX200 Instruction Manual 4-3115OPERATION49-51 50-52 50 90 903.4-3.5 3.4-3.6 3.4 6.2 6.2Shield Gas Pressure

Page 185 - 010297 REVA

4-32 MAX200 Instruction Manual15OPERATION49-51 50-52 50 120 1203.4-3.5 3.4-3.6 3.4 8.3 8.3Shield Gas Inlet Pressure (psi)

Page 186 - Line Disconnect Switch

MAX200 Instruction Manual 4-3315OPERATION49-51 50-52 50 120 1203.4-3.5 3.4-3.6 3.4 8.3 8.3Shield Gas Inlet Pressure (psi)

Page 187 - EMI Filter Parts List

4-34 MAX200 Instruction Manual15OPERATIONShield Gas PressureMaterial ThicknessArc Voltage SettingApprox. Motion Delay

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