Hypertherm MAX200 Service Manual User Manual

Plasma Arc Cutting SystemService Manual801620 – Revision 15MAX200®EN50199EN50192EN60974-1

TABLE OF CONTENTSMAX200 Service Manual vii14Replacement ...

MAX200 Service Manual 4-51-97PARTS LISTFront Wall Outside – MAX200 Power SupplyPartItem Number Description Designator Qty.001233 Panel, MAX200 Front

4-6 MAX200 Service Manual3-96PARTS LISTFigure 4-2 Power Supply – Control Panel SA, FrontDBEACNote: Refer to page 4-58 for the list of internalh

MAX200 Service Manual 4-715PARTS LISTControl Panel SA – MAX200 Power SupplyPartItem Number Description Designator Qty.029319 Contr Pnl SA, MAX200 Thu

4-8 MAX200 Service ManualPARTS LISTFigure 4-3 Power Supply – Base Plate with ComponentsSee Figure 4-4 for detail167910885243

MAX200 Service Manual 4-91-97PARTS LISTBase Plate – MAX200 Power SupplyPartItem Number Description Designator Qty.1 001229 Base, MAX200 12 014078 Tra

4-10 MAX200 Service Manual3-96PARTS LISTFigure 4-4 Power Supply – Plasma Gas SAABCDEFGNote: Refer to page 4-58 for the list of internal hose to

MAX200 Service Manual 4-112-00PARTS LISTPlasma Gas SA – MAX200 Power SupplyPartItem Number Description Designator Qty.029314 Plasma Gas SA, MAX200 11

4-12 MAX200 Service ManualPARTS LISTFigure 4-5 Power Supply – Center Wall Left Side101132117177128A8B161365A5B15144129

MAX200 Service Manual 4-1315PARTS LISTCenter Wall Left Side – MAX200 Power SupplyPartItem Number Description Designator Qty.1 001230 Panel, MAX200 Ce

4-14 MAX200 Service Manual3-96PARTS LISTBAFigure 4-6 Power Supply – Center Wall Right SideNote: Refer to page 4-58 for the list of internal hos

TABLE OF CONTENTSviii MAX200 Service Manual15Machine Torch Consumable Parts Kits ...

MAX200 Service Manual 4-1515PARTS LISTCenter Wall Right Side – MAX200 Power SupplyPartItem Number Description Designator Qty.1 001230 Panel, MAX200 C

4-16 MAX200 Service ManualPARTS LISTFigure 4-7 Power Supply – Front Wall, InsideSee page 4-19for detail of CH1See page 4-21for detail of CH212

MAX200 Service Manual 4-1715PARTS LISTFront Wall Inside – MAX200 Power SupplyPartItem Number Description Designator Qty.1 *128789 Kit: chopper, 15KW

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MAX200 Service Manual 4-1915PARTS LISTChopper SA Front Wall Inside Left – MAX200 Power SupplyPartItem Number Description Designator Qty.128789 Kit: c

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MAX200 Service Manual 4-2115PARTS LISTChopper SA Front Wall Inside Right – MAX200 Power SupplyPartItem Number Description Designator Qty.128789 Kit:

4-22 MAX200 Service Manual3-96PARTS LISTFigure 4-10 Power Supply -- Rear Wall, InsideFor detail of Spark Gap SA,see page 4-24For detail of High Fr

MAX200 Service Manual 4-2315PARTS LISTRear Wall Inside – MAX200 Power SupplyPartItem Number Description Designator Qty.029314 Plasma Gas Valve SA1 00

4-24 MAX200 Service Manual15PARTS LISTFigure 4-11 Power Supply – Spark Gap Assembly99514910101013131313121233241111111111367815

Hypertherm Plasma Systems 1-18-06Section 1SAFETYIn this section:Recognize safety information ...

MAX200 Service Manual 4-2515PARTS LISTSpark Gap Assembly – MAX200 Power SupplyPartItem Number Description Designator Qty.009350 Spark Gap Assembly SG

4-26 MAX200 Service Manual3-96PARTS LISTFigure 4-12 Power Supply – High Frequency & I/O PCB AssemblyBCANote: Refer to page 4-58 for the lis

MAX200 Service Manual 4-27PARTS LISTHigh Frequency and I/O PCB – MAX200 Power SupplyPartItem Number Description Designator Qty.029312 HF & I/O PC

4-28 MAX200 Service Manual9-99PARTS LIST32113121415161110984567Figure 4-13 Power Supply – Rear Wall, Outside

MAX200 Service Manual 4-2915PARTS LISTRear Wall Outside – MAX200 Power SupplyPartItem Number Description Designator Qty.129252 Pump Motor Subassembly

4-30 MAX200 Service Manual15PARTS LISTRecommended Spare PartsPower SupplyPartNumber Description Designator005041 Switch, tog 2pl Maint ON/ON S1005121

MAX200 Service Manual 4-3115PARTS LISTRecommended Spare Parts (cont.)MAX200 Rev 1 90° Hand Torch and Torch LeadsPartNumber Description020484 Torch Ma

4-32 MAX200 Service Manual14PARTS LIST020615020485020688020448020446020607020613020608020611020689020605020616020604020617220021020415120547020423Fig

MAX200 Service Manual 4-3314PARTS LISTPart NumbersPlasma Gas/ Nozzle Type RetainingShield Gas (Amps) Shield Cap Nozzle Swirl Ring ElectrodeAir/Air 20

4-34 MAX200 Service ManualPARTS LIST123412569111078027130Screw (9)Figure 4-15 MAX200 Rev 1 Hand Torch Assembly

1-2 Hypertherm Plasma Systems11-98SAFETYRECOGNIZE SAFETY INFORMATIONThe symbols shown in this section are used to identifypotential hazards. When you

MAX200 Service Manual 4-3515PARTS LISTMAX200 Rev 1 Hand Torch AssemblyThe following is a listing of the MAX200 Rev 1 90° Hand Torch with 25 foot and

4-36 MAX200 Service Manual15PARTS LISTMAX200 Rev 1 Hand Torch Lead Assembly PartsItem Part Number Description Qty029309 Hand Torch Lead, 25 Ft. 11 02

MAX200 Service Manual 4-371-99PARTS LISTMAX200 Rev 1 Hand Torch Lead ExtensionsPart No. Description Length028496 Lead Extensions, Hand Torch 100 ft02

4-38 MAX200 Service Manual14PARTS LIST020615020485020688020424020448020566020618020607020613020608020611020689020605020616020604020617220021020415120

MAX200 Service Manual 4-3914PARTS LISTPart NumbersPlasma Gas/ Nozzle Type RetainingShield Gas (Amps) Shield Cap Nozzle Swirl Ring ElectrodeAir/Air 20

4-40 MAX200 Service Manual14PARTS LISTMAX200 Machine Torch Consumable Parts KitsPart # Description Quantity028392 Kit, Consum Parts, MAX200 Mach 1001

MAX200 Service Manual 4-41PARTS LIST14Figure 4-18 MAX200 Machine Torch AssemblyMAX200 Machine Torch Assembly with 1.75" diameter Torch Body a

4-42 MAX200 Service ManualPARTS LIST14Figure 4-18a MAX200 Machine Torch Assembly (Optional)MAX200 Machine Torch Assembly with 2" Stainless St

MAX200 Service Manual 4-43PARTS LIST14Figure 4-18b MAX200 Machine Torch Assembly (Optional)MAX200 Machine Torch Assembly with 1.75" diameter

4-44 MAX200 Service ManualPARTS LIST15Machine Torch Lead AssembliesSee Figure 4-19PartItem Number Description Qty.028454 Shield Torch Lead, 10 Ft. 11

Hypertherm Plasma Systems 1-38-06SAFETYTouching live electrical parts can cause a fatal shockor severe burn.• Operating the plasma system completes an

MAX200 Service Manual 4-45PARTS LIST15Machine Torch Lead Assemblies (cont.)See Figure 4-19PartItem Number Description Qty.028383 Shield Torch Lead, 2

4-46 MAX200 Service ManualPARTS LIST15Machine Torch Lead Assemblies (cont.)See Figure 4-19PartItem Number Description Qty.028459 Shield Torch Lead, 4

MAX200 Service Manual 4-47PARTS LIST15Machine Torch Lead Assemblies (cont.)See Figure 4-19PartItem Number Description Qty.028773 Shield Torch Lead, 6

4-48 MAX200 Service ManualPARTS LIST15Machine Torch Lead Assemblies (cont.)Note: Hypertherm does not recommend using torch leads longer than 75 Fe

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4-50 MAX200 Service ManualPARTS LISTFigure 4-20 Switch Remote (SR) V/C Control Station12310166525242223292730137891121212019417122628151814

MAX200 Service Manual 4-51PARTS LIST15Switch Remote (SR) V/C ControlPart Figure 5-1Item Number Description Designator Qty.073001 Control Station, SW

4-52 MAX200 Service ManualPARTS LISTFigure 4-21 Digital Remote (DR) V/C Control17132212171819201185 6314 15162191024

MAX200 Service Manual 4-53PARTS LIST15Digital Remote (DR) V/C ControlPart Figure 5-2Item Number Description Designator Qty.073007 Control Station, Di

4-54 MAX200 Service ManualPARTS LIST1987202111161724 514 136312 1315181019Figure 4-22 Programmable (PR)V/C Control

1-4 Hypertherm Plasma Systems8-06SAFETYThe plasma arc by itself is the heat source used forcutting. Accordingly, although the plasma arc has notbeen i

MAX200 Service Manual 4-55PARTS LISTProgrammable Remote (PR) V/C ControlPart Figure 5-3Item Number Description Designator Qty.055004 Control, Program

4-56 MAX200 Service ManualPARTS LISTFigure 4-23 Inductive IHS Control Module1111213141215171018111612895 6412273

MAX200 Service Manual 4-57PARTS LIST15Inductive IHS Control ModulePartItem Number Description Designator Qty.053016 Control Module, IND IHS, HT4001 0

4-58 MAX200 Service ManualPARTS LIST3-96MAX200 Power Supply Internal HosingTo identify hosing, find lettered item where one of the ends of the hosing

MAX200 Service Manual 4-59PARTS LISTPart No. Length023334 25 ft (7.6m)023335 50 ft (15m)023336 75 ft (23m)023337 100 ft (30m)023338 150 ft (46m)02333

4-60 MAX200 Service ManualPARTS LISTLug Color Description and Comments81 Red Plasma Emergency Stop (24VAC) – 1X1 pins 28, 33;80 Yel cable lugs 80, 81

MAX200 Service Manual 4-61PARTS LISTPart No. Length023319 25 ft (7.6m)023328 50 ft (15m)023329 75 ft (23m) 023330 100 ft (30.5m)023331 150 ft (46m)02

4-62 MAX200 Service ManualPARTS LIST15Part No. Length023346 25 ft (7.6 m)023347 50 ft (15 m)023348 75 ft (23 m)023349 100 ft (30.5 m)023742 125 ft (3

MAX200 Service Manual 4-63PARTS LIST15Figure 4-27 Computer Cable – Programmable Remote (PR) V/C to Computer InterfaceProgrammable Remote EndSCKT C

4-64 MAX200 Service ManualPARTS LIST1-99PartItem Number Description Qty.028720 Inductive IHS,2" - used with standard & stainless steel torch

Hypertherm Plasma Systems 1-55-02SAFETYInstant-on torchesPlasma arc comes on immediately when the torchswitch is activated.A PLASMA ARC CAN CAUSE INJU

MAX200 Service Manual 4-65PARTS LIST15PartItem Number Description Qty.1 004085 Nut, Ins, Ind Sensor 22 005078 Cap, Sensor, UW-IHS 23 005085 Sensor, I

4-66 MAX200 Service ManualPARTS LIST3124See Figure 4-31 for detailSee Figure 4-32 for detailFigure 4-30 Lead sets for IHS System

MAX200 Service Manual 4-67PARTS LISTInterconnecting Leads for Inductive IHS System028244 028245 028282 028246 028247 028356Item (25 ft) (50 ft) (75

4-68 MAX200 Service ManualPARTS LISTFigure 4-32 HS Interface Cable – Power Supply to IHSIndicates PairsIndicates Pairs w/DrainNote: On IHS End,

MAX200 Service Manual 4-69PARTS LIST15IHS Fittings KitPartNumber Description Qty.028243 Kit, Fittings, IHS, HT400008144 Plug, 3 Pin F Ind Sensr UW-IH

4-70 MAX200 Service ManualPARTS LIST86878687RedRedBlackBlackShieldShieldX Ft, 047125, Belden #9320-20 AWG, 1 Pair Overall Shielded, CSA CertifiedQty

MAX200 Service Manual 4-71PARTS LISTPAC200T/E Hand Torch SystemsPAC200T (90°) Hand Torch Cutting SystemsPAC200T (90°) HAND TORCH CUTTING SYSTEMSPAC20

4-72 MAX200 Service ManualPARTS LIST14Plasma Gas/ Retaining SwirlMetal Amps Shield Gas Shield Cap Nozzle Ring ElectrodeMild 200 Air / Air 020918 0209

MAX200 Service Manual 4-73PARTS LIST14020611 (100A Air, H35)020616 (100A O2)020689 (40A Air) RetainingCap020915Figure 4-34 PAC200T (Cutting) Trigg

4-74 MAX200 Service ManualPARTS LIST14PAC200T Cutting Torch Consumable Parts Kit 028750PartNumber Description Qty.028750 Parts Kit: PAC200T001067 Box

1-6 Hypertherm Plasma Systems11-98SAFETY• Never lubricate cylinder valves or regulators with oilor grease.• Use only correct gas cylinders, regulators

MAX200 Service Manual 4-75PARTS LISTThis page left blank intentionally

4-76 MAX200 Service ManualPARTS LIST14PAC200T (90°) Cutting Torch AssemblyPartItem Number Description Qty.073190 PAC200T (90°) Cutting Torch Assembly

MAX200 Service Manual 4-77PARTS LIST1-99Figure 4-36 PAC200T (Cutting) Torch Assembly†† See page 4-81 for detail of torch leads.†283457162

4-78 MAX200 Service ManualPARTS LIST14PAC200T (65°) Cutting Torch AssemblyPartItem Number Description Qty.073187 PAC200T (65°) Cutting Torch Assembly

MAX200 Service Manual 4-79PARTS LISTPAC200E Gouging Torch AssemblyPartItem Number Description Qty.073188 PAC200E Gouging Torch Assembly* 11 002244 Sa

4-80 MAX200 Service ManualPARTS LIST1-99† See page 4-81 for detail of torch leads.†† Heat Shield 020881 not included in PAC200E Torch Assembly. Order

MAX200 Service Manual 4-81PARTS LISTTrigger Torch 25 – Foot Lead Assembly (Torch to Power Supply)*PartItem Number Description Qty.029865 Leads SA:PAC

4-82 MAX200 Service ManualPARTS LIST15Extended LeadsPartNumber Description Qty. Length028715 PAC200T/E Torch Leads Ext 50' 1 50 ft*029866 Leads

MAX200 Service Manual 4-83PARTS LISTTrigger Torch 25 – Foot Lead Assembly (Torch to Extension Box)PartItem Number Description Qty.029866 Leads SA:PAC

MAX200 Service Manual a-11-99Appendix ATORCH COOLANT MATERIAL SAFETYDATA SHEETSIn this section:Torch Coolant Requirements...

Hypertherm Plasma Systems 1-78-99SAFETYWARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and mainten

a-2 MAX200 Service Manual1-97APPENDIX ATorch Coolant RequirementsThe power supply is shipped without any coolant in the tank. A standard mixture of p

MAX200 Service Manual a-315MATERIAL SAFETY DATA SHEETSECTION 1 – CHEMICAL PRODUCT AND COMPANY IDENTIFICATIONSECTION 2 – COMPOSITION / INFORMATION ON

a-4 MAX200 Service Manual15SECTION 4 – FIRST AID MEASURESMSDSPage 2 of 4ProductHypertherm Torch CoolantCODEIngestionNever give anything by mouth to a

MAX200 Service Manual a-515SECTION 8 – EXPOSURE CONTROLS / PERSONAL PROTECTIONSECTION 9 – PHYSICAL AND CHEMICAL PROPERTIESSECTION 10 – STABILITY AND

a-6 MAX200 Service Manual15Ye s NoXCODE2 – HDPESECTION 12 – ECOLOGICAL INFORMATIONSECTION 13 – DISPOSAL CONSIDERATIONSSECTION 14 – TRANSPORT INFORMAT

MAX200 Service Manual b-115Appendix BELECTROMAGNETIC COMPABILITY (EMC)In this section:General...

b-2 MAX200 Service ManualAPPENDIX B – ELECTROMAGNETIC COMPABILITY (EMC)GeneralThis appendix will enable a qualified electrician to install the power

MAX200 Service Manual b-31-97APPENDIX B – ELECTROMAGNETIC COMPABILITY (EMC)2. Unscrew the four filter cover screws and remove cover to access input

b-4 MAX200 Service Manual15APPENDIX B – ELECTROMAGNETIC COMPABILITY (EMC)Line Disconnect SwitchConnecting the power cable to the line disconnect swit

MAX200 Service Manual b-515APPENDIX B – ELECTROMAGNETIC COMPABILITY (EMC)EMI Filter Parts ListPartItem Number Description Qty.001557 Cover: 200/2000-

1-8 Hypertherm Plasma Systems8-99SAFETYWARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and mainten

b-6 MAX200 Service ManualAPPENDIX B – ELECTROMAGNETIC COMPABILITY (EMC)

MAX200 Service Manual c-19-99Appendix CDIAGRAMSIn this section:Switch Remote (SR) Wiring Diagram...

c-2 MAX200 Service ManualAPPENDIX CRemote Switch (SR) Wiring Diagram

MAX200 Service Manual c-3APPENDIX CDigital Remote (DR) Signal/AC Diagram0411870293021PC

c-4 MAX200 Service Manual9-99APPENDIX CProgrammable Remote (PR) Signal/AC DiagramDrwg 13-2-056

MAX200 Service Manual c-59-99APPENDIX CInitial Height Sensing (IHS) Wiring DiagramUP15 RECP16 RECP14 RECP112233598441234041043009041BROWNGREENBLUEFLOW

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

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

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

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

MAX200Plasma Arc Cutting SystemService Manual(P/N 801620)Revision 15 – April, 2008for Serial Numbersbeginning with200-003200© 2008 Hypertherm, Inc.All

8-06Hyper therm Systèmes plasma 1a-1Section 1aSÉCURITÉDans cette section :Identifier les consignes de sécurité...

154 BLK153 WHT6514117Torch Height ControlPCB10REC1Divide4CommonHeight7Complete56IHS120 VACCH1+CH2 CurrentR3 ShuntREC5START9PL18128111413DOWNAutoRela

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

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

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

PLASMAGASSHIELDGASGASPLASMATORCHCAPNOZZLECAPGASSHIELDV1V3V5V9PS160psiV5V2PS34psiPS426psiPG1V4PG2CO1CO3CO2PS270psiGAS FLOW DIAGRAMPLASMA STEP GAS SOLEN

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

ChangedPageDescription of change for revision 15 (date of change - 4/2008)Revisionchange pagesAdded changes for revisions 14 and 15. Pages moved to th

11-981a-2 Hypertherm Systèmes plasmaSÉCURITÉIDENTIFIER LES CONSIGNES DE SÉCURITÉLes symboles indiqués dans cette section sont utilisés pouridentifier

8-06Toucher une pièce électrique sous tension peut provoquerun choc électrique fatal ou des brûlures graves.• La mise en fonctionnement du système pla

8-061a-4 Hypertherm Systèmes plasmaSÉCURITÉL’arc plasma est lui-même la source de chaleurutilisée pour le coupage. Par conséquent, bien quel’arc plasm

5-02Torches à allumage instantanéL’arc plasma s’allume immédiatement après que la torchesoit mise en marche.L’ARC PLASMA PEUT PROVOQUER DES BLESSURES

11-981a-6 Hypertherm Systèmes plasmaSÉCURITÉ• Ne jamais lubrifier les robinets des bouteilles ou lesrégulateurs avec de l’huile ou de la graisse.• Uti

8-99Étiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilisateur et le technicien de maintenance comp

8-991a-8 Hypertherm Systèmes plasmaSÉCURITÉÉtiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilisate

8-06Hypertherm Sistemas plasma 1b-1Seccíon 1bSEGURIDADEn esta sección:Reconocimiento de información de seguridad...

11-98SEGURIDAD1b-2 Hypertherm Sistemas plasmaRECONOCIMIENTO DEINFORMACIÓN DE SEGURIDADLos símbolos que se muestran en esta sección se utilizanpara ide

1/19/07Hypertherm, Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)[email protected]

8-06El contacto directo con piezas eléctricas conectadas puedeprovocar un electrochoque fatal o quemaduras graves.• Al hacer funcionar el sistema de p

8-06SEGURIDAD1b-4 Hypertherm Sistemas plasmaEl arco plasma es por si solo la fuente de calor quese usa para cortar. Según esto, aunque el arco deplasm

5-02Antorchas de encendido instantáneoEl arco de plasma se enciende inmediatamente después deactivarse el interruptor de la antorcha.EL ARCO DE PLASMA

11-98SEGURIDAD1b-6 Hypertherm Sistemas plasma•Nunca lubrique reguladores o válvulas de cilindros conaceite o grasa.•Utilice solamente cilindros, regul

8-99Etiqueta de advertenciaEsta etiqueta de advertencia se encuentra adherida a la fuente de energía.Es importante que el operador y el técnico de man

8-99SEGURIDAD1b-8 Hypertherm Sistemas plasmaEtiqueta de advertenciaEsta etiqueta de advertencia se encuentra adherida a la fuente de energía.Es import

MAX200 Service Manual 2-12-96Section 2SPECIFICATIONSIn this section:General...

2-2 MAX200 Service Manual1-99SPECIFICATIONSGeneralMAX200s are normally shipped from the factory configured for mild steel cutting with air supplied to

MAX200 Service Manual 2-31-99SPECIFICATIONS# 073005*...220/380/415 VAC, 3Ø, 50 Hz, 98/57/52

2-4 MAX200 Service Manual1-99SPECIFICATIONSGas Requirements:Gas Type/Quality...Air (compressed)/clean,

ELECTROMAGNETIC COMPATIBILITY (EMC)Hypertherm i6-07EMC IntroductionHypertherm’s CE-marked equipment is built in compliancewith standard EN60974-10. Th

MAX200 Service Manual 2-51-99SPECIFICATIONSPAC200T (90° & 65°) Cutting/PAC200E (65°) Gouging/MAX200 Rev 1 (90°) Hand TorchesMaximum cutting thickn

2-6 MAX200 Service Manual1-99SPECIFICATIONSDigital Remote (DR) V/C Control – OptionalControls...

MAX200 Service Manual 3-11-99Section 3MAINTENANCEIn this section:Introduction...

3-2 MAX200 Service Manual1-99MAINTENANCEWARNINGSHOCK HAZARD: The large electrolytic capacitor(s) (blue-cased cylinder(s)) store large amounts ofenergy

MAX200 Service Manual 3-37-99MAINTENANCERoutine MaintenanceThe MAX200 system is designed to require very little regular maintenance under normal use.

3-4 MAX200 Service ManualMAINTENANCETheory of Operation: “Chopper” Power SupplyIntroductionThe MAX200 plasma unit uses a “chopper” control circuit to

MAX200 Service Manual 3-5MAINTENANCEFilter Inductor and Chopper Module Diode CircuitDuring the off interval of the chopper module output cycle, the ma

3-6 MAX200 Service ManualMAINTENANCETheory of Operation: High FrequencyIntroductionThe MAX200 power supply uses a high frequency transformer to initia

MAX200 Service Manual 3-7MAINTENANCESequence of EventsOn the following pages is a detailed flow chart outlining the sequence of events during proper M

3-8 MAX200 Service Manual1-97MAINTENANCEPush ON button(PB1)110V relay (CR2)on PCB6 closes.Power light on, fan on.D5 (-12VDC) onPCB9 illuminate.24VAC r

ELECTROMAGNETIC COMPATIBILITY (EMC)ii Hypertherm8-06Earthing of workpieceWhere the workpiece is not bonded to earth for electricalsafety, nor connecte

MAX200 Service Manual 3-9MAINTENANCETopage 3-10Frompage 3-8Switch to TESTSet machine delayAdjust flow rates, set currentSwitch toRUNTHC installed?YesP

3-10 MAX200 Service ManualMAINTENANCEFrompage 3-9Push STARTbuttonIHS probes extend,D2 on PCB9 active.Torch indexes to workand IHS probes retract.Plasm

MAX200 Service Manual 3-11MAINTENANCEFrompage 3-10Main Contactor (CON1) closes,pilot arc relay (CR1) closes,power to high voltage transformer (T5),hig

3-12 MAX200 Service ManualMAINTENANCEFrompage 3-11NoNoTHCinstalled?THCinstalled?YesYesYesSTOP pressed (machine torch),START button released (hand torc

MAX200 Service Manual 3-138-98MAINTENANCEInitial ChecksBefore trouble-shooting specific problems, it is good practice to do a visual check, and verify

3-14 MAX200 Service Manual8-9MAINTENANCEFigure 3-1 MAX200 Initial ChecksPrimary, 3-Phase, ACPower CableL3L2L1PC Board PCB6LinkboardFuse F1/F2Contactor

MAX200 Service Manual 3-158-99MAINTENANCE6. Measure voltage at power distribution board PCB6 (Figure 3-1, item 1). Look on the board for fuses F1 thro

3-16 MAX200 Service Manual1-97MAINTENANCETroubleshootingThe troubleshooting section is presented by following normal operational sequence.Before troub

MAX200 Service Manual 3-171-97MAINTENANCE3. The green POWER ONpushbutton switch PB1 ispressed, the fans are operating,but the green POWER ONindicator

3-18 MAX200 Service Manual1-97MAINTENANCE• Check temperature switches (normally closed).• Check pins, connectors and associated wiring totemperature s

WARRANTYHypertherm iii6-07AttentionGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system. Anydamage caused

MAX200 Service Manual 3-191-97MAINTENANCE• Verify that the torch cap is on tight, and that no hissingfrom gas leakage is heard.• Check for damage to O

3-20 MAX200 Service Manual1-97MAINTENANCE3e.2. Pressure switch PS1 not functioning.This switch is normally open, and closes when plasma gaspressure is

MAX200 Service Manual 3-211-97MAINTENANCE• Using the 013-2-179 wiring diagram, check pins,connections and associated wiring from PL21 to REC5 ofPCB6.

3-22 MAX200 Service Manual1-97MAINTENANCE5. All status indicatorsextinguished, switch to TEST,plasma gas flow present, butno shield gas flow.5.1. V6 i

MAX200 Service Manual 3-231-97MAINTENANCEProblem Possible Causes and Solutions• Disconnect PL26 from REC26 and check for 120VAC atPL26 after START com

3-24 MAX200 Service Manual1-97MAINTENANCEProblem Possible Causes and Solutions8.3. Main contactor (CON1) or PCB7 is defective.• With an AC voltmeter,

MAX200 Service Manual 3-251-97MAINTENANCEProblem Possible Causes and Solutions• On Machine-Torch system: Cutting machine switch(normally open) to term

3-26 MAX200 Service Manual1-97MAINTENANCEProblem Possible Causes and Solutions10.4. Torch is getting insufficient current.Check the arc current settin

MAX200 Service Manual 3-271-97MAINTENANCEProblem Possible Causes and Solutions11.3. IHS system not getting start command from Control BoardPCB7, or CR

3-28 MAX200 Service Manual1-97MAINTENANCE12. IHS in use – no auto retractafter cut (machine-torchsystems with IHS option).12.1. No upper limit switch,

WARRANTYiv Hypertherm6-07obligation to indemnify shall be conditioned uponHypertherm’s sole control of, and the indemnified party’scooperation and ass

MAX200 Service Manual 3-291-97MAINTENANCE14. No torch DOWN (machine-torch systems with THCoption)14.1. Torch lifter motor defective.Replace torch lift

3-30 MAX200 Service Manual6-94MAINTENANCEWARNINGSHOCK HAZARD: Always use caution when servicing a power supply when the covers are removed.Dangerous v

MAX200 Service Manual 3-31MAINTENANCEWARNINGSHOCK HAZARD: Use extreme care when working near the chopper modules. The large electrolyticcapacitor(s) (

3-32 MAX200 Service Manual3-00MAINTENANCE8. If chopper still does not output 280V after completing step 7, there may be a problem with the control sig

MAX200 Service Manual 3-336-94MAINTENANCEVoltage Divider Test Procedure (Machine-Torch Systems)The voltage between the electrode and the workpiece dur

3-34 MAX200 Service ManualMAINTENANCEMAX200 Rev 1 90° Hand Torch Removal and ReplacementTo remove and replace the hand torch main body from the torch

MAX200 Service Manual 3-35MAINTENANCE020536 LEAD INSULATOR029309TORCH LEAD, 25 FT (7.6 M)029310TORCH LEAD, 50 FT (15.2 M)001258HANDLE005094TORCH SWITC

3-36 MAX200 Service ManualMAINTENANCEMAX200 Rev 1 90° Hand Torch Lead Set and Individual Leads Removal andReplacementTorch Lead SetTo remove and repla

MAX200 Service Manual 3-37MAINTENANCETB2A.C.T. COILADAPTERTorch CoolantReturn Hose(Blue w/Red Band)Plasma Gas Hose(Red)Torch StartSwitch LeadsPilot Sh

3-38 MAX200 Service ManualMAINTENANCE5. Holding one end of the the torch lead, pull the sheath (9) off of the torch lead.6. Cut the tape (every 18 inc

TABLE OF CONTENTSMAX200 Service Manual v14Electromagnetic Compatibility (EMC)...

MAX200 Service Manual 3-39MAINTENANCEMAX200 Rev 1 90° Hand Torch Lead Set AssembliesItem Part NumberDescription Qty029309 Hand Torch Lead, 25 Ft. 11 0

3-40 MAX200 Service Manual1-99MAINTENANCEMAX200 Machine Torch Removal and ReplacementTo remove and replace the torch main body from the torch lead, pe

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3-42 MAX200 Service Manual1-99MAINTENANCEMAX200 Machine Torch Lead Set and Individual Leads Removal andReplacement Torch Lead SetTo remove and replace

MAX200 Service Manual 3-431-99MAINTENANCEFigure 3-7 MAX200 Machine Torch Lead Connections to Power Supply

3-44 MAX200 Service Manual1-99MAINTENANCEIndividual Torch Leads To remove and replace individual torch leads, perform the following procedure and see

MAX200 Service Manual 3-451-99MAINTENANCEItemDescription Qty1 Lead Pilot, Shield Gas (blue) 12 Lead, Plasma Gas (red) 13 Lead, Cap Sensor (gray) 1 4 C

3-46 MAX200 Service ManualMAINTENANCEPAC200T/E Torches Removal and ReplacementRemoval1. Remove the six (6) Screws securing the two Handle halves and s

MAX200 Service Manual 3-47MAINTENANCEHandleTorchMain BodySwitchHandleScrewsLeadsBootLeadInsulatorSafetyTriggerTriggerSpringFigure 3-9 PAC200T Torch As

3-48 MAX200 Service ManualMAINTENANCEPAC200T/E Torch Lead Assembly Removal and ReplacementNote: To change lengthof torch lead assemblies, see Increase

TABLE OF CONTENTSvi MAX200 Service Manual14Seguridad de toma a tierra...

MAX200 Service Manual 3-49MAINTENANCEPlasma STARTswitch leadshigh-frequencycoiladapter 2CAP SENSEgreyadapter 1Plasma GasredCoolant Supplyblue w/green

3-50 MAX200 Service ManualMAINTENANCEIncrease or Decrease PAC200T/E Torch Lead LengthIn order to increase or decrease the torch lead length between 50

MAX200 Service Manual 3-51MAINTENANCEFigure 5-2 Extended Torch Lead InterconnectionsBox: Torch Leads Ext.#001313Center Section Leads#029593 (50')

3-52 MAX200 Service ManualMAINTENANCEFigure 3-12 Extension Connectors015036UN: Right Hand‘A’ Male Brass015049UN: Left Hand‘A’ Male Brass015208Adapter:

MAX200 Service Manual 3-53MAINTENANCEAdjusting Plasma GasIf you have increased torch lead length from 50 feet or under to 75 feet or over, the plasma

3-54 MAX200 Service Manual8-98MAINTENANCED5 (+12VDC)D2 (IHS) D3 (Up)D4 (Down)CR1CR2CR3D5 (-12VDC) 111111111REC2REC3REC4REC5Figure 3-14 PCB9 THC Mother

MAX200 Service Manual 4-12-00Section 4PARTS LISTIn this section:Introduction...

4-2 MAX200 Service ManualPARTS LISTIntroductionIn this section is a parts list breakdown with accompanying drawings for the MAX200 machine and hand-t

MAX200 Service Manual 4-3PARTS LISTDesignator: Represents a cross reference to wiring diagrams or pneumatic diagrams. (Ex. PB1 refers to pushbutton P

4-4 MAX200 Service Manual3-96PARTS LISTSee Figure 4-2 for detail of control panelABFigure 4-1 Power Supply – Front Wall, OutsideNote: Refer to