Hypertherm Powermax600 Operator Manual User Manual

Plasma ArcCutting SystemOperator Manual803390 Revision 3powermax600®

SAFETY8-98Hypertherm Plasma Systems 1-3Touching live electrical parts can cause a fatal shockor severe burn.• Operating the plasma system completes an

SAFETY5/6/021-4 Hypertherm Plasma SystemsInstant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.A PLASMA ARC CAN CAUSE IN

SAFETY11-98Hypertherm Plasma Systems 1-5• Never lubricate cylinder valves or regulators withoil or grease.• Use only correct gas cylinders, regulators

SAFETY8-011-6 Hypertherm Plasma SystemsWARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and mainten

2/12/01Hypertherm Systèmes plasma 1a-1Section 1aSÉCURITÉDans cette section :Identifier les consignes de sécurité ...

SÉCURITÉ2/12/011a-2 Hypertherm Systèmes plasmaIDENTIFIER LES CONSIGNES DE SÉCURITÉLes symboles indiqués dans cette section sont utiliséspour identifie

SÉCURITÉ2/12/01Hypertherm Systèmes plasma 1a-3Toucher une pièce électrique sous tension peut provoquerun choc électrique fatal ou des brûlures graves.

SÉCURITÉ5/6/021a-4 Hypertherm Systèmes plasmaTorches à allumage instantanéL’arc plasma s’allume immédiatement après que la torchesoit mise en marche.L

SÉCURITÉ2/12/01Hypertherm Systèmes plasma 1a-5• Ne jamais lubrifier les robinets des bouteilles ou lesrégulateurs avec de l’huile ou de la graisse.• U

SÉCURITÉ2/12/011a-6 Hypertherm Systèmes plasmaÉtiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilis

Plasma Arc Cutting SystemOperator ManualIM-339(P/N 803390)© Copyright 2013 Hypertherm, Inc.All Rights ReservedHypertherm and Powermax are trademarks o

powermax600Operator Manual 2-10Section 2SPECIFICATIONSIn this section:Specifications, Power Supply ...

2-2 powermax600 Operator ManualSPECIFICATIONS0Specifications, Power SupplyRated Open Circuit Voltage (U0) 300 VDCRated Output Current (I2) 20 A – 40 A

SPECIFICATIONSpowermax600Operator Manual 2-30Specifications PAC123 TorchesMaximum Cutting Capacity40A PAC123T 5/8 inch / 16 mm @ 50 % duty cycle40A PA

2-4 powermax600 Operator ManualSPECIFICATIONS0OlSymbols and MarkingsS MARK (230/400 Volt only)The S mark indicates that the power supply and torc

powermax600Operator Manual 3-1Section 3SETUPIn this section:Lifting Power Supply ...

SETUP3-2 powermax600 Operator ManualLifting Power SupplyWARNINGThe power supply weighs up to 54 lb / 25 kg. Do not lift the power supply by ONE handle

SETUPpowermax600Operator Manual 3-3Power Hookup (Continued)Install Power Cord PlugUse a power cord plug that is certified by national or local electri

SETUP3-4 powermax600 Operator ManualLine Voltage Disconnect BoxUse a line disconnect box for each power supply so that the operator can turn the power

SETUPpowermax600Operator Manual 3-5Minimum Gas Inlet Pressure 90 psi / 6.2 barGas Flow 6 scfm @ 90 psi / 170 l/min @ 6.2 barGas HookupGas Requirements

3-6SETUPpowermax600 Operator ManualGas Supply Connection•Use an inert gas hose to connect the gas supply (air or nitrogen) to the power supply gas inl

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

SETUPpowermax600Operator Manual 3-7PAC123M.06Pigtail from MachineTorch LeadOn/Off PendantPAC123M ON/OFF Pendant ConnectionPAC123M Torch AlignmentMount

SETUP3-8 powermax600 Operator Manual

powermax600Operator Manual 4-110-99Section 4OPERATIONIn this section:Controls and Indicators...

OPERATION10-994-2 powermax600 Operator ManualPMX600.05ONOFFControls and IndicatorsCurrent(Amps)AdjustmentKnobIndicator LampsPressureGaugePower LampSee

OPERATION10-99powermax600Operator Manual 4-3Confirm Torch ConsumablesMachineCuttingUnshielded *120827 120600 120826Deflector120574120303 120600 120606

OPERATION10-994-4 powermax600 Operator ManualWARNINGINSTANT-ON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURNSPlasma arc comes on immediately when the to

OPERATION10-99powermax600Operator Manual 4-5Turn On PowerPosition the power switch to ON.Check that the POWER ON lamp is illuminated.Check Indicator L

OPERATION10-994-6 powermax600 Operator ManualTurn the current adjustment knob to the gas test setting.40Push the knob down tolock the regulator.•

OPERATION10-99powermax600Operator Manual 4-7Hand Torch OperationWARNINGINSTANT-ON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURNSPlasma arc comes on imme

OPERATION10-994-8 powermax600 Operator ManualHand Torch Cutting TechniqueFiring the torch unnecessarily reduces nozzle and electrode life.When cutting

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

OPERATION10-99powermax600Operator Manual 4-9Attach the work clamp securely to theworkpiece. Remove rust, paint or othercoatings to ensure good electri

OPERATION10-994-10 powermax600 Operator ManualWARNINGSPARKS AND HOT METAL CAN INJURE EYES AND BURN SKINWhen firing the torch at an angle, sparks and h

OPERATION10-99powermax600Operator Manual 4-11GougingHold the torch perpendicular to the workpiece.Pull the trigger to transfer the arc.Rotate the torc

OPERATION10-994-12 powermax600 Operator ManualMachine Torch OperationCut Chart - 40 Amp Standard Consumables• The following recommended settings are f

powermax600Operator Manual 5-110-99Section 5MAINTENANCE AND PARTSIn this section:Routine Maintenance...

MAINTENANCE AND PARTS10-995-2 powermax600 Operator ManualRoutine MaintenanceWARNINGELECTRIC SHOCK CAN KILLDisconnect electrical power before performin

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-3Inspect ConsumablesMissingCastellationShieldWear of castellations Castellations must not bewor

MAINTENANCE AND PARTS10-995-4 powermax600 Operator ManualInspect Consumables (Continued)External surfacesDamage or debris Clean and no damage ReplaceE

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-5WARNINGELECTRIC SHOCK CAN KILLDisconnect electrical power before performing any maintenance.Al

MAINTENANCE AND PARTS10-995-6 powermax600 Operator ManualDisconnect electrical power and gas supply before removing the old work cable.Installation1.

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

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-7Power Cord ReplacementDisconnect electrical power and gas supply before removing the old power

MAINTENANCE AND PARTS10-995-8 powermax600 Operator ManualAir Filter Element ReplacementCompress the hose fitting collar andpull the gas hose from

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-9Air Filter Element Replacement (continued)Push the pressure line fully into the hose fitting.

MAINTENANCE AND PARTS10-995-10 powermax600 Operator ManualBasic TroubleshootingPMX600.05ONOFFControls and Indicator LampsGreen POWER IS ON When illumi

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-11Problem Cause / Solution1. The ON/OFF power switch is set to I (ON),but the fan does not oper

MAINTENANCE AND PARTS10-995-12 powermax600 Operator ManualProblem Cause / Solution6. The POWER ON lamp is illuminatedand the SYSTEM READY lamp is noti

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-13Problem Cause / Solution9. The arc blows out, but re-ignites whenthe torch switch is depresse

MAINTENANCE AND PARTS10-995-14 powermax600 Operator ManualPartsPAC123T Hand Torch Assembly (No Quick Disconnect)Item Part Number Description Quantity0

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-15PAC123T.01* Included with replacementassembly.*PAC123T Hand Torch and Lead Assembly

MAINTENANCE AND PARTS10-995-16 powermax600 Operator ManualPAC123T Hand Torch Assembly (With Quick Disconnect)Item Part Number Description Quantity0860

TABLE OF CONTENTSpowermax600Operator Manual iiiELECTROMAGNETIC COMPATIBILITY ...

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-17PAC123T.02* Included with replacementlead assembly.***PAC123T Hand Torch and Lead A

MAINTENANCE AND PARTS10-995-18 powermax600 Operator ManualPAC123M Machine Torch Assembly (No Quick Disconnect)Item Part Number Description Quantity086

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-19PAC123M.03On/Off Pendant (not part of machine torch assembly -See Powermax600 Field Upgrade K

MAINTENANCE AND PARTS10-995-20 powermax600 Operator ManualPAC123M Machine Torch Assembly (With Quick Disconnect) Item Part Number Description Quantity

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-21M.04PAC123On/Off Pendant (not part of machine torch assembly -See Powermax600 Field Upgrade K

MAINTENANCE AND PARTS10-995-22 powermax600 Operator ManualPartItem Number Description Qty.1 011086 Air filter element 12 011087 O-ring 1Power Supply –

MAINTENANCE AND PARTS10-99powermax600Operator Manual 5-23Powermax600 LabelsPowermax600 Field Upgrade Kits and Optional PartsPart Number Description028

MAINTENANCE AND PARTS10-995-24 powermax600 Operator Manual

iv powermax600 Operator ManualTABLE OF CONTENTSSection 4 OperationControls and Indicators...

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

SAFETY11-981-2 Hypertherm Plasma SystemsRECOGNIZE SAFETY INFORMATIONThe symbols shown in this section are used toidentify potential hazards. When you