power max 45 operator manual

45Plasma arc cutting system

Operator Manual 805780 Revision 1

Register your new Hypertherm systemRegister your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number: Purchase date: Distributor: _____________________________________________ _____________________________________________ _____________________________________________

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powermax45

Operator Manual (P/N 805780)

Revision 1 October 2010

Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: [email protected]

Copyright 2010 Hypertherm, Inc. All Rights Reserved Hypertherm and Powermax 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 5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 (Technical Service) Hypertherm (Shanghai) Trading Co., Ltd. Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax

Hypertherm Europe B.V. Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) Hypertherm Japan Ltd. Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax Hypertherm Brasil Ltda. Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm Mxico, S.A. de C.V. Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegacin lvaro Obregn Mxico, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

12/17/09

eleCtROMAGNetIC COMPAtIbIlItY (eMC) IntroductionHyperthermsCE-markedequipmentisbuilt incompliancewithstandardEN60974-10. Theequipmentshouldbein talledandused s inaccordancewiththeinformationbeowto l achieveelecro ag etccom at ily. t m n i p ib it ThelimitsrequiredbyEN60974-10may notbeadequatetocom leteyeliminate p l interferencewhentheaffectedequip ent m isincloseproximityorhasahighdegreeof sen itivity.Insuchcasesitmaybenec ssary s e touseothermea urestofurtherre uce s d interference. Thiscuttingequipmentisdesignedforuse onlyinanin usri lenvironment. d t a electromagnetcproblemsinthesur oundng i r i area.Thefollowingshallbetakeninto ccount: a a. thersupplycables,controlcables, O signallingandtelephoneca les;above, b belowandadjacenttothecuttingequipment. b. adioandtelevisiontransmittersand R r eceivers. c. omputerandothercontrolequip ent. C m d. afetycriticalequipment,forexample S guardingofindustrialequipment. e. ealthofthepeoplearound,forexamplethe H useofpacemakersandhearngaids. i f. quipmentusedforcalibrationor E measurement. g. mmunityofotherequipmentinthe I environment.Usershallensurethatother equipmentbeingusedintheenvironment iscom at le.Thismayrequiread iion l p ib dt a protectionmeasures. h. imeofdaythatcuttingorotheracivies T t it aretobecarriedout. Thesizeofthesur oundngareatobe r i consideredwilldependonthestructureof thebuildingandotheractivitiesthataretaking place.Thesurroundingareamayexend t beyondthebound riesofthepre ises. a m

Installation and useTheuserisresponsibleforinstallingand usingtheplasmaequipmentaccordingtothe manufacturersinstructions.Ifelecromagnetc t i disturbancesaredeect dthenitshallbe t e therespon i ilyoftheusertore olvethe s b it s situationwiththetechnicalas isanceofthe s t man acur r.Insomecasesthisremedial uf t e actionmaybeassim leasearthingthe p cuttingcircuit,seeEarthingof Workpiece. Inothercas sitcouldinvolveconstructingan e electromag etcscreenenclosingthepow r n i e sourceandtheworkcompletewithassociated inputfilters.Inallcaseselecro ag etc t m n i disturbanc smustbereducedtothepoint e wheretheyarenolongertrou le ome. b s

Methods of reducing emissionsMains supplyCuttingequipmentmustbecon ect dtothe n e mainssupplyaccordingtotheman acur rs uf t e recom en aions.Ifinerer nceoccurs,itmay m d t t f e

Assessment of areaBeforeinstallingtheequipmenttheuser shallmakeanassessmentofpoenial t t

ComplianceInformation

eMC-19/10

eleCtROMAGNetIC COMPAtIbIlItY (eMC)

benecessarytotakeaddiionalprecautions t suchasfilerngofthemainssupply. t i Considerationshouldbegiventoshieldngthe i supplycableofper a entyinstalledcutting m n l equip ent,inmetallicconduitorequiv ent. m al Shieldingshouldbeelecri alycontinuous t c l through utitslength.Theshieldingshould o becon ect dtothecuttingmainssupply n e sothatgoodelectricalcontactismaintained betweentheconduitandthecuttingpow r e sourceenclosure.

earthing of workpieceWheretheworkpieceisnotbondedtoearth forelectricalsafety,norconnectedtoearth becauseofitssizeandposition,forexample,shipshullorbuildingsteel ork,a w con ecionbondingthework iecetoearth n t p mayreduceemis ionsinsome,butnotall s instances.Careshouldbetakentopreventthe earthingofthework ieceincreasingtherisk p ofinjurytousers,ordamagetootherelecri al t c equipment.Wherenecessary,thecon ecion n t oftheworkpiecetoearthshouldbemadeby adirectconnectiontothework iece,butin p somecountrieswheredirectconnectionisnot permitted,thebondingshouldbeachievedby suit blecapacitancesseect daccordingto a l e nationalregulations. Note:thecuttingcircuitmayormaynot beearthedforsafetyreasons.Changing theearthingarrangementsshouldonlybe authorizedbyapersonwhoiscom eentto p t assesswhetherthechang swillin reasethe e c riskofinjury,forexample,byalowngparallel l i cuttingcur entreturnpathswhichmaydamage r theearthcir uitsofotherequipment.Further c guid nceisprovidedinIEC60974-9,Arc a WeldingEquip ent,Part9:Installationand m Use.

Maintenance of cutting equipmentThecuttingequipmentmustberouiney t l maintainedaccordingtotheman acur rs uf t e recom en aions.Allac essandservicedoors m d t c andcoversshouldbeclosedandproperly fastenedwhenthecuttingequip entisin m operation.Thecuttingequipmentshouldnotbe modifiedinanywayexceptassetforthinand inaccordancewiththemanufacturerswritten instructions.Forexample,thesparkgapsof arcstrikingandsta iizngdevicesshouldbe bl i adjustedandmaintainedaccordingtothe manuacur rsrecommendations. f t e

Cutting cablesThecuttingcablesshouldbekeptasshort aspossibleandshouldbepo iionedclose st together,runningatorclosetothefloorlevel.

Screening and shieldingSelectivescreeningandshieldingofother cablesandequipmentinthesurrounding areamayalleviateproblemsofinererence. t f Screeningoftheentireplas acutting m installationmaybecon id redforspecial s e applications.

equipotential bondingBondingofallmetalliccomponentsinthe cuttinginstallationandadjacenttoitshould beconsidered.However,metalliccom o ents p n bondedtotheworkpiecewillincreasetherisk thattheop r orcouldreceiveashockby e at touchngthesemetalliccompo entsandthe i n electrode(nozzleforlaserheads)atthesame time.Theop r orshouldbein uat dfromall e at s l e suchbondedmetalliccomponents.

eMC-29/10


WARRANtY

AttentionGenuineHyperthermpartsarethefactoryrecommended eplacementpartsforyour r Hyperthermsystem.Anydamageorinjury causedbytheuseofotherthangenuine Hyperthermpartsmaynotbecoveredbythe Hyperthermwarranty,andwillconstitutemisuse oftheHyperthermProduct. Youaresolelyresponsibleforthesafeuseof theProduct.Hyperthermdoesnotandcannot makeanyguaranteeorwarrantyregardingthe safeuseoftheproductinyour nvironment. e

ThiswarrantyshallnotapplytoanyPowermax brandpowersuppliesthathavebeenusedwith phaseconverters.Inaddition,Hyperthermdoes notwarrantysystemsthathavebeendamaged asaresultofpoorpowerquality,whetherfrom phaseconvertersorincominglinepower.This warrantyshallnotapplytoanyProductwhich hasbeenincorrectlyinstalled,modified,or otherwisedamaged. Hyperthermprovidesrepair,replacementor adjustmentoftheProductasthesoleand exclusiveremedy,ifandonlyifthewarranty setforthhereinproperlyisinvokedand applies.Hypertherm,atitssoleoption,shall repair,replace,oradjust,freeofcharge,any defectiveProductscoveredbythiswarranty whichshallbereturnedwithHyperthermsprior authorization(whichshallnotbeunreasonably withheld),properlypacked,toHypertherms placeofbusinessinHanover,NewHampshire, ortoanauthorizedHyperthermrepairfacility, allcosts,insuranceandfreightprepaidby thecustomer.Hyperthermshallnotbeliable foranyrepairs,replacement,oradjustments ofProductscoveredbythiswarranty,except thosemadepursuanttothisparagraphand withHyperthermspriorwrittenconsent. Thewarrantysetforthaboveisexclusiveandis inlieuofallotherwarranties,express,implied, statutory,orotherwisewithrespecttothe Productsorastotheresultswhichmaybe obtainedtherefrom,andallimpliedwarranties orconditionsofqualityorofmerchantability orfitnessforaparticularpurposeoragainst infringement.Theforegoingshallconstitutethe soleandexclusiveremedyforanybreachby Hyperthermofitswarranty.

GeneralHypertherm,Inc.warrantsthatitsProducts shallbefreefromdefectsinmaterialsand workmanshipforthespecificperiodsoftime setforthhereinandasfollows:ifHypertherm isnotifiedofadefect(i)withrespecttothe powersupplywithinaperiodoftwo(2)years fromthedateofitsdeliverytoyou,withthe exceptionofPowermaxbrandpowersupplies, whichshallbewithinaperiodofthree(3)years fromthedateofdeliverytoyou,and(ii)with respecttothetorchandleadswithinaperiod ofone(1)yearfromitsdateofdeliverytoyou, andwithrespecttotorchlifterassemblies withinaperiodofone(1)yearfromitsdateof deliverytoyou,andwithrespecttolaserheads withinaperiodofone(1)yearfromitsdateof deliverytoyou,andwithrespecttoAutomation productsone(1)yearfromitsdateofdelivery toyou,withtheexceptionoftheEDGEPro CNCandArcGlideTHC,whichshallbewithin aperiodoftwo(2)yearsfromthedateof deliverytoyou.


W-19/10

WARRANtYDistributors/OEMsmayofferdifferentor additionalwarranties,butDistributors/OEMs arenotauthorizedtogiveanyadditional warrantyprotectiontoyouormakeany representationtoyoupurportingtobebinding uponHypertherm. Distributors/OEMsmayofferdifferentor additionalwarranties,butDistributors/OEMs arenotauthorizedtogiveanyadditional warrantyprotectiontoyouormakeany representationtoyoupurportingtobebinding uponHypertherm.

limitation of liabilityIn no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages.

Patent indemnityExceptonlyincasesofproductsnot manufacturedbyHyperthermormanufactured byapersonotherthanHyperthermnotinstrict conformitywithHyperthermsspecifications andincasesofdesigns,processes,formulae, orcombinationsnotdevelopedorpurported tobedevelopedbyHypertherm,Hypertherm willhavetherighttodefendorsettle,at itsownexpense,anysuitorproceeding broughtagainstyouallegingthattheuse oftheHyperthermproduct,aloneandnot incombinationwithanyotherproductnot suppliedbyHypertherm,infringesanypatent ofanythirdparty.YoushallnotifyHypertherm promptlyuponlearningofanyactionor threatenedactioninconnectionwithany suchallegedinfringement(andinanyevent nolongerthanfourteen(14)daysafter learningofanyactionorthreatofaction),and Hyperthermsobligationtodefendshallbe conditioneduponHyperthermssolecontrol of,andtheindemnifiedpartyscooperationand assistancein,thedefenseoftheclaim.

National and local codesNationalandlocalcodesgoverningplumbing andelectricalinstallationshalltakeprecedence overanyinstructionscontainedinthismanual. InnoeventshallHyperthermbeliableforinjury topersonsorpropertydamagebyreasonof anycodeviolationorpoorworkpractices.

liability capIn no event shall Hypertherms liability, if any, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

InsuranceAtalltimesyouwillhaveandmaintain insuranceinsuchquantitiesandtypes,and withcoveragesufficientandappropriateto defendandtoholdHyperthermharmlessinthe eventofanycauseofactionarisingfromthe useoftheproducts.

W-29/10


WARRANtY

transfer of rightsYoumaytransferanyremainingrightsyoumay havehereunderonlyinconnectionwiththe saleofallorsubstantiallyallofyourassetsor capitalstocktoasuccessorininterestwho agreestobeboundbyallofthetermsand conditionsofthisWarranty.Withinthirty(30) daysbeforeanysuchtransferoccurs,you agreetonotifyinwritingHypertherm,which reservestherightofapproval.Shouldyou failtimelytonotifyHyperthermandseekits approvalassetforthherein,theWarrantyset forthhereinshallbenullandvoidandyouwill havenofurtherrecourseagainstHypertherm undertheWarrantyorotherwise.


W-39/10

Safety informationBeforeoperatinganyHyperthermequipment,readtheseparateSafety and Compliance Manual (80669C)includedwithyourproductforimportantsafety information.

tAble OF CONteNtSElectromagneticcompatibility.................................................................................................................. EMC-1 Warranty............................................................................................................................................................. W-1 Section 1 SPeCIFICAtIONS Systemdescription............................................................................................................................................ 1-2 Wheretofindinformation................................................................................................................................ 1-2 Powersupplydimensionsandweights........................................................................................................ 1-3 Dimensions............................................................................................................................................... 1-3 Weights..................................................................................................................................................... 1-3 Powersupplyratings........................................................................................................................................ 1-4 . T45vtorchdimensions.................................................................................................................................... 1-5 T45mtorchdimensions................................................................................................................................... 1-5 . T45vandT45mtorchspecifications............................................................................................................ 1-6 . Symbolsandmarkings..................................................................................................................................... 1-7 . IECsymbols............................................................................................................................................. 1-8 . Section 2 POWeR SUPPlY SetUP UnpackthePowermax45................................................................................................................................. 2-2 Claims........................................................................................................................................................ 2-2 Contents.................................................................................................................................................... 2-2 Positionthepowersupply................................................................................................................................ 2-3 Preparetheelectricalpower........................................................................................................................... 2-3 Voltageconfigurations........................................................................................................................... 2-3 . Installaline-disconnectswitch............................................................................................................ 2-4 Requirementsforgrounding................................................................................................................. 2-4 Powercordconsiderations............................................................................................................................. 2-5 . Extensioncordrecommendations....................................................................................................... 2-5 Generatorrecommendations............................................................................................................... 2-7 . Preparethegassupply.................................................................................................................................... 2-7 . Connectthegassupply........................................................................................................................ 2-8 . Additionalgasfiltration.......................................................................................................................... 2-8 . Section 3 tORCH SetUP Introduction......................................................................................................................................................... 3-2 Consumablelife................................................................................................................................................. 3-2 . Handtorchsetup............................................................................................................................................... 3-3 Choosetheconsumables..................................................................................................................... 3-3 . Installtheconsumables......................................................................................................................... 3-5 .

powermax45 OperatorManual

i

tAble OF CONteNtSMachinetorchsetup.......................................................................................................................................... 3-6 Mountthetorch....................................................................................................................................... 3-6 . Choosetheconsumables(cutcharts)............................................................................................... 3-8 Alignthetorch........................................................................................................................................3-26 Connecttheremote-startpendant...................................................................................................3-26 . Connectamachineinterfacecable..................................................................................................3-27 Connectthetorchlead..................................................................................................................................3-30 . Section 4 OPeRAtION Controlsandindicators.................................................................................................................................... 4-2 FrontcontrolsandLEDs........................................................................................................................ 4-2 Rearcontrols............................................................................................................................................ 4-3 OperatethePowermax45............................................................................................................................... 4-4 . Connecttheelectricalpowerandgassupply.................................................................................. 4-4 TurnONthesystem............................................................................................................................... 4-4 . Setthemodeswitch.............................................................................................................................. 4-5 . Adjustthegaspressure......................................................................................................................... 4-5 ChecktheindicatorLEDs..................................................................................................................... 4-6 Attachtheworkclamp........................................................................................................................... 4-7 Understandduty-cyclelimitations.................................................................................................................. 4-7 Howtousethehandtorch.............................................................................................................................. 4-8 Operatethesafetytrigger..................................................................................................................... 4-8 Handtorchcuttinghints........................................................................................................................ 4-9 Startacutfromtheedgeoftheworkpiece.....................................................................................4-10 Pierceaworkpiece...............................................................................................................................4-11 . Gougeaworkpiece..............................................................................................................................4-12 Commonhand-cuttingfaults..............................................................................................................4-14 Howtousethemachinetorch.....................................................................................................................4-15 . Ensurethetorchandtablearesetupcorrectly.............................................................................4-15 Understandandoptimizecutquality................................................................................................4-15 . Topierceaworkpieceusingthemachinetorch............................................................................4-17 Commonmachine-cuttingfaults.......................................................................................................4-18 . Section 5 MAINteNANCe AND RePAIR Performroutinemaintenance.......................................................................................................................... 5-2 Inspecttheconsumables................................................................................................................................. 5-3 Basictroubleshooting....................................................................................................................................... 5-4 Repairs................................................................................................................................................................. 5-8 ii

powermax45OperatorManual

tAble OF CONteNtSRemoveandreplacethecoverandMylarbarrier........................................................................ 5-8 . Replacetheworklead(CSAandCE).............................................................................................5-10 Replacethegasfilterelement............................................................................................................5-11 Section 6 PARtS Powersupplyparts........................................................................................................................................... 6-2 . T45vhandtorchparts....................................................................................................................................... 6-5 T45vhandtorchconsumables............................................................................................................ 6-6 . T30v(Powermax30)30Aconsumables........................................................................................... 6-6 T45mmachinetorchparts.............................................................................................................................. 6-7 . T45mmachinetorchconsumables..................................................................................................... 6-8 Accessoryparts.................................................................................................................................................. 6-8 Powermax45labels........................................................................................................................................... 6-8


iii

tAble OF CONteNtS

iv

powermax45OperatorManual

Section 1 SPeCIFICAtIONS

In this section:Systemdescription............................................................................................................................................ 1-2 Wheretofindinformation................................................................................................................................ 1-2 Powersupplydimensionsandweights........................................................................................................ 1-3 Dimensions............................................................................................................................................... 1-3 Weights..................................................................................................................................................... 1-3 Powersupplyratings........................................................................................................................................ 1-4 . T45vtorchdimensions.................................................................................................................................... 1-5 T45mtorchdimensions................................................................................................................................... 1-5 . T45vandT45mtorchspecifications............................................................................................................ 1-6 . Symbolsandmarkings..................................................................................................................................... 1-7 . IECsymbols............................................................................................................................................. 1-8 .


1-1

SPeCIFICAtIONS

System descriptionThePowermax45isahighlyportable,45-amp,handheldandmechanizedplasmacutting systemappropriateforawiderangeofapplications.ThePowermax45usesairornitrogentocut electricallyconductivemetals,suchasmildorstainlesssteeloraluminum.Withit,youcancut thicknessesupto1inch(25.4mm)andpiercethicknessesupto3/8inch(9.5mm). ThestandardPowermax45systemincludesacompletesetoftheconsumablesneededforcutting (shield,retainingcap,swirlring,nozzle,electrode),2spareelectrodes,2sparenozzles,gouging consumables(handheldconfigurationsonly),aquick-disconnectairfitting(1/4NPTonCSA unitsand1/4NPTxG-1/4BSPPonCEunits),aconsumablesbox,ashoulderstrap,anOperator Manual,aQuickSetupCard,andaSetupDVD.Mechanizedconfigurationsincludearemote-start pendantaswell. Youcanorderadditionalconsumablesandaccessoriessuchastheplasmacuttingguidefrom anyHyperthermdistributor.SeeSection6,Parts,foralistofspareandoptionalparts. ThepowercordsontheCSApowersuppliesareshippedwitha50A,250Vplug(NEMA6-50P) onthepowercord.TheCEunitsareshippedwithoutaplugonthepowercord.SeePrepare the electrical powerinSection2formoreinformation.

Where to find informationSystemspecificationssuchassize,weight,detailedelectricalspecifications,andcutspeedscan befoundinthissection.Forinformationon: afetyinformationseetheSafetyandComplianceManualfordetailedsafetyinformation. S etuprequirements,includingpowerrequirements,grounding,powercordconfigurations, S extensioncordrequirements,andgeneratorrecommendationsseeSection2,Power supply setup. andheldandmachinetorchconsumables,cutcharts,andtorchsetupinformationsee H Section3,Torch setup. nformationaboutthecontrolsandLEDs,stepsforsystemoperation,andhintsforimproving I cutqualityseeSection4,Operation. outinemaintenanceandrepairseeSection5,Maintenance and repair. R artnumbersandorderinginformationforaccessories,consumables,andreplacement P partsseeSection6,Parts.

1-2


SPeCIFICAtIONS

Power supply dimensions and weightsDimensions

13.7in (34.8cm) 12.19in (31cm)

16.75in (42.6cm)

6.75in (17.2cm)

WeightsPowersupplyweightsgivenbelowincludethehandtorchwith20ft(6.1m)lead,a20ft(6.1m) worklead,anda10ft(3m)powercord. SApowersupply:37lbs(16.8kg) C E230Vpowersupply:36.5lbs(16.6kg) C CE400Vpowersupply:35lbs(15.9kg)


1-3

SPeCIFICAtIONS

Power supply ratingsRatedopen-circuitvoltage(U0) CSA/CE,single-phase CE,3-phase Ratedoutputcurrent(I2) Ratedoutputvoltage(U2) Dutycycleat40C (Seedataplateonpowersupplyfor moreinformationondutycycle.) Operatingtemperature Storagetemperature Powerfactor 200240VCSA,230VCE,1-phase 400V,3-phaseCE Inputvoltage(U1)/Inputcurrent(I1)at ratedoutput(U2MAX,I2MAX) (SeeVoltage configurationsinSection3for moreinformation.) Gastype Gasquality Recommendedgasinletflow andpressure * EquipmentcomplieswithIEC61000-3-12. ** quipmentcomplieswithIEC61000-3-12providedthattheshort-circuitpowerSscisgreater E thanorequalto692KVAattheinterfacepointbetweentheuserssupplyandthepublic system.Itistheresponsibilityoftheinstalleroruseroftheequipmenttoensure,byconsultation withthedistributionnetworkoperatorifnecessary,thattheequipmentisconnectedonlytoa supplywithashort-circuitpowerSscgreaterthanorequalto692KVA. 275VDC 20Ato45A 132VDC 50%(I2=45A,U2=132V) 60%(I2=41A,U2=132V) 100%(I2=32A,U2=132V) 14to104F(-10to40C) -13to131F(-25to55C) 0.99 0.94 200240VAC/3428A(CSA) 230VAC/30A(230VCE)* 400VAC10A(400VCE)** Air Clean,dry,oil-freeper ISO8573-1Class1.2.2 Nitrogen 99.995%pure

360scfh@90psi(170l/[email protected])

1-4


SPeCIFICAtIONS

t45v torch dimensions8.72in(22.1cm) 8.5in(21.6cm)

3.28in (8.3cm)

75angle 1.91in(4.9cm)

1.58in (4.0cm)

1in (2.5cm)

t45m torch dimensions14.36in (36.5cm)

1in (2.5cm)

12in (30.5cm) 13in (33.0cm)

1.43in(3.6cm)outer dimension,1.3in (3.3cm)flatsides


1-5

SPeCIFICAtIONS

t45v and t45m torch specificationsHandheld cut capacity (material thickness) Recommendedcutcapacity(hand cutting) Maximumcutcapacity(handcutting ormechanizededgestart) Severancecapacity(handcuttingor mechanizededgestart) Mechanized pierce capacity (material thickness) Piercecapacity (foredgestarts,thecapacitiesare thesameasthehandheldcapacities) Recommended cut speed (on mild steel) 1/4in(6.35mm) 3/8in(9.53mm) 1/2in(12mm) 3/4in(18mm) 1in(24mm) Gouging capacity Metalremovalrateonmildsteel Weight T45vtorchonly T45vwith20ft(6.1m)lead T45vwith50ft(15.24m)lead T45mtorchonly T45mwith25ft(7.62m)lead T45mwith35ft(10.7)lead T45mwith50ft(15.24)lead 0.6lbs(0.27kg) 3.4lbs(1.55kg) 7.8lbs(3.54kg) 1.0lbs(0.45kg) 5.0lbs(2.27kg) 6.4lbs(2.9kg) 8.5lbs(3.85kg) 6.2lbs/hr(2.8kg/hr) 60ipm(1524mm/min) 32ipm(813mm/min) 20ipm(508mm/min) 8ipm(203mm/min) 4ipm(102mm/min) 3/8in(9.5mm) 1/2in(12.7mm) 3/4in(19.1mm) 1in(25.4mm)

1-6


SPeCIFICAtIONS

Symbols and markingsYourHyperthermproductmayhaveoneormoreofthefollowingmarkingsonornearthedata plate.Duetodifferencesandconflictsinnationalregulations,notallmarksareappliedtoevery versionofaproduct. S mark symbol TheSmarksymbolindicatesthatthepowersupplyandtorcharesuit bleforoperationscarriedout a inen i on entswithin reasedhazardofelecri alshockperIEC60974-1. vr m c t c CSA mark HyperthermproductswithaCSAmarkmeettheUnitedStatesandCanadianregulationsforproduct safety.Theproductswereevaluated,tested,andcertifiedbyCSA-International.Alternativelythe productmayhaveamarkbyoneoftheotherNationallyRecognizedTestingLaboratories(NRTL) accreditedinboththeUnitedStatesandCanada,suchasUnderwritersLaboratories,Incorporated (UL)orTV. Ce marking T heCEmarkingsignifiesthemanufacturersdeclarationofconformitytoapplicableEuropean directivesandstandards.OnlythoseversionsofHyperthermproductswithaCEmarkinglocatedon ornearthedataplatehavebeentestedforcompliancewiththeEuropeanLowVoltageDirectiveand theEuropeanElectromagneticCompatibility(EMC)Directive.EMCfiltersneededtocomplywiththe EuropeanEMCDirectiveareincorporatedwithinversionsoftheproductwithaCEmarking. GOSt-R mark CEversionsofHyperthermproductsthatincludeaGOST-Rmarkofconformitymeettheproduct safetyandEMCrequirementsforexporttotheRussianFederation. c-tick mark C EversionsofHyperthermproductswithac-TickmarkcomplywiththeEMCregulationsrequired forsaleinAustraliaandNewZealand. CCC mark TheChinaCompulsoryCertification(CCC)markindicatesthattheproducthasbeentestedand foundcompliantwithproductsafetyregulationsrequiredforsaleinChina.


1-7

SPeCIFICAtIONS IeC symbolsThefollowingsymbolsmayappearonthepowersupplydataplate,controllabels,switches, andLEDs:

Directcurrent(DC) Alternatingcurrent (AC) Plasmatorchcutting1~ f 1f2

l O

PowerisON PowerisOFF Aninverter-basedpower source,either1-phaseor 3-phase Volt/ampcurve,drooping characteristic PowerisON(LED) Systemfault(LED) Inletgaspressure(LED)

Platemetalcutting Expandedmetal cutting Gouging ACinputpower connection Theterminalforthe externalprotective (earth)conductor Gastestmode

AC

Missingorloose consumables(LED)

Powersupplyisoutof temperaturerange(LED)

1-8


Section 2 POWeR SUPPlY SetUP

In this section:UnpackthePowermax45................................................................................................................................. 2-2 Claims........................................................................................................................................................ 2-2 Contents.................................................................................................................................................... 2-2 Positionthepowersupply................................................................................................................................ 2-3 Preparetheelectricalpower........................................................................................................................... 2-3 Voltageconfigurations........................................................................................................................... 2-3 . Installaline-disconnectswitch............................................................................................................ 2-4 Requirementsforgrounding................................................................................................................. 2-4 Powercordconsiderations............................................................................................................................. 2-5 . Extensioncordrecommendations....................................................................................................... 2-5 Generatorrecommendations............................................................................................................... 2-7 . Preparethegassupply.................................................................................................................................... 2-7 . Connectthegassupply........................................................................................................................ 2-8 . Additionalgasfiltration.......................................................................................................................... 2-8 .


2-1

POWeR SUPPlY SetUP

Unpack the Powermax451. erifythatallitemsonyourorderhavebeenreceivedingoodcondition.Contactyourdistributor V ifanypartsaredamagedormissing. 2.nspectthepowersupplyfordamagethatmayhaveoccurredduringshipping.Ifthereis I evidenceofdamage,refertoClaims,below.Allcommunicationsregardingthisequipmentmust includethemodelnumberandtheserialnumberlocatedonthebottomofthepowersupply. 3. eforeyousetupandoperatethisHyperthermsystem,readtheSafetyandComplianceManual. B

Claims laims for damage during shipment Ifyourunitwasdamagedduringshipment, C youmustfileaclaimwiththecarrier.Hyperthermwillfurnishyouwithacopyofthebill ofladinguponrequest.Ifyouneedadditionalassistance,callthenearestHyperthermoffice listedinthefrontofthismanual. laims for defective or missing merchandiseIfanycomponentismissingor C defective,contactyourHyperthermdistributor.Ifyouneedadditionalassistance,call thenearestHyperthermofficelistedinthefrontofthismanual.

ContentsVerifytheitemsintheboxagainsttheillustration.

OperatorManual (CSA) QuickSetupCard 230V(CE) RegistrationCard SetupDVD or Boxwithextra consumables

400V(CE)

Remote-startpendant(optional)

Shoulderstrap

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POWeR SUPPlY SetUP

Position the power supplyLocatethePowermax45nearanappropriate200240voltpowerreceptacleforCSAorCE 1-phasepowersupplies,ora400voltreceptaclefor3-phaseCEpowersupplies.The Powermax45hasa10-foot(3m)powercord.Allowatleast10inches(0.25m)ofspacearound thepowersupplyforproperventilation.

Prepare the electrical powerThemaximumoutputvoltagewillvarybasedonyourinputvoltageandthecircuitsamperage. Becausethecurrentdrawvariesduringstartup,slow-blowfusesarerecommendedasshownin thechartbelow.Slow-blowfusescanwithstandcurrentsupto10timestheratedvalueforshort periodsoftime.

Voltage configurationsThefollowingchartshowsthemaximumratedoutputfortypicalcombinationsofinputvoltageand amperage.Acceptableinputvoltagescanbe10%ofthevaluesgivenbelow. Caution: Protect the circuit with appropriately sized time-delay (slow-blow) fuses and a line-disconnect switch.

Model

Input Input Recommended current Input voltage Phase Rated output current at slow-blow fuse during arc 6 kw output size stretch 200240VAC 1 1 1 3 1 3 45A,132V 45A,132V 45A,132V 45A,132V 45A,132V 45A,132V 3428A 33A 3428A 10A 31A 11A 5545A 54.5A 5545A 15.5A 53A 14A 50A 50A 35or50*A 15or20*A 35or50*A 15A

CSA 208VAC 200240VAC CE 400VAC 220VAC CE/CCC 380VAC

* Usethehigheramperagefuseforapplicationsthatrequirealongarcstretch.


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POWeR SUPPlY SetUP Install a line-disconnect switchUsealine-disconnectswitchforeachpowersupplysothattheoperatorcanturnofftheincoming powerquicklyinanemergency.Locatetheswitchsothatitiseasilyaccessibletotheoperator. Installationmustbeperformedbyalicensedelectricianaccordingtonationalandlocalcodes.The interruptleveloftheswitchmustequalorexceedthecontinuousratingofthefuses.Inaddition,the switchshould: solatetheelectricalequipmentanddisconnectallliveconductorsfromtheincomingsupply I voltagewhenintheOFFposition. aveoneOFFandoneONpositionthatareclearlymarkedwithO(OFF)andI(ON). H aveanexternaloperatinghandlethatcanbelockedintheOFFposition. H ontainapower-operatedmechanismthatservesasanemergencystop. C aveslow-blowfusesinstalledasrecommendedinthetableonthepreviouspage. H

Requirements for groundingToensurepersonalsafety,properoperation,andtoreduceelectromagneticinterference(EMI),the Powermax45mustbeproperlygrounded: hepowersupplymustbegroundedthroughthepowercordaccordingtonationalandlocal T electricalcodes. ingle-phaseservicemustbeofthe3-wiretypewithagreenorgreen/yellowwireforthe S protectiveearthgroundandmustcomplywithnationalandlocalrequirements.Do not use a 2-wire service. hree-phaseservice(CEonly)mustbeofthe4-wiretypewithagreenorgreen/yellowwire T fortheprotectiveearthgroundandmustcomplywithnationalandlocalrequirements. efertoGrounding safetyintheSafetyandComplianceManualformoreinformation. R

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POWeR SUPPlY SetUP

Power cord considerationsPowermax45powersuppliesareshippedwithCSAandCEpowercordconfigurations. ThepowercordsontheCSApowersuppliesareshippedwitha50A,250Vplug(NEMA6-50P) onthepowercord. TheCEpowersuppliesareshippedwithoutaplugonthepowercord.Obtainthecorrectplugfor yourunit(either230Vor400V)andlocationhaveitinstalledbyalicensedelectrician.

extension cord recommendationsAnyextensioncordmusthaveanappropriatewiresizeforthecordlengthandsystemvoltage. Useacordthatmeetsnationalandlocalcodes. Thetablesonthenextpageprovidestherecommendedgaugesizeforvariouslengthsandinput voltages.Thelengthsinthetablesarethelengthoftheextensioncordonly;theydonotinclude thepowersupplyspowercord.


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POWeR SUPPlY SetUPextension cord recommendations english

Input voltage 208VAC 220VAC 200240VAC 380VAC 400VAC

Phase 1 1 1 3 3

< 10 ft 8AWG 8AWG 8AWG 12AWG 12AWG

1025 ft 8AWG 8AWG 8AWG 12AWG 12AWG




Metric

Input voltage 208VAC 220VAC 200240VAC 380VAC 400VAC

Phase 1 1 1 3 3

power max 45 operator manual

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