Powermax 1000 G3

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<ul><li><p>15-25 ft4.5-7.5 m</p><p>35-50 ft12-15 m</p><p>6.0 BAR5.04.0 PSI</p><p>807050 60</p><p>80</p><p>AMPS</p><p>120926 120925120978</p><p>120927120928</p><p>120928</p><p>120929</p><p>120977</p><p>110378 Rev. A</p><p>6.0BAR</p><p>5.04.0</p><p>PSI8070</p><p>50 60</p><p>60</p><p>40</p><p>AMPS</p><p>80</p><p>25</p><p>AC</p><p>+</p><p>_</p><p>15-50 ft4.5-15 m</p><p>15-25 ft4.5-7.5 m</p><p>35-50 ft12-15 m</p><p>6.0 BAR5.04.0PSI807050 60</p><p>80</p><p>AMPS</p><p>80</p><p>AMPS</p><p>Plasma ArcCutting System</p><p>Service Manual804300 Revision 0</p><p>powermax1000</p></li><li><p>Service Manual</p><p>(P/N 804300)</p><p>Revision 0 December, 2001</p><p>Hypertherm, Inc.Hanover, NH USA</p><p>www.hypertherm.com</p><p> Copyright 2001 Hypertherm, Inc.All Rights Reserved</p><p>Hypertherm and Powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.</p><p>powermax1000</p></li><li><p>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 (Technical Service)800-737-2978 Tel (Customer Service) </p><p>Hypertherm Automation5 Technology DriveWest Lebanon, NH 03755 USA603-298-7970 Tel 603-298-7977 Fax</p><p>Hypertherm Plasmatechnik GmbHTechnologiepark HanauRodenbacher Chaussee 6 63457 Hanau-Wolfgang, Deutschland49 6181 58 2100 Tel 49 6181 58 2134 Fax49 6181 58 2123 (Technical Service)</p><p>Hypertherm Singapore Pte LtdNo. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore65 841 2489 Tel 65 841 2490 Fax 65 841 2489 (Technical Service)</p><p>Japan1952-14 Yata-NatsumegiMishima City, Shizuoka Pref.411-0801 Japan81 0 559 75 7387 Tel81 0 559 75 7376 Fax</p><p>Hypertherm UK Ltd9 Berkeley Court, Manor Park Runcorn, Cheshire, England WA7 1TQ44 1928 579 074 Tel 44 1928 579 604 Fax </p><p>France15 Impasse des Rosiers95610 Eragny, France0805 050 111 Tel 0805 050 222 Fax </p><p>Hypertherm S.r.L.Via Torino 220123 Milano, Italia39 02 725 46 312 Tel 39 02 725 46 400 Fax39 02 725 46 314 (Technical Service)</p><p>Hypertherm B.V.Burg. Haverkampstraat 13 7091 CN Dinxperlo, Nederland31 315 655866 Tel 31 315 655886 Fax</p><p>Hypertherm B.V. (ETSO)Vaartveld 94704 SE Roosendaal, Nederland00 800 49 73 7843 toll-free in Europa 31 165 596900 Tel31 165 596901 Fax</p><p>7/13/01</p></li><li><p>ELECTROMAGNETIC COMPATIBILITY (EMC)</p><p>EMC INTRODUCTION</p><p>Hypertherm's CE-marked equipment is builtin compliance with standard EN50199. Theequipment should be installed and used inaccordance with the information below toachieve electromagnetic compatibility.</p><p>The limits required by EN50199 may not beadequate to completely eliminate interfer-ence when the affected equipment is inclose proximity or has a high degree of sen-sitivity. In such cases it may be necessary touse other measures to further reduce inter-ference.</p><p>This plasma equipment is designed for useonly in an industrial environment. </p><p>INSTALLATION AND USE</p><p>The user is responsible for installing andusing the plasma equipment according tothe manufacturer's instructions. If electro-magnetic disturbances are detected then itshall be the responsibility of the user to re-solve the situation with the technical assis-tance of the manufacturer. In some casesthis remedial action may be as simple asearthing the cutting circuit, see Earthing ofWorkpiece. In other cases it could involveconstructing an electromagnetic screen en-closing the power source and the work com-plete with associated input filters. In allcases electromagnetic disturbances mustbe reduced to the point where they are nolonger troublesome.</p><p>ASSESSMENT OF AREA</p><p>Before installing the equipment the usershall make an assessment of potential elec-tromagnetic problems in the surroundingarea. The following shall be taken intoaccount:a. Other supply cables, control cables, sig-nalling and telephone cables; above, belowand adjacent to the cutting equipment.b. Radio and television transmitters andreceivers.c. Computer and other control equipment.d. Safety critical equipment, for exampleguarding of industrial equipment.e. Health of the people around, for example the use of pacemakers and hear-ing aids.f. Equipment used for calibration or mea-surement.g. Immunity of other equipment in the en-vironment. User shall ensure that otherequipment being used in the environment iscompatible. This may require additional pro-tection measures.h. Time of day that cutting or other activitiesare to be carried out.</p><p>Earthing of Workpiece</p><p>Where the workpiece is not bonded to earthfor electrical safety, nor connected to earthbecause of its size and position, for example,ship's hull or building steelwork, a connectionbonding the workpiece to earth may reduceemissions in some, but not all instances.Care should be taken to prevent the earthingof the workpiece increasing the risk of injuryto users, or damage to other electrical equip-ment. Where necessary, the connection ofthe workpiece to earth should be made by adirect connection to the workpiece, but insome countries where direct connection isnot permitted, the bonding should beachieved by suitable capacitances selectedaccording to national regulations.</p><p>Note. The cutting circuit may or may not beearthed for safety reasons. Changing theearthing arrangements should only be au-thorized by a person who is competent toassess whether the changes will increasethe risk of injury, for example, by allowingparallel cutting current return paths whichmay damage the earth circuits of otherequipment. Further guidance is given in IECTC26 (sec)94 and IEC TC26/108A/CD ArcWelding Equipment Installation and Use. </p><p>Screening and Shielding</p><p>Selective screening and shielding of othercables and equipment in the surroundingarea may alleviate problems of interference.Screening of the entire plasma cutting in-stallation may be considered for special ap-plications</p><p>The size of the surrounding area to be con-sidered will depend on the structure of thebuilding and other activities that are takingplace. The surrounding area may extendbeyond the boundaries of the premises.</p><p>METHODS OF REDUCING EMISSIONS</p><p>Mains Supply</p><p>Cutting equipment must be connected to themains supply according to the manufactur-er's recommendations. If interference oc-curs, it may be necessary to take additionalprecautions such as filtering of the mainssupply. Consideration should be given toshielding the supply cable of permanentlyinstalled cutting equipment, in metallic con-duit or equivalent. Shielding should be elec-trically continuous throughout its length.The shielding should be connected to thecutting mains supply so that good electricalcontact is maintained between the conduitand the cutting power source enclosure</p><p>Maintenance of Cutting Equipment</p><p>The cutting equipment must be routinelymaintained according to the manufacturer'srecommendations. All access and servicedoors and covers should be closed andproperly fastened when the cutting equip-ment is in operation. The cutting equipmentshould not be modified in any way except forthose changes and adjustments covered inthe manufacturer's instructions. In particu-lar, the spark gaps of arc striking and stabi-lizing devices should be adjusted and main-tained according to the manufacturer'srecommendations.</p><p>Cutting Cables</p><p>The cutting cables should be kept as shortas possible and should be positioned closetogether, running at or close to the floorlevel.</p><p>Equipotential Bonding</p><p>Bonding of all metallic components in thecutting installation and adjacent to it shouldbe considered. However, metallic compo-nents bonded to the workpiece will increasethe risk that the operator could receive ashock by touching these metallic compo-nents and the electrode at the same time.The operator should be insulated from allsuch bonded metallic components.</p><p>Hypertherm Plasma Systems i</p></li><li><p>WARRANTY</p><p>ii Hypertherm Plasma Systems9-01</p><p>WARNINGGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system. Any damagecaused by the use of other than genuine Hypertherm parts maynot be covered by the Hypertherm warranty.</p><p>WARNINGYou are responsible for the safe use of the Product.Hypertherm does not and cannot make any guarantee orwarranty regarding the safe use of the Product in yourenvironment. </p><p>GENERALHypertherm, Inc. warrants that its Products shall be free fromdefects in materials and workmanship, if Hypertherm is notifiedof a defect (i) with respect to the power supply within a periodof two (2) years from the date of its delivery to you, with theexception of G3 Series power supplies, which shall be within aperiod of three (3) years from the date of delivery to you, and(ii) with respect to the torch and leads within a period of one (1)year from its date of delivery to you. This warranty shall notapply to any Product which has been incorrectly installed,modified, or otherwise damaged. Hypertherm, at its soleoption, shall repair, replace, or adjust, free of charge, anydefective Products covered by this warranty which shall bereturned with Hypertherms prior authorization (which shall notbe unreasonably withheld), properly packed, to Hyperthermsplace of business in Hanover, New Hampshire, or to anauthorized Hypertherm repair facility, all costs, insurance andfreight prepaid. Hypertherm shall not be liable for any repairs,replacement, or adjustments of Products covered by thiswarranty, except those made pursuant to this paragraph or withHypertherms prior written consent. The warranty above isexclusive and is in lieu of all other warranties, express,implied, statutory, or otherwise with respect to theProducts or as to the results which may be obtainedtherefrom, and all implied warranties or conditions ofquality or of merchantability or fitness for a particularpurpose or against infringement. The foregoing shallconstitute the sole and exclusive remedy for any breachby Hypertherm of its warranty. Distributors/OEMs may offerdifferent or additional warranties, but Distributors/OEMs arenot authorized to give any additional warranty protection to youor make any representation to you purporting to be bindingupon Hypertherm.</p><p>PATENT INDEMNITYExcept only in cases of products not manufactured byHypertherm or manufactured by a person other thanHypertherm not in strict conformity with Hyperthermsspecifications and in cases of designs, processes, formulae, orcombinations not developed or purported to be developed byHypertherm, Hypertherm will defend or settle, at its ownexpense, any suit or proceeding brought against you allegingthat the use of the Hypertherm product, alone and not incombination with any other product not supplied by</p><p>Hypertherm, infringes any patent of any third party. You shallnotify Hypertherm promptly upon learning of any action orthreatened action in connection with any such allegedinfringement, and Hypertherms obligation to indemnify shall beconditioned upon Hypertherms sole control of, and theindemnified partys cooperation and assistance in, the defenseof the claim.</p><p>LIMITATION OF LIABILITYIn no event shall Hypertherm be liable to any person orentity for any incidental, consequential, indirect, orpunitive damages (including but not limited to lost profits)regardless of whether such liability is based on breach ofcontract, tort, strict liability, breach of warranties, failure ofessential purpose or otherwise and even if advised of thepossibility of such damages.</p><p>LIABILITY CAPIn no event shall Hypertherms liability, whether suchliability is based on breach of contract, tort, strict liability,breach of warranties, failure of essential purpose orotherwise, for any claim action suit or proceeding arisingout of or relating to the use of the Products exceed in theaggregate the amount paid for the Products that gave riseto such claim.</p><p>INSURANCEAt all times you will have and maintain insurance in suchquantities and types, and with coverage sufficient andappropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of theProducts. </p><p>NATIONAL AND LOCAL CODESNational and Local codes governing plumbing and electricalinstallation shall take precedent over any instructionscontained in this manual. In no event shall Hypertherm beliable for injury to persons or property damage by reason of anycode violation or poor work practices.</p><p>TRANSFER OF RIGHTSYou may transfer any remaining rights you may havehereunder only in connection with the sale of all or substantiallyall of your assets or capital stock to a successor in interest whoagrees to be bound by all of the terms and conditions of thisWarranty.</p></li><li><p>TABLE OF CONTENTS</p><p>powermax1000 Service Manual iii0</p><p>Electromagnetic Compatibility .......................................................................................................................................iWarranty .......................................................................................................................................................................ii</p><p>Section 1 SafetyRecognize Safety Information...................................................................................................................................1-2Follow Safety Instructions.........................................................................................................................................1-2Cutting Can Cause Fire or Explosion .......................................................................................................................1-2Electric Shock Can Kill..............................................................................................................................................1-3Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4Grounding Safety......................................................................................................................................................1-4Compressed Gas Equipment Safety ........................................................................................................................1-5Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5Noise Can Damage Hearing.....................................................................................................................................1-5Pacemaker and Hearing Aid Operation ....................................................................................................................1-5A Plasma Arc Can Damage Frozen Pipes ................................................................................................................1-5Additional Safety Information....................................................................................................................................1-5Warning Label................................................................................................</p></li></ul>