Hypertherm MAX200 Instruction Manual

MAX200 ® EN50199 EN60974-1

5/10/02 3.21 Added part numbers for cable lengths 25 ft-200 ft 3.27 Call-outs for ends of cable changed. Power supply end was 1X4, changed to 1X2. DR/PR end was 5X1, changed to 5X2. 4.6 & 4.14 Added SilverPlus information. Electrode P/N 220083 4.10, 4.13, 4.19, 4.26, 4.31-4.46 Retaining cap part number changed from 120837 to 020423. Ohmic contact does not work with 40Amp,under water, beveling or gouging processes. Sections 5 & 6 The maintenance section is now section 5 (was 6). Standard components is now the parts list, section 6. This matches our other manuals. 6.2 Updated art. Old picture lost. 6.4 Updated art. Old picture lost. 6.10 Updated art to show current chopper. Renumbered call-outs. 6.11 Renumbered items. Removed references to obsolete chopper (P/N 029320). Removed art for chopper # 129118 from bottom of page. 6.12 Updated art to show current chopper. Renumbered call-outs. 6.13 Renumbered items. Removed references to obsolete chopper (P/N 029320). Removed art for chopper # 129118 from bottom of page. 6.15 Item # 14 corrected. Was 029618 now 129618. 6.16 Part # corrected. Filter, coolant, deionizing - was 027137 now 027005. 6.17 Part # corrected. Torch main body was 020470, changed to 120584. Removed revision reference, it said revision 1 next to P/N in parentheses. 6.18 Retaining cap part number changed from 120837 to 020423. Ohmic contact does not work with 40Amp,under water, beveling or gouging processes. 6.19 Retaining cap part number 020423 and art added to cutting section. 6.20 & 6.22 Retaining cap part number changed from 120837 to 020423, For Consumable Parts Kit # 028429 (6.20) & machine torch assembly part # 128365. Section 7/Wiring diagrams 013179 drawings uprev'd from U to V. Sheet 9 of 9 is the only one that changed. Timing chart and gas system designators updated. Format change (all pages) from 8.5X11" pages to 11X17" pages folded to fit. Changed Page Description 800980 Rev 13 to 14 5/01 4.11-4.41 Electrode part# change from 120667 to 220021. Cap part 3 changed from 020423 to 120837 (art changed) 4.18, 25, 39, 43 Changed Electrode part# to 120547 (100A air/air) 5.7 Revised item 8 and 10 part numbers 5.9 Revised item 2 part number 5.13 Revised item 14 part number 5.15 Item # 14 P/N 029618 changed to 129618 5.18-5.23 Electrode part# change from 120667 to 220021. Cap part 3 changed from 020423 to 120837 (art changed) 5.26 Part # correction 50' plasma gas lead was 024194 changed to 024195 5.27 & 28 Added note about extended leads causing start problems: not recommended

7/99 Cover New Revision Title Page New Revision i Added plumbing/electrical code statement to warranty page 1.1-1.6 New safety section 1a.1-1a.6 New French safety section 3.3 Added pre-installation for plumbing/electrical codes 3.4 Added hard plumbing statement 3.5 Shifted text from page 3-4 3.6 Revised coolant mixture 3.22 Added P/N 128404, DC relay 4.13 Part number correction 4.19 Part number correction 4.20 General correction 4.21 General correction 4.26 Part number correction 4.11-4.46 Added production cutting recommendation to applicable cut charts. 5.1 General correction 5.14 & 5.15 New Coolant tank 5.21 New 120894 sleeve 5.22 Added diameter to torch sleeve 5.23 Spelling correction 6.7 Removed page number reference 7 Deleted section 7. Standards included in section 1. Diagrams Revised 013179 sheet 7 Diagrams Revised 013179 sheet 8

Cover New Revision Title Page New Revision 2.2 Revised duty cycle rating 2.3 Added 073036 & 073039 power supply 3.31 Removed P/N reference 3.33 Removed P/N reference 3.41 Revised water muffler install options 4.10-4.46 Added 120667 electrode, revised motion delay and notes 5.5 General correction 5.11 Corrected 007022 shunt rating 5.13 Corrected item 9 P/N and description 5.14&5.15 Revised coolant pump and motor listing 5.18-5.20 Added 120667 electrode 5.21-5.23 Added new machine torch and optional torches 5.24-5.28 Page number shift 6.6 Removed P/N reference b.1 Spelling correction diagrams Spelling correction Changed Page Description 800980 Rev 10 to 11 Cover New Revision Title Page New Revision 2.3 General Correction, PS P/N 5.14 Revise Figure 5-73, New Solenoid valve subassembly 5.15 New Solenoid valve subassembly Ap. B New Coolant MSDS Diagrams 013179, Added sheet 9 Changed Page Description 800980 Rev 9 to 10 Cover Uprevved manual Title Page Uprevved manual 4.9 General Correction 4.12 Added new Electrode 4.15 Added new Electrode 4.35 Added new Electrode 4.37 Added new Electrode 5.18 Added new Electrode 5.19 Added new Electrode 5.20 Revised Kit contents 5.21 Added torch assembly P/N

Cover Uprevved manual due to LVD compliance Title Page Uprevved manual due to LVD compliance 0.01 Changed reference from 220-380-415V CE to 400V CE 0.03 updated table of contents 0.04 updated table of contents 0.05 updated table of contents 0.06 updated table of contents 1.01 New Safety section 1.02 New Safety section 1.03 New Safety section 1.04 New Safety section 1a.01 New French Safety section 1a.02 New French Safety section 1a.03 New French Safety section 1a.04 New French Safety section 2.02 Changed reference from 220-380-415V CE to 400V CE 2.04 Changed reference from 220-380-415V CE to 400V CE 3.01 Changed reference from 220-380-415V to 220-380-400-415V 3.06 Changed warning on propylene glycol to not induce vomiting. 3.08 Added specs for 400V 3.10 Changed figures of transformers to show new configurations 3.11 Changed figures of transformers to show new configurations 3.12 Changed reference from 220-380-415V CE to 400V CE 3.13 Changed figure to show new designations 3.14 Changed figure to show new designations 3.15 Changed figure to show new designations 3.33 Changed figure to show new designations 4.01 Added STATUS indicators Before Startup to Sect. 4 TOC 4.02 Added new STATUS logic. Added STATUS indicators Before Startup 4.04 Added "See Status Indicators Before Startup" to step 5. 5.03 Changed part nos. of items 1 &10 5.07 Changed reference from 220-380-415V to 220-380-400-415V 5.07 Changed part nos. of items 11 &12. Added temp sw. 5.09 Changed reference from 220-380-415V to 220-380-400-415V 5.09 Changed part nos. of items 18 &20. Added temp sw. 5.11 Changed reference from 220-380-415V to 220-380-400-415V 5.11 Changed part no. of chopper. Added temp sw. 5.13 Changed reference from 220-380-415V to 220-380-400-415V 5.13 Changed part no. of chopper. Added temp sw. 5.15 New coolant reservoir part no.; added part nos. for gauge, drain valve. 5.16 Changed part nos. in Recommended Spare Parts 6.03 Changed troubleshooting (second problem) 6.04 Removed word "red" in second & third problem descriptions 6.05 Removed word "red" in first problem description d.03 Changed reference from 220-380-415V CE to 400V CE 8 sheets MAX200 wiring diagram format change 013-2-179 Rev K

for Serial Numbers beginning with 200-003654 © Copyright 2002 Hypertherm, Inc. All Rights Reserved Hypertherm and Command THC are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries Hypertherm, Inc. Hanover, NH USA www.hypertherm.com

Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) 800-643-9878 Tel (Technical Service) 800-737-2978 Tel (Customer Service) Hypertherm Automation, LLC 5 Technology Drive West Lebanon, NH 03755 USA 603-298-7970 Tel 603-298-7977 Fax Hypertherm Plasmatechnik, GmbH Technologiepark Hanau Rodenbacher Chaussee 6 63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm (S) Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 (Technical Service) Japan 1952-14 Yata-Natsumegi Mishima City, Shizuoka Pref. 411-0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax Hypertherm UK, Ltd 9 Berkeley Court, Manor Park Runcorn, Cheshire, England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax France 15 Impasse des Rosiers 95610 Eragny, France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S.r.l. Via Torino 2 20123 Milano, Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax 39 02 725 46 314 (Technical Service) Hypertherm Europe B.V. Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596908 Tel 31 165 596901 Fax Technical Service: 00 800 49 73 7843 – toll-free in Europe 31 165 596900 Tel Hypertherm Brasil Ltda. Rua Visconde de Santa Isabel, 20 – Sala 611 Vila Isabel, RJ Brasil CEP 20560-120 55 21 2278 6162 Tel 55 21 2578 0947 Fax 3/27/03

EMC INTRODUCTION Hypertherm's CE-marked equipment is built in compliance with standard EN50199. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility. The limits required by EN50199 may not be adequate to completely eliminate interfer- ence when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be neces- sary to use other measures to further reduce interference. This plasma equipment is designed for use only in an industrial environment. INSTALLATION AND USE The user is responsible for installing and using the plasma equipment according to the manufacturer's instructions. If electro- magnetic disturbances are detected then it shall be the responsibility of the user to re- solve the situation with the technical assis- tance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome. ASSESSMENT OF AREA Before installing the equipment the user shall make an assessment of potential elec- tromagnetic problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equip- ment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding 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 other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out. Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship's hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equip- ment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations. Note. The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be au- thorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC TC26 (sec)94 and IEC TC26/108A/CD Arc Welding Equipment Installation and Use. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications The size of the surrounding area to be considered will depend on the structure of the building and other activities that are tak- ing place. The surrounding area may extend beyond the boundaries of the premises. METHODS OF REDUCING EMISSIONS Mains Supply Cutting equipment must be connected to the mains supply according to the manufactur- er's recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of per- manently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connect- ed to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment must be routinely maintained according to the manufacturer's recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjust- ments covered in the manufacturer's instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer's recommendations. Cutting Cables The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level. Equipotential Bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic compo- nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components. Hypertherm Plasma Systems i

9-01 WARNING Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty. WARNING You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment. GENERAL Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of G3 Series power supplies, which shall be within a period 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 not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty. Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm. PATENT INDEMNITY Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherm’s obligation to indemnify shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim. LIMITATION OF LIABILITY In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages. LIABILITY CAP In no event shall Hypertherm’s liability, 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 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. INSURANCE At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products. NATIONAL AND LOCAL CODES National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices. TRANSFER OF RIGHTS You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.

MAX200 Instruction Manual iii 15 Electromagnetic Compatibility (EMC).......................................................................................................................i Warranty .....................................................................................................................................................................ii Section 1 SAFETY..................................................................................................................................................1-1 Recognize Safety Information...................................................................................................................................1-2 Follow Safety Instructions.........................................................................................................................................1-2 Cutting Can Cause Fire or Explosion .......................................................................................................................1-2 Electric Shock Can Kill..............................................................................................................................................1-3 Cutting Can Produce Toxic Fumes...........................................................................................................................1-3 A Plasma Arc Can Cause Injury and Burns..............................................................................................................1-4 Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4 Grounding Safety......................................................................................................................................................1-4 Compressed Gas Equipment Safety ........................................................................................................................1-5 Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5 Noise Can Damage Hearing.....................................................................................................................................1-5 Pacemaker and Hearing Aid Operation ....................................................................................................................1-5 A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5 Additional Safety Information....................................................................................................................................1-5 Warning Label...........................................................................................................................................................1-6 Section 1a SÉCURITÉ........................................................................................................................................1a-1 Identifier les consignes de sécurité.........................................................................................................................1a-2 Suivre les instructions de sécurité ..........................................................................................................................1a-2 Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2 Les chocs électriques peuvent être fatals...............................................................................................................1a-3 Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3 L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4 Mise à la masse et à la terre...................................................................................................................................1a-4 Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4 Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5 Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5 Pacemakers et prothéses auditives........................................................................................................................1a-5 Étiquette de sécurité ...............................................................................................................................................1a-6 Section 2 SPECIFICATIONS................................................................................................................................2-1 General .....................................................................................................................................................................2-2 Product Specifications ..............................................................................................................................................2-2 MAX200 Power Supplies .................................................................................................................................2-2 MAX200 CE Power Supplies ...........................................................................................................................2-3 MAX200 Machine Torch...................................................................................................................................2-4 Section 3 SETUP..................................................................................................................................................3-1 Claims and Technical Questions ..............................................................................................................................3-3 Pre-Installation..........................................................................................................................................................3-3 Air and Gas Supply Requirements ...........................................................................................................................3-4 Air Supply.........................................................................................................................................................3-4

iv MAX200 Instruction Manual 15 Adjusting the Filter/Pressure Regulator ...........................................................................................................3-5 Additional Air Filtration .....................................................................................................................................3-5 Gas Supply.......................................................................................................................................................3-5 Torch Coolant Requirements....................................................................................................................................3-6 Filling the System.............................................................................................................................................3-7 Power Supply Placement..........................................................................................................................................3-7 Routing the Torch Lead ............................................................................................................................................3-7 Power Requirements ................................................................................................................................................3-8 Line Disconnect Switch....................................................................................................................................3-8 Power Cables...................................................................................................................................................3-8 240/480V Linkboard Configurations.................................................................................................................3-9 220/380/400/415V Transformer T1 and T2 Configurations............................................................................3-10 Power, Gas, and Torch Lead Connections.............................................................................................................3-12 Connect the Power Cable ..............................................................................................................................3-12 Connect the Air and Gas Hoses.....................................................................................................................3-13 Connect the Torch Lead.................................................................................................................................3-16 Connect the Work Cable................................................................................................................................3-16 Grounding ...............................................................................................................................................................3-16 Work Table.....................................................................................................................................................3-16 Work Clamp ...................................................................................................................................................3-16 Machine Torch System Installations ..............................................................................................................3-19 Install the MAX200 without THC Option.........................................................................................................3-19 Install the MAX200 with THC Option..............................................................................................................3-23 Install the MAX200 with IHS Option...............................................................................................................3-31 Adjust the Torch Position ...............................................................................................................................3-40 Install the Water Muffler Option......................................................................................................................3-41 Section 4 OPERATION ........................................................................................................................................4-1 Front Panel Controls.................................................................................................................................................4-2 Power ..............................................................................................................................................................4-2 Status...............................................................................................................................................................4-2 Status Indicators Before Startup ......................................................................................................................4-2 Gas...................................................................................................................................................................4-3 Pre-operation ............................................................................................................................................................4-4 Operation ..................................................................................................................................................................4-4 Operating Tips ..........................................................................................................................................................4-5 Changing Consumable Parts ...........................................................................................................................4-5 Cutting Techniques ..........................................................................................................................................4-7 Torch Alignment...........................................................................................................................................4-7 Cutting..........................................................................................................................................................4-8 Piercing ........................................................................................................................................................4-8 Common Cutting Faults ...............................................................................................................................4-9 Duty Cycle....................................................................................................................................................4-9 Claims and Technical Questions ..............................................................................................................................4-9

MAX200 Instruction Manual v 15 Cut Charts...............................................................................................................................................................4-10 Section 5 MAINTENANCE ...................................................................................................................................5-1 Routine Maintenance................................................................................................................................................5-2 Troubleshooting ........................................................................................................................................................5-2 Removal and Replacement of Torch ........................................................................................................................5-6 Removal and Replacement of Torch Lead ...............................................................................................................5-7 Removal and Replacement of Individual Torch Leads .............................................................................................5-7 Section 6 PARTS LIST.........................................................................................................................................6-1 MAX200 Power Supply.............................................................................................................................................6-2 Illustrations/Parts Lists .....................................................................................................................................6-2 Recommended Spare Parts...........................................................................................................................6-16 MAX200 Consumables,Torch Assembly and Torch Leads ....................................................................................6-18 MAX200 Machine Torch Consumables..........................................................................................................6-18 Consumable Configurations ...................................................................................................................................6-19 Consumable Parts Kits ...........................................................................................................................................6-20 MAX200 Machine Torch Assembly ..............................................................................................................6-21 Machine Torch Lead Assemblies ..................................................................................................................6-24 Section 7 WIRING DIAGRAMS............................................................................................................................7-1 MAX200 Electrical Schematic & Block Diagram (013-2-179) ..........................................................................9 Sheets Coolant System Schematic/Diagram (029-2-313) .............................................................................................1 Sheet Appendix A FILTERS...........................................................................................................................................a-1 Appendix B PROPYLENE GLYCOL SAFETY DATA .........................................................................................b-2 BENZOTRIAZOLE SAFETY DATA .................................................................................................b-7 Appendix C AERATION MANIFOLD ...................................................................................................................c-1 Appendix D ELECTROMAGNETIC COMPATIBILITY (EMC) .............................................................................d-1 General .....................................................................................................................................................................d-2 Power Cable .............................................................................................................................................................d-2 Connect Power Cable...............................................................................................................................................d-2 Power Supply...................................................................................................................................................d-2 Line Disconnect Switch....................................................................................................................................d-4 EMI Filter Parts List ..................................................................................................................................................d-5

1-1 Section 1 SAFETY In this section: Recognize Safety Information...................................................................................................................................1-2 Follow Safety Instructions.........................................................................................................................................1-2 Cutting Can Cause Fire or Explosion .......................................................................................................................1-2 Electric Shock Can Kill..............................................................................................................................................1-3 Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3 A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4 Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4 Grounding Safety......................................................................................................................................................1-4 Compressed Gas Equipment Safety ........................................................................................................................1-5 Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5 Noise Can Damage Hearing.....................................................................................................................................1-5 Pacemaker and Hearing Aid Operation ....................................................................................................................1-5 A Plasma Arc Can Damage Frozen Pipes ................................................................................................................1-5 Additional Safety Information....................................................................................................................................1-5 Warning Label...........................................................................................................................................................1-6

11-98 SAFETY RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard. FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety labels on your machine. • Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately. • Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction. • Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life. DANGER WARNING CAUTION A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards. • DANGER and WARNING safety labels are located on your machine near specific hazards. • WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly. • CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly. Fire Prevention • Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby. • Remove all flammables within 35 feet (10 m) of the cutting area. • Quench hot metal or allow it to cool before handling or before letting it touch combustible materials. • Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first. • Ventilate potentially flammable atmospheres before cutting. • When cutting with oxygen as the plasma gas, an exhaust ventilation system is required. Explosion Prevention • Do not use the plasma system if explosive dust or vapors may be present. • Do not cut pressurized cylinders, pipes, or any closed container. • Do not cut containers that have held combustible materials. CUTTING CAN CAUSE FIRE OR EXPLOSION WARNING Explosion Hazard Argon-Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma. WARNING Hydrogen Detonation with Aluminum Cutting • When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations. • Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Refer to the Appendix section of this manual for aeration manifold details.

or severe burn. • Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit. • Never touch the torch body, workpiece or the water in a water table when the plasma system is operating. Electric Shock Prevention All Hypertherm plasma systems use high voltage in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system: • Wear insulated gloves and boots, and keep your body and clothing dry. • Do not stand, sit or lie on – or touch – any wet surface when using the plasma system. • Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution. • Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation. • When using a water table, be sure that it is correctly connected to earth ground. ELECTRIC SHOCK CAN KILL • Install and ground this equipment according to the instruction manual and in accordance with national and local codes. • Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill. • Inspect and replace any worn or damaged torch leads. • Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process. • Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply. • Never bypass or shortcut the safety interlocks. • Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge. • Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard. • When making input connections, attach proper grounding conductor first. • Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard. Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death. • Keep the cutting area well ventilated or use an approved air-supplied respirator. • Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation. • Do not cut metal coated or containing toxic materi- als, such as zinc (galvanized), lead, cadmium or CUTTING CAN PRODUCE TOXIC FUMES beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut. • Never cut containers with potentially toxic materials inside – they must be emptied and properly cleaned first. • This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. Hypertherm Plasma Systems 1-3 8-99 SAFETY

5/6/02 SAFETY Instant-On Torches Plasma arc comes on immediately when the torch switch is activated. A PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc will cut quickly through gloves and skin. • Keep away from the torch tip. • Do not hold metal near the cutting path. • Never point the torch toward yourself or others. Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. • Use eye protection in accordance with applicable national or local codes. • Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays. Lens Shade Arc Current AWS (USA) ISO 4850 Up to 100 A No. 8 No. 11 100-200 A No. 10 No. 11-12 200-400 A No. 12 No. 13 Over 400 A No. 14 No. 14 ARC RAYS CAN BURN EYES AND SKIN Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks and hot metal. • Gauntlet gloves, safety shoes and hat. • Flame-retardant clothing to cover all exposed areas. • Cuffless trousers to prevent entry of sparks and slag. • Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting. Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light: • Paint walls and other surfaces with dark colors to reduce reflection. • Use protective screens or barriers to protect others from flash and glare. • Warn others not to watch the arc. Use placards or signs. Work Cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete. Work Table Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes. GROUNDING SAFETY Input Power • Be sure to connect the power cord ground wire to the ground in the disconnect box. • If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly. • Place the power cord's ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly. • Tighten all electrical connections to avoid excessive heating.

1-5 11-98 SAFETY • Never lubricate cylinder valves or regulators with oil or grease. • Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application. • Maintain all compressed gas equipment and associated parts in good condition. • Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national or local codes. GAS CYLINDERS CAN EXPLODE IF DAMAGED COMPRESSED GAS EQUIPMENT SAFETY Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. • Handle and use compressed gas cylinders in accordance with applicable national or local codes. • Never use a cylinder that is not upright and secured in place. • Keep the protective cap in place over valve except when the cylinder is in use or connected for use. • Never allow electrical contact between the plasma arc and a cylinder. • Never expose cylinders to excessive heat, sparks, slag or open flame. • Never use a hammer, wrench or other tool to open a stuck cylinder valve. Prolonged exposure to noise from cutting or gouging can damage hearing. • Use approved ear protection when using plasma system. • Warn others nearby about the noise hazard. NOISE CAN DAMAGE HEARING Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations. To reduce magnetic field hazards: • Keep both the work cable and the torch lead to one side, away from your body. • Route the torch leads as close as possible to the work cable. • Do not wrap or drape the torch lead or work cable around your body. • Keep as far away from the power supply as possible. PACEMAKER AND HEARING AID OPERATION ADDITIONAL SAFETY INFORMATION 1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135 2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 1430 Broadway, New York, NY 10018 3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 1430 Broadway, New York, NY 10018 4. AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202 7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada 8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210 9. NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210 10. OSHA, Safety and Health Standards, 29FR 1910 U.S. Government Printing Office, Washington, D.C. 20402 A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

8-99 SAFETY WARNING LABEL This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label. 1. Cutting sparks can cause explosion or fire. 1.1 Keep flammables away from cutting. 1.2 Keep a fire extinguisher nearby, and have a watchperson ready to use it. 1.3 Do not cut on any closed containers. 2. The plasma arc can cause injury and burns. 2.1 Turn off power before disassembling torch. 2.2 Do not hold the material near cutting path. 2.3 Wear complete body protection. 3. Electric shock from torch or wiring can kill. Protect yourself from electric shock. 3.1 Wear insulating gloves. Do not wear wet or damaged gloves. 3.2 Insulate yourself from work and ground. 3.3 Disconnect input plug or power before working on machine. 4. Breathing cutting fumes can be hazardous to your health. 4.1 Keep your head out of the fumes. 4.2 Use forced ventilation or local exhaust to remove the fumes. 4.3 Use ventilating fan to remove the fumes. 5. Arc rays can burn eyes and injure skin. 5.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 6. Become trained and read the instructions before working on the machine or cutting. 7. Do not remove or paint over (cover) warning labels.

1a-1 2/12/01 Section 1a SÉCURITÉ Dans cette section : Identifier les consignes de sécurité.........................................................................................................................1a-2 Suivre les instructions de sécurité ..........................................................................................................................1a-2 Danger Avertissement Précaution ........................................................................................................................1a-2 Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2 Prévention des incendies, Prévention des explosions...................................................................................1a-2 Risque d’explosion argon-hydrogène et méthane..........................................................................................1a-2 Détonation de l’hydrogène lors du coupage de l’aluminium...........................................................................1a-2 Les chocs électriques peuvent être fatals...............................................................................................................1a-3 Prévention des chocs électriques ..................................................................................................................1a-3 Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3 L’arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4 Torches à allumage instantané ......................................................................................................................1a-4 Les rayons de l’arc peuvent brûler les yeux et la peau...........................................................................................1a-4 Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4 Mise à la masse et à la terre...................................................................................................................................1a-4 Câble de retour, Table de travail, Alimentation...............................................................................................1a-4 Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5 Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5 Pacemakers et prothèses auditives........................................................................................................................1a-5 Un arc plasma peut endommager les tuyaux gelés................................................................................................1a-5 Étiquette de sécurité ...............................................................................................................................................1a-6

2/12/01 IDENTIFIER LES CONSIGNES DE SÉCURITÉ Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels. Si vous trouvez un symbole de sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques. SUIVRE LES INSTRUCTIONS DE SÉCURITÉ Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine. • Les étiquettes de sécurité doivent rester lisibles. Remplacer immédiatement les étiquettes manquantes ou abîmées. • Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. Ne laisser personne utiliser la machine sans connaître son fonctionnement. • Garder la machine en bon état. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement. DANGER AVERTISSEMENT PRÉCAUTION Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux. • Les étiquettes de sécurité DANGER et AVERTISSEMENT sont situées sur la machine pour signaler certains dangers spécifiques. • Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement. • Les messages de PRÉCAUTION précèdent les instructions d’utilisation contenues dans ce manuel et signalent que le matériel risque d’être endommagé si les instructions ne sont pas suivies correctement. Prévention des incendies • Avant de commencer, s’assurer que la zone de coupage ne présente aucun danger. Conserver un extincteur à proximité. • Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage. • Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles. • Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement. • Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma. • Lors de l’utilisation d’oxygène comme gaz plasma, un système de ventilation par aspiration est nécessaire. Prévention des explosions • Ne pas couper en présence de poussière ou de vapeurs. • Ne pas couper de bouteilles, de tuyaux ou autres récipients fermés et pressurisés. • Ne pas couper de récipients contenant des matières combustibles. LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT Risque d’explosion argon-hydrogène et méthane L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane. AVERTISSEMENT Détonation de l’hydrogène lors du coupage de l’aluminium • Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche la partie inférieure de la pièce d’aluminium, de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma. • Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération.

1a-3 2/12/01 Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves. • La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique. • Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma. Prévention des chocs électriques Tous les systèmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 à 400 V). On doit prendre les précautions suivantes quand on utilise le système plasma : • Porter des bottes et des gants isolants et garder le corps et les vêtements au sec. • Ne pas se tenir, s’asseoir ou se coucher sur une surface mouillée, ni la toucher quand on utilise le système plasma. • S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide, procéder avec une extrême prudence. • Installer un sectionneur avec fusibles appropriés, à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence. • En cas d’utilisation d’une table à eau, s’assurer que cette dernière est correctement mise à la terre. LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS • Installer et mettre à la terre l’équipement selon les instructions du présent manuel et conformément aux codes électriques locaux et nationaux. • Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer. • Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés. • Ne pas saisir la pièce à couper ni les chutes lors du coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage. • Avant de vérifier, de nettoyer ou de remplacer les pièces de la torche, couper l’alimentation ou débrancher la prise de courant. • Ne jamais contourner ou court-circuiter les verrouillages de sécurité. • Avant d’enlever le capot du système ou de la source de courant, couper l’alimentation électrique. Attendre ensuite 5 minutes pour que les condensateurs se déchargent. • Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux. • Lors de l’installation des connexions, attacher tout d’abord la prise de terre appropriée. • Chaque système plasma Hypertherm est conçu pour être utilisé uniquement avec des torches Hypertherm spécifiques. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité. Le coupage peut produire des vapeurs et des gaz toxiques qui réduisent le niveau d’oxygène dans l’air et peuvent provoquer des blessures, voire la mort. • Conserver le poste de coupage bien aéré ou utiliser un masque respiratoire homologué. • Ne pas procéder au coupage près d’endroits où s’effectuent le dégraissage, le nettoyage ou la vapori- sation. Certains solvants chlorés se décomposent sous l’effet des rayons ultraviolets et forment du phosgène. • Ne pas couper des métaux peints ou contenant des matières toxiques comme le zinc (galvanisé), le plomb, le cadmium ou le béryllium, à moins que la zone de travail LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES soit très bien ventilée et que l’opérateur porte un masque respiratoire. Les revêtements et métaux contenant ces matières peuvent produire des vapeurs toxiques lors du coupage. • Ne jamais couper de récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement. • Quand on utilise ce produit pour le soudage ou le coupage, il dégage des fumées et des gaz qui contiennent des produits chimiques qui, selon l’État de Californie, provoquent des anomalies congénitales et, dans certains cas, le cancer.

5/6/02 Torches à allumage instantané L’arc plasma s’allume immédiatement après que la torche soit mise en marche. L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES L’arc plasma coupe facilement les gants et la peau. • Rester éloigné de l’extrémité de la torche. • Ne pas tenir de métal près de la trajectoire de coupe. • Ne jamais pointer la torche vers soi ou d’autres personnes. Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau. • Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur. • Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc. Puissance des verres teintés Courant de l’arc AWS (É.-U.) ISO 4850 Jusqu’à 100 A No 8 No 11 100-200 A No 10 No 11-12 200-400 A No 12 No 13 Plus de 400 A No 14 No 14 Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets, les étincelles et le métal brûlant : LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU • Gants à crispin, chaussures et casque de sécurité. • Vêtements ignifuges couvrant toutes les parties exposées du corps. • Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger. • Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes. Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette : • Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière. • Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération. • Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux. Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher. Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés. MISE À LA MASSE ET À LA TERRE Alimentation • S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur. • S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système, s’assurer que le fil de terre est correctement branché. • Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. Bien serrer l’écrou de retenue. • S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe.

1a-5 2/12/01 • Ne jamais lubrifier les robinets des bouteilles ou les régulateurs avec de l’huile ou de la graisse. • Utiliser uniquement les bouteilles, régulateurs, tuyaux et accessoires appropriés et conçus pour chaque application spécifique. • Entretenir l’équipement et les pièces d’équipement à gaz comprimé afin de les garder en bon état. • Étiqueter et coder avec des couleurs tous les tuyaux de gaz afin d’identifier le type de gaz contenu dans chaque tuyau. Se référer aux codes locaux ou nationaux en vigueur. LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ Les bouteilles de gaz contiennent du gaz à haute pression. Si une bouteille est endommagée, elle peut exploser. • Manipuler et utiliser les bouteilles de gaz comprimé conformément aux codes locaux ou nationaux. • Ne jamais utiliser une bouteille qui n’est pas placée à la verticale et bien assujettie. • Le capuchon de protection doit être placé sur le robinet sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation. • Éviter à tout prix le contact électrique entre l’arc plasma et une bouteille. • Ne jamais exposer des bouteilles à une chaleur excessive, aux étincelles, aux scories ou aux flammes nues. • Ne jamais utiliser des marteaux, des clés ou d’autres outils pour débloquer le robinet des bouteilles. Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs. • Utiliser un casque de protection homologué lors de l’utilisation du système plasma. • Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit. LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma. Pour réduire les risques associés aux champs magnétiques : • Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche. • Faire passer le faisceau de la torche le plus près possible du câble de retour. • Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. • Se tenir le plus loin possible de la source de courant. PACEMAKERS ET PROTHÈSES AUDITIVES Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS

2/12/01 Étiquette de sécurité Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images. 1. Les étincelles produites par le coupage peuvent provoquer une explosion ou un incendie. 1.1 Pendant le coupage, éloigner toute matière inflammable. 1.2 Conserver un extincteur à proximité et s’assurer qu’une personne soit prête à l’utiliser. 1.3 Ne jamais couper de récipients fermés. 2. L’arc plasma peut provoquer des blessures et des brûlures. 2.1 Couper l’alimentation avant de démonter la torche. 2.2 Ne pas tenir la surface à couper près de la trajectoire de coupe. 2.3 Porter des vêtements de protection couvrant tout le corps. 3. Un choc électrique causé par la torche ou les câbles peut être fatal. Se protéger contre les risques de chocs électriques. 3.1 Porter des gants isolants. Ne pas porter de gants mouillés ou abîmés. 3.2 S’isoler de la surface de travail et du sol. 3.3 Débrancher la prise ou la source de courant avant de manipuler l’équipement. 4. L’inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé. 4.1 Garder le visage à l’écart des vapeurs. 4.2 Utiliser un système de ventilation par aspiration ou d’échappement localisé pour dissiper les vapeurs. 4.3 Utiliser un ventilateur pour dissiper les vapeurs. 5. Les rayons de l’arc peuvent brûler les yeux et provoquer des lésions de la peau. 5.1 Porter un casque et des lunettes de sécurité. Se protéger les oreilles et porter une chemise dont le col peut être déboutonné. Porter un casque de soudure dont la protection filtrante est suffisante. Porter des vêtements protecteurs couvrant la totalité du corps. 6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité.

2-1 14 Section 2 SPECIFICATIONS In this section: General .....................................................................................................................................................................2-2 Product Specifications ..............................................................................................................................................2-2 MAX200 Power Supplies .................................................................................................................................2-2 MAX200 CE Power Supplies ...........................................................................................................................2-3 MAX200 Machine Torch ...................................................................................................................................2-4

14 SPECIFICATIONS General MAX200s are normally shipped from the factory (configured for mild steel cutting) with air supplied to both the plasma and shield gas inlets from a single pressure/filter regulator. The regulator ensures that the correct air pressure is supplied to the system at the proper quality. For better cut quality on metals such as stainless steel, aluminum, and other non-ferrous materials, either nitrogen or argon/hydrogen (Hypertherm recommends a mixture of 35% hydrogen and 65% argon) can be used as the plasma gas. When cutting mild steel, oxygen can also be used as the plasma gas. Shield gases other than air which can be used are nitrogen and carbon dioxide. An EMI filter, standard with all 400V CE power supplies (073200 and 073213) meets the CE requirement for filtering incoming power. Refer to Appendix D to connect incoming power to the filter and for part numbers specific to the CE power supplies. Product Specifications MAX200 Power Supplies The MAX200 is a constant current, secondary converter chopper power supply providing continuously variable amperage from 40 amps to 200 amps. It conforms to the following specifications: Maximum OCV.....................................................280 VDC Output Current .....................................................40-200 amps Output Voltage .....................................................150 VDC Duty Cycle Rating ................................................100% up to 30 kw Input Power: # 073002*.............................................................240/480 VAC, 3Ø, 60 Hz, 90/45 amps # 073020** # 073003*.............................................................600 VAC, 3Ø, 60Hz, 36 amps # 073021** # 073004*.............................................................208 VAC, 3Ø, 60Hz, 104 amps # 073022** # 073005*.............................................................220/380/415 VAC, 3Ø, 50 Hz, # 073023** ...........................................................98/57/52 amps # 073026*.............................................................200 VAC, 3Ø, 50 Hz, 108 amps # 073024** # 073036*.............................................................500 VAC, 3Ø, 50 Hz, 43 amps # 073039**

2-3 14 SPECIFICATIONS Dimensions: Width ....................................................................28-1/4" (71 cm) Height...................................................................35-1/2" (90 cm) w/o casters 43" (109 cm) w/casters Depth....................................................................41-1/4" (104 cm) w/o handle 50" (127 cm) w/handle Weight ..................................................................780 pounds Cooling................................................................Forced Air (Class F) ** MAX200 Power Supply – Machine Torch w/o THC Configuration ** MAX200 Power Supply – Machine Torch w/THC Configuration Gas Requirements: Gas Type/Quality..................................................Air (compressed)/clean, dry, oil-free Oxygen (liquid)/99.5% Nitrogen (liquid)/99.995% Carbon Dioxide (compressed or liquid)/ 99.5% Plasma Gases......................................................Air, Oxygen (O2), Nitrogen (N2), Argon/Hydrogen (H35 = 35% Hydrogen/65% Argon) Shield Gases........................................................Air, Carbon Dioxide (CO2 ), Nitrogen (N2) Plasma Gas Flow .................................................66 scfh (Air), 60 scfh (N2), 70 scfh (H35), 72 scfh (O2) Shield Gas Flow ...................................................220 scfh (CO2), 280 scfh (Air), 290 scfh (N2) Plasma Gas Inlet Pressure ..................................90/120 psi dynamic (flowing) Shield Gas Inlet Pressure ....................................90 psi dynamic (flowing) Plasma Gas Pressure (Test/Run).........................13/48, 22/48 psi (Air); 13/44, 15/48 psi (O2); 15/35, 17/37 psi (N2); 23/56 psi (H35) Shield Gas Pressure ............................................70 psi Torch Coolant Tank Capacity............................2.9 gallons (11 liters); refer to Section 3, Torch Coolant System, for coolant specifications, warning, and cautions CE Power Supplies The specifications specific to the 400V CE, 3 Ph, 50 Hz power supplies (073200 and 073213) are listed below. These CE power supplies conform to all other non CE power suppy specifictions as listed above. Refer to Appendix D for EMC requirements, power cable connections, and parts information specific to the MAX200 CE power supplies. Input Power (Input Voltage (U1) x Input Current (I1)): # 073200 (without THC) .......................................400 VAC, 3Ø, 50 Hz, 56 amps # 073213 (with THC) ............................................400 VAC, 3Ø, 50 Hz, 56 amps Dimensions: Height...................................................................40-3/4" (104 cm) w/o casters 48-1/4" (122 cm) w/casters Weight ..................................................................800 pounds (363 kg)

14 SPECIFICATIONS MAX200 Machine Torch The MAX200 machine torch conforms to the following specifications: Maximum cutting thickness ..................................2 inches Maximum current at 100% duty cycle ..................200 amps Plasma Gas Flow .................................................66 scfh (Air), 60 scfh (N2), 70 scfh (H35), 72 scfh (O2) Shield Gas Flow ...................................................220 scfh (CO2), 280 scfh (Air), 290 scfh (N2) Water Coolant Flow Rate .....................................0.8 gpm Weight ..................................................................2-1/2 lbs. (1.13 kg)

3-1 15 Section 3 SETUP In this section: Upon Receipt ............................................................................................................................................................3-2 Claims and Technical Questions...............................................................................................................................3-3 Pre-Installation..........................................................................................................................................................3-3 Air and Gas Supply Requirements ...........................................................................................................................3-4 Air Supply.........................................................................................................................................................3-4 Adjusting the Filter/Pressure Regulator ...........................................................................................................3-5 Additional Air Filtration .....................................................................................................................................3-5 Gas Supply.......................................................................................................................................................3-5 Torch Coolant Requirements ....................................................................................................................................3-6 Filling the System.............................................................................................................................................3-7 Power Supply Placement..........................................................................................................................................3-7 Routing the Torch Lead.............................................................................................................................................3-7 Power Requirements ................................................................................................................................................3-8 Line Disconnect Switch....................................................................................................................................3-8 Power Cables...................................................................................................................................................3-8 240/480V Linkboard Configurations.................................................................................................................3-9 220/380/400/415V Transformer T1 and T2 Configurations............................................................................3-10 Power, Gas, and Torch Lead Connections..............................................................................................................3-12 Connect the Power Cable ..............................................................................................................................3-12 Connect the Air and Gas Hoses.....................................................................................................................3-13 Connect the Torch Lead .................................................................................................................................3-16 Connect the Work Cable ................................................................................................................................3-16 Grounding ...............................................................................................................................................................3-16 Work Table .....................................................................................................................................................3-16 Work Clamp ...................................................................................................................................................3-16 Machine Torch System Installations...............................................................................................................3-19 Install the MAX200 without THC Option.........................................................................................................3-19 Install the MAX200 with THC Option..............................................................................................................3-23 Install the MAX200 with IHS Option...............................................................................................................3-31 Adjust the Torch Position................................................................................................................................3-40 Install the Water Muffler Option......................................................................................................................3-41

14 SETUP Upon Receipt The MAX200 power supply is shipped mounted to a skid and protected by a heavy carton cover. Before unpacking the unit, inspect the carton for evidence of damage during shipment. 1. Remove all packing material and discard and remove the power supply from the shipping skid. 2. Verify that the MAX200 torch standard system configuration items and parts listed below are included. Also, ensure all the required options are included. Alert your distributor if any of the items or parts are missing. All communications regarding this equipment must include the model number and serial number (located on the back of the MAX200). See the Claims and Technical Questions in this section for details. MAX200 System – Machine Torch Configuration • MAX200 Power Supply • MAX200 machine torch and torch lead assembly • 25-foot work cable (ground) with clamp • Consumable spare parts kit • Torch coolant – four gallons • Instruction manual 800980 Options: • Torch Height Control (THC) • Remote Module – Switch Remote (SR) – Digital Remote (DR) – Program Remote (PR) • Initial Height Sensor (IHS) • Remote Start/Stop Switch • Water Muffler (refer to manual IM-97)

3-3 14 SETUP Claims and Technical Questions Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. Claims for defective merchandise – All units shipped from Hypertherm undergo rigorous quality control testing. However, if your unit does not function correctly: 1. Read the Troubleshooting section of this manual. You may find the problem is quite easy to fix, such a loose connection. 2. If you are unable to solve the problem, call your distributor. He will be able to help you, or refer you to an authorized Hypertherm repair facility. 3. If you need additional assistance, call Technical Service listed in the front of this manual or your authorized Hypertherm distributor. Pre-Installation Installation and service of the electrical and plumbing systems must conform to national or local electrical and plumbing codes. Have this work performed only by qualified, licensed personnel.

14 SETUP Air and Gas Supply Requirements If making hard plumbing connections, avoid using iron pipe. Never use teflon tape on any joint preparation. After installation, pressurize the entire system and check for leaks. Air Supply Two different sources of air can be used to supply the plasma and shield gas requirements of the MAX200: cylinder compressed air or shop compressed air. Use an inert gas hose to connect the air supply to the input connection on the filter/pressure regulator mounted on the rear of the power supply. Cylinder Compressed Air The cylinder air supply must be clean, dry and oil-free. A high-pressure regulator on the cylinder must be used and must be capable of delivering air at a pressure of between 110 and 130 psi to the filter/pressure regulator on the power supply. The filter/pressure regulator must be set for a 90 psi input to the power supply (refer to the procedure below). Refer to Section 4, Cut Charts for detailed information. Shop Compressed Air The shop air supply must be clean, dry and oil-free. Shop air must capable of delivering air at a pressure of between 110 and 130 psi to the filter/pressure regulator on the power supply. The filter/pressure regulator must be set for a 90 psi input to the power supply (refer to the procedure below). Refer to Section 4, Cut Charts for detailed information. WARNING Do not exceed 150 psi to the filter/pressure regulator when using cylinder compressed air or shop compressed air. The plastic filter bowl may explode if this pressure is exceeded, causing serious injury. See the warning label on the filter bowl for other safety warnings.

3-5 14 SETUP Adjusting the Filter/Pressure Regulator To adjust the filter/pressure regulator for the required air pressure (90 psi) to the power supply: 1. Turn the Lock Knob, which secures the Adjusting Knob, counter clockwise (ccw). 2. Set the Adjusting Knob until the pressure gauge indicates 90 psi. 3. Turn the Lock Knob clockwise (cw) to secure the Adjusting Knob. Additional Air Filtration When site conditions introduce moisture, oil, or other contaminants into the air line, additional filtration is required. Refer to Appendix A for filtration components and mounting sequence. Gas Supply Use inert gas hoses to connect the plasma and shield gas supplies to the gas input connectors on the rear of the power supply. Plasma Gas To use liquid nitrogen, liquid oxygen, or argon/hydrogen as the plasma gas, it must be supplied to the MAX200 at these purities: nitrogen, 99.995% and oxygen, 99.5%. The gas supply source can be compressed gas cylinders or liquid containers. It must be capable of delivering the required gas at a delivery pressure of 120 psi to the power supply. Refer to Section 4, Cut Charts for detailed information. Note: If the purity level of the gas is too low or if there are leaks in the supply hoses or connections: • Cut speeds can decrease • Cut quality can deteriorate • Cutting thickness capability can decrease • Parts life can shorten Shield Gas To use liquid nitrogen or carbon dioxide (compressed or liquid) as the shield gas, it must be supplied to the MAX200 at these purities: nitrogen, 99.995% and carbon dioxide, 99.5%. The gas supply source can be compressed gas cylinders or liquid containers. It must be capable of delivering the required gas at a delivery pressure of 90 psi to the power supply. Refer to Section 4, Cut Charts for detailed information.

14 SETUP Torch Coolant Requirements The power supply is shipped without any coolant in the tank. A standard mixture of propylene glycol (30%), deionized water (69.9%) and 0.1% benzotriazole is recommended. This mixture resists freezing to +10° F (-12° C) and contains a corrosion inhibitor (benzotriazole) to protect copper surfaces in the coolant loop. This mixture is available in one-gallon containers by ordering 028872. 100% propylene glycol is available by ordering 028873. For operating temperatures colder than the temperature stated above, the percentage of propylene glycol must be increased. Refer to graph below. Failure to do so could result in a cracked torch head, hoses, or other damage to the torch coolant system due to the coolant freezing. Observe the warning and cautions below. Refer to the Material Safety Data Sheets in Appendix B for data on safety, handling, and storage of propylene glycol and benzotriazole. WARNING Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed. Upon contact, flush skin or eyes with water. If swallowed, drink water and call a physician immediately. Do not induce vomiting. Caution: Always use propylene glycol in the coolant mixture. Do not use anti-freeze in place of propylene glycol. Anti-freeze contains corrosion inhibitors that will damage the torch coolant system. Always use purified water in the coolant mixture in order to prevent corrosion in the torch coolant system. The hardness of purified water should be between .206 and 8.5 ppm. If using a conductivity meter to measure water purity, the recommended level is between .5 and 18 µSiemens/cm at 77° F (25° C). -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 0 10 20 30 40 50 60 32 °F (0 °C) 10 °F (-12 °C) (mixture resists freezing to this temperature) Propylene Glycol (%) Temperature ° F

3-7 14 SETUP Caution: Do not route the torch lead with the torch connected. Damage to the torch could result from dropping, banging, or scraping. Filling the System To fill the torch coolant tank prior to initial startup: 1. Ensure the torch lead is connected. Refer to Connect the Torch Lead in this section. Note: Always add coolant with the MAX200 system off. 2. Fill the tank with coolant until the level reaches the bottom of the neck, approximately 2.9 gallons (11liters). Power Supply Placement Prior to positioning the power supply, route the torch lead to the cutting machine. Once the torch lead has been routed to the cutting machine, the power supply can be positioned, so that the torch lead and other system interconnecting cables can be connected. This also allows the line disconnect switch box to be placed close to the power supply for safety purposes. Placement of the power supply should also include the following criteria: • Place the power supply in an area that is free of excessive moisture, has proper ventilation, and is relatively clean. • Place the power supply so that air flow is not blocked in any way. (Cooling air is drawn in through the front panel grating, and is exhausted through the rear of the unit by a cooling fan.) • Do not place any filter device over the air intake locations. This reduces cooling efficiency and VOIDS THE WARRANTY. Routing the Torch Lead When routing the torch lead to the cutting machine, you will generally need to route the torch lead through a festoon or a power track. Before routing the lead using either method, remove the torch from the torch lead. Once the torch lead has been routed, replace the torch; it is now ready to be mounted to the torch mounting bracket. Refer to the Maintenance section for the torch removal and replacement procedures.

14 SETUP Power Requirements A separate line disconnect switch should be provided for each MAX200 power supply. The disconnect box should be sized to the following requirements: Rated Input Input Current @ Recommended Voltage Phase 30 kw Output Fuse Size 200 VAC 3 108 amps 150 amps 208 VAC 3 104 amps 150 amps 220 VAC 3 98 amps 150 amps 380 VAC 3 57 amps 80 amps 400 VAC 3 56 amps 80 amps 415 VAC 3 52 amps 70 amps 480 VAC 3 45 amps 60 amps 600 VAC 3 36 amps 50 amps Line Disconnect Switch • Use a primary line disconnect switch for each power supply. This disconnect switch allows you to turn the power supply off quickly in an emergency situation. The switch should be located on a wall near the power supply, and should be easily accessible to the operator. The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses. Refer to Power Requirements listed above. Power Cables • Use AWG wire sizes as outlined by applicable local electrical codes. Wire sizes vary based on the distance of the receptacle from the main box. • Use a 4-conductor Type SO input power cable with a conductor temperature rating of 60°C (140°F) according to the following requirements: Input Voltage Cable Size Current Rating 200 VAC 1/4 107 amps 208 VAC 1/4 107 amps 220 VAC 1/4 107 amps 380 VAC 4/4 69 amps 400 VAC 4/4 69 amps 415 VAC 4/4 69 amps 480 VAC 6/4 52 amps 600 VAC 8/4 39 amp

3-9 14 SETUP 240/480V Linkboard Configurations • The 240/480-volt unit (# 073002 and # 073020) is shipped from the factory linked for 480-volt operation. The links must be moved for 240-volt operation. Ensure that the linkboard is configured properly to the appropriate voltage line (see Figure 3-1). WARNING Danger: High Voltage. Line voltage may be present on this linkboard. Disconnect input power before servicing. Figure 3-1 Dual Voltage 240/480-Volt Linkboard Configurations 240-Volt Configuration 480-Volt Configuration

14 SETUP 220/380/400/415V Transformer T1 and T2 Configurations • The 220/380/400/415-volt, 3Ø, 50 Hz power supply is normally shipped from the factory set up for 380-volt operation, unless otherwise specified. To change the power supply to a different voltage, control transformer T1 and 30 kw transformer T2 must be reconfigured (see Figure 3-2) WARNING Danger: High Voltage. Line voltage is present in the power supply unless disconnected. Always disconnect input power at the line disconnect switch before servicing. T2 T1 220 380 T1 T2 * A long # 6 wire is shipped with every unit. Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations (1 of 2)

3-11 14 SETUP 400 T1 T2 415 T2 T1 Figure 3-2 220/380/400/415V Transformer T1 and T2 Configurations (2 of 2)

14 SETUP Power, Gas, and Torch Lead Connections Connect the Power Cable To connect the power cable to the 400V CE power supplies (073200 and 073213), refer to Appendix D. For other power supply voltages use the procedure below. To connect the power cable to the MAX200, proceed as follows (see Figure 3-3): 1. Insert the power cable through the strain relief at the rear of the MAX200. Connect the power cable leads to TB1 located at the rear center panel of the right side. 2. Connect the power leads to the L1, L2, and L3 terminals of TB1. 3. Connect the ground lead to the yellow/green terminal of TB1. Figure 3-3 Power Cable Connections L1 L2 L3 TB1 PRIMARY, 3 PHASE, AC POWER CABLE

3-13 14 SETUP Connect the Air and Gas Hoses When connecting pipeline shop air or compressed gas cylinders, use inert gas hoses for the plasma and shield connections to the MAX200. Plasma (Air) and Shield (Air) Hoses MAX200 systems are normally shipped from the factory configured, so that air is supplied to both the PLASMA and SHIELD GAS inlets from a single filter/pressure regulator. The filter is used to maintain a high air purity level. All moisture, oil, and other contaminants must be removed. If the air hoses must be re-connected, proceed as follows (see Figure 3-4): 1. Connect the plasma air hose from the regulator to the PLASMA gas inlet. 2. Connect the shield air hose from the regulator to the SHIELD gas inlet. 3. Connect the shop-supplied or cylinder-supplied air hose to the input of the filter/pressure regulator. Figure 3-4 Plasma Air and Shield Air Connections Plasma Air Hose Shield Air Hose Filter/Pressure Regulator Air Supply Hose

14 SETUP Figure 3-5 Plasma Gas and Shield Air Connections Plasma Gas Supply Hose Shield Air Hose Filter/Pressure Regulator Air Supply Hose Plasma (Gas) and Shield (Air) Hoses When the plasma required is a gas other than air and the shield gas required is air, connect the hoses as follows (see Figure 3-5): 1. Connect the plasma gas supply hose to the PLASMA gas inlet. 2. Connect the shield air hose from the regulator to the SHIELD gas inlet. Note: In this configuration, the plasma air hose must be disconnected from the regulator and replaced by a supplied # 6 JIC cap. The cap is required to stop the discharge of air from the regulator plasma output in order to keep the shield air pressure within specification. 3. Connect the shop-supplied or cylinder-supplied air hose to the input of the filter pressure regulator.

3-15 14 SETUP Figure 3-6 Plasma Gas and Shield Gas Connections Plasma Gas Supply Hose Shield Gas Supply Hose Plasma (Gas) and Shield (Gas) Hoses When gases other than air are used, connect the liquid or compressed bottled gases to the MAX200 as follows (see Figure 3-6): 1. Connect the plasma gas supply hose to the PLASMA gas inlet. 2. Connect the shield gas supply hose to the SHIELD gas inlet.

14 SETUP Connect the Torch Lead To connect the machine torch lead to the MAX200, proceed as follows (see Figure 3-7 ): 1. Connect the torch coolant return hose (blue-w/red band) to the bulkhead adapter. 2. Connect the torch coolant supply hose (blue-w/green band) to the bulkhead adapter. 3. Connect the pilot (shield) gas hose (blue) to the bulkhead adapter. 4. Connect the plasma gas hose (red) to the adapter. This connection is left hand-threaded; it tightens in a counter-clockwise (ccw) direction. 5. Connect the cap sensor hose (gray) to the adapter. Connect the Work Cable To connect the work cable to the MAX200, connect the work cable (black) to the bulkhead adapter. (See Figure 3-7.) Grounding To ensure proper operation, personal safety, and to reduce emission of radio frequency interference, the properly ground the MAX200 as follows: Work Table Connect the work table to a high-quality earth ground within 20 feet of the table. A suitable ground consists of a solid copper rod of at least 1/2-inch diameter driven to a depth of at least 8 feet into the earth below the permanent moisture level. Work Clamp 1. Attach the work clamp to the workpiece or to the work table. Make sure that the work clamp and the workpiece or work table make good metal-to-metal contact. 2. Do not attach the work clamp to the portion of the workpiece being cut away (see Figure 3-8). 3. For more information, refer to the National Electrical Code, Article 250, Section H, Grounding Electrode System or other appropriate code.

3-19 14 SETUP Machine Torch System Installations The MAX200 machine torch system can be installed in any of the following system configurations, depending on the options selected. • MAX200 without a Torch Height Control (THC) • MAX200 with a THC • MAX200 with an Initial Height Sensor (IHS) Refer to the following procedures in order to install a machine torch system. Install the MAX200 without THC Option Installing the MAX200 without the THC option requires the user to connect the MAX200 to the cutting machine and to connect the Remote Switch. See Figure 3-9 to make interconnections. Connect the Cutting Machine to the MAX200 Connect the interface cable from the MACHINE -1X6 receptacle on the MAX200 to the cutting machine interface. See Figure 3-10 for cable layout, cable part numbers and lengths, socket pin configurations, and wire colors and signal names. Connect the Remote Switch to the MAX200 1. Remove the right side cover of the power supply. 2. Feed the remote switch cable through the feed-through at the rear of the power supply. Locate terminal strips TB3 and TB4 on the inside rear panel, right side. Connect the remote switch cable pairs as follows (see Figure 3-9): 3. Replace and secure the right side cover. Cable leads TB3 Signal Name Black 82 Plasma Start Red 83 Plasma Start TB4 Black 76 24 VAC Hot White 77 24 VAC Neut

14 SETUP Figure 3-9 Machine Torch System Interconnection Diagram without THC Option Remote Switch Assembly Machine Interface Cable (Fig. 3-10)

3-21 15 SETUP Refer to Machine Interface Cable Signal List on next page. Figure 3-10 MAX200 to Machine Interface Cable Diagram (1 of 2) Part No. Length 023334 25 ft. (7.6 m) 023335 50 ft. (15.2 m) 023336 75 ft. (23 m) 023337 100 ft. (30.5 m) 023338 150 ft. (46 m) 023339 200 ft. (61 m)

14 SETUP Machine Interface Cable Signal List * Signals are AC relays. DC relays are available as an option from Hypertherm by ordering kit # 128404. FUNCTION COLOR 1X6 MACH HOLD-SIG WHT 1 87 HOLD-COM BLK 5 86 SHIELD N/A 10 INITIAL HEIGHT-SIG YEL 2 173 INITIAL HEIGHT-COM BLK 6 174 SHIELD N/A 11 AUTOHEIGHT-SIG BRN 3 171 AUTOHEIGHT-COM BLK 7 172 SHIELD N/A 12 CURRENT 50%-SIG ORN 4 135 CURRENT 50%-COM BLK 8 136 SHIELD N/A 13 PLASMA START-SIG BLU 9 82 PLASMA START-SIG BLK 15 83 SHIELD N/A 14 KEY 008190 19 — 24VAC, NEUTRAL WHT 21 76 24VAC, HOT RED 22 77 SHIELD N/A 20 DOWN RELAY-LINE BLK 29 170 DOWN RELAY-LOAD* RED 34 169 SHIELD N/A 23 UP RELAY-LINE BLK 30 168 UP RELAY-LOAD* GRN 35 167 SHIELD N/A 24 MACHINE MOTION DELAYED-SIG BLU 31 85 MACHINE MOTION DELAYED-SIG RED 36 84 SHIELD N/A 25 MACHINE MOTION ADVANCED-SIG GRN 32 78 MACHINE MOTION ADVANCED-SIG RED 37 79 SHIELD N/A 26 PLASMA STOP-SIG YEL 28 80 PLASMA STOP-SIG RED 33 81 SHIELD N/A 27 Figure 3-10 MAX200 to Machine Interface Cable Diagram (2 von 2)

3-23 14 SETUP Install the MAX200 with THC Option The THC option consists of: • The THC Subassembly (located in the MAX200) • The Remote Control Station • The MAX200 to Remote Control Station interconnection cable. To install the Remote Control Station and then connect it to the MAX200, perform the following procedures. See Figure 3-11 to make interconnections. Mount the Remote Control Station Mount the required Remote Control Station adjacent to the guidance machinery controls, so that the operator has convenient access to this unit when operating the system. After mounting the Remote Control Station, the unit is ready to be connected. Connect the Remote Control Station to the MAX200 Connect the interface cable from either the Switch Remote (SR), Digital Remote (DR), or Programmable Remote (PR) receptacle at the rear to the REMOTE V/C - 1X4 receptacle at the rear of MAX200. See Figures 3-12 through 3-14 for cable layouts, cable part numbers and lengths, socket pin configurations, and wire colors and signal names. Connect the Programmable Remote to the Computer If the Programmable Remote is used, connect the computer interface cable from the right rear receptacle to the computer (see Figure 3-14). Connect the Cutting Machine to the MAX200 Connect the interface cable from the MACHINE -1X6 receptacle on the MAX200 to the cutting machine interface. See Figure 3-10 for cable layouts, cable part numbers and lengths, socket pin configurations, and wire colors and signal names.

14 SETUP SR Interface Cable (Fig. 3-12) PR/DR Interface Cable (Fig. 3-13) PR to Computer Interface Cable (used with PR only) (Fig. 3-14) Remote V/C Option Serial Remote (SR) Digital Remote (DR) Programmable Remote (PR) (shown) Machine Interface Cable (Fig. 3-10) Figure 3-11 Machine Torch System Interconnection Diagram with THC Option

3-25 14 SETUP FUNCTION COLOR 1X4 5X1 PLASMA START-SIG BLU 1 2 PLASMA START-COM BLK 5 4 SHIELD N/A 10 — INITIAL HEIGHT-SIG YEL 2 1 INITIAL HEIGHT-COM BLK 6 3 SHIELD N/A 11 — AUTO HEIGHT-SIG BRN 3 6 AUTO HEIGHT-COM BLK 7 5 SHIELD N/A 12 — SERIAL INPUT DATA-SIG GRN 4 9 SERIAL INPUT DATA-COM BLK 8 10 SHIELD N/A 13 — SERIAL OUTPUT DATA-SIG RED 9 7 SERIAL OUTPUT DATA-COM BLK 15 8 SHIELD N/A 14 — RED — UNUSED WHT 19 — N/A — RED — UNUSED GRN 20 — N/A — 24 VAC AUX-HOT ORN 29 11 24 VAC AUX-NEUT BLK 23 12 SHIELD N/A 24 — 120 VAC-NEUT WHT 35 16 120 VAC-HOT BLK 36 15 SHIELD N/A 31 — KEY (BLANK) — 22 — Power Supply SR Remote Figure 3-12 MAX200 to Switch Remote Interface Cable Diagram Part No. Length 023319 25 ft. (7.6 m) 023328 50 ft. (15.2 m) 023329 75 ft. (23 m) 023330 100 ft. (30.5 m) 023331 150 ft. (46 m) 023332 200 ft. (61 m)

3-27 15 SETUP Power Supply – 1X2 DR/PR Remote – 5X2 LEGEND – POWER SUPPLY END LEGEND – DR/PR REMOTE END PIN COLOR FUNCTION PIN COLOR PIN COLOR SOCKET COLOR FUNCTION 1 14 SHIELD–RED/BLK 27 1 GRN SID DATA INPUT TO PS–THC 2 15 BLK SOD COMMON 28 2 BLK SID COMMON 3 16 29 3 RED SOD DATA 4 GRN SID DATA 17 30 4 5 18 31 SHIELD (AC PWR) WHT/BLK 5 KEY 6 19 32 6 BLK SOD COMMON 7 20 33 7 WHT AC POWER 8 BLK SID COMMON 21 34 8 BLK AC POWER 9 RED SOD DATA 22 008176 KEY (BLANK) 35 WHT AC POWER 9 10 23 36 BLK AC POWER 11 24 37 12 25 13 SHIELD-GRN/BLK 26 INPUT DATA TO THC OUTPUT FROM THC OUTPUT FROM PS–THC INDICATES PAIRS. Part No. Length 023346 25 ft (7.6 m) 023347 50 ft (15 m) 023348 75 ft (23 m) 023349 100 ft (30.5 m) 023742 125 ft (38.1 m) 023350 150 ft (46 m) 023351 200 ft (61 m) 023813 250 ft (76 m) 023577 275 ft (83.6 m) 023818 300 ft (91.5 m) Figure 3-13 MAX200/Digital Remote and Programmable Remote Interface Cable

3-29 14 SETUP LEGEND – DR/PR REMOTE END SOCKET COLOR FUNCTION 1 Blk Current Program I20 2 Blu " " I40 3 Grn " " I80 4 Wht " " I100 5 Orn " " I200 6 Red " " I400 7 Wht on Blk Common (Remote Chassis) 8 Wht on Blk Voltage Program V5 9 Blk on Blu " " V10 10 Blk on Grn " " V20 11 Blk on Orn " " V40 12 Blk on Red " " V80 13 Wht on Grn " " V100 14 Wht on Red " " V200 15 Blk on Wht Spare (Remote Chassis) 16 Shield Wire Shield (Remot Chassis Part No. Length 023098 10 ft (3 m) 023099 25 ft (7.6 m) 023100 50 ft (15.2 m) Figure 3-14 Programmable Remote to Computer Interface Cable Diagram 5X2

3-31 14 SETUP Install the MAX200 with IHS Option The IHS option can only be used when the THC option has been installed as described above. The IHS option consists of: • The Inductive IHS Control Module • The Torch Mounting Subassembly To install the IHS option, perform the following procedures. See Figure 3-15 to make interconnections. Mount the IHS Control Module Mount the IHS Control Module on to the cutting machine frame. It must be located within 40 feet of the torch. After mounting the IHS Control Module, the unit is ready to be connected to the MAX200 and the shop air supply. Connect to the MAX200 Connect the interface cable from the receptacle at the IHS Control Module to the IHS - 1X9 receptacle at the rear of MAX200 (see Figure 3-15). Also see Figure 3-16 for the cable layout, cable part numbers and lengths, socket pin configurations, and wire colors and signal names. Connect to the Shop Air Supply 1. The customer must supply the 20 psig regulated shop air and the air hose. A #4 swivel fitting (# 015006) is provided. 2. Attach the swivel fitting to the air hose. Connect this fitting to the air inlet fitting on the IHS Control Module (see Figure 3-15). 3. Attach the other end of the air hose to the regulated shop air supply. Mount the Torch Mounting Subassembly 1. Mount the Torch Mounting Subassembly on to the torch lifter of the cutting machine. 2. Mount the machine torch, connect the inductor sensors to the IHS Control Module, and connect the air hose from the Torch Mounting Subassembly to the IHS Control Module as follows: Mount the Machine Torch 1. Install the machine torch (with torch lead attached) in the bracket of the Torch Mounting Subassembly (see Figure 3-15).

14 SETUP 2. Position the torch until the torch body extends all the way through the bracket, so that the bracket is now around the plastic torch sleeve. Tighten the bracket. 3. The final torch position adjustment is described on page 3-40.

3-33 14 SETUP Upper Limit Switch and Cable (customer supplied) Inductive Probe Assy (Fig. 3-17) Air Hose Assy Torch Mounting SA Torch Lifter (Typical) 1TB Inductive Sensor Air Cylinder Swivel Fitting Air Hose (customer supplied) 20 Psi Regulated Shop Air IHS Sensor Cables (Fig. 3-17) IHS Interface Cable (Fig. 3-16) Machine Hold Cable (Fig. 3-18) Machine Interface Cable (Fig. 3-10) PR to Computer Interface Cable (Fig. 3-14)*** PR/DR Interface Cable (Fig. 3-13) SR Interface Cable (Fig. 3-12)* Remote V/C Option SR-073001 DR-073007 PR-055004** * Cable used depends on Remote V/C option selected ** PR is shown *** Used only with PR TB3 Figure 3-15 Machine Torch System Interconnection Diagram with IHS Option

3-35 14 SETUP LEGEND – POWER SUPPLY END – 1X3 LEGEND – IHS END PIN COLOR FUNCTION SOCKET COLOR FUNCTION 1 Red IHS Complete Sig. 1 Red IHS Complete Sig 2 Grn Upper Limit Sw. Sig. 2 Grn Upper Limit Sw. Sig 3 3 Blk Upper Limit Sw. Com 4 Blk IHS Complete Com 4 Blk IHS Complete Com 5 Blk Upper Limit Sw Com 5 Drain Shield – Grn/Blk 6 6 7 Drain Shield – Wht/Blk 7 Key 8 Drain Shield – Red/Blk 8 Wht AC Power 9 Drain Shield – Grn/Blk 9 Blk AC Power 10 11 Blk AC Power 12 13 14 Wht AC Power Part No. Length 023111 25 ft (7.6 m) 023112 50 ft (15 m) 023155 75 ft (23 m) 023113 100 ft (30.5 m) 023114 150 ft (46 m) 023284 200 ft (61 m) Figure 3-16 MAX200 to IHS Interface Cable Indicates Pairs. NOTE: On IHS End, Cut Red/Black Shield & White/Black Shield Wires 008176 Pin (9) 008190 Key 047002 Cable, 22–3 Pr Shielded Belden #8777 Insert Key In Face Of Plug Tapered End First Until It “Locks” In Detent 008186 Socket (7) 008187 Strain Relief 008192 Strain Relief 008202 Plug, Shell 17–14 008185 Plug, Shell 13–9 Power Supply End 1X3 IHS End

14 SETUP LEGEND – IHS END LEGEND – INDUCTIVE SENSOR END PIN COLOR FUNCTION SOCKET COLOR FUNCTION 1 Clear Signal A Red Power (+15 VDC) 2 Blk Common B Blk Common 3 Braid Shield C Clear Signal 4 Red Power (+15 VDC) Part No. Length 023111 40 ft (12.2 m) IHS/Sensor Cable NOTE: Cut Shield Sensor End. 008176 Pin (4) 047029 Cable, 22–3 TW, OA Shielded Belden #8771 (40') 008144 Plug, 3–Pin F (Amphenol) 008195 Strain Relief 009211 Plug, Shell 11–4, Rev Sex Inductive Sensor End IHS End LEGEND – INDUCTIVE SENSOR END SOCKET COLOR FUNCTION A Brn Power (+15 VDC) B Blu Common C Blk Signal Part No. 005074 Inductive Probe Assembly Figure 3-17 IHS Control Module to Inductive Probe Assembly Interface Cables Rearview 004085 Nut, Insulating 027109 Hose Clamp 046023, 3' Tygon Tubing 005085 Inductive Probe 005078 Probe Cap (Ref Cable Boot 008145 RECP, 3 Pin Male Inductive Sensor End

3-37 14 SETUP Connect to the Inductor Sensor Assembly 1. At the Torch Mounting Subassembly, connect the two (2) 40-foot IHS/Sensor cables to the two (2) 3-pin connectors of the inductor probe assemblies (see Figure 3-15). Also see Figure 3-17 for the cable layout, cable part numbers and lengths, socket pin configurations and wire colors and signal names. 2. Route the two (2) IHS/Senor cables to the IHS Control Module and connect to 4- pin receptacles (see Figure 3-15). Connect the Air Hose Assembly 1. At the Torch Mounting Subassembly, connect the air hose (# 024144) to the air cylinder adapter (# 027024) (see Figure 3-15 ). 2. Route the air hose to the air outlet fittng (same side as the inductor sensor connections) on the IHS Control Module. Install the Upper Limit Switch and Cable (customer-supplied) Install the upper limit switch on to the torch lifter. This switch is to be normally closed. It opens when the torch is fully retracted. The required operating specifications are +12 VDC @ 1.2 mA. Gold-type contacts are preferred. Connect the Upper Limit Switch to the IHS Control Module Caution: To avoid electromagnetic interference problems caused by the close proximity of the upper limit switch cable to the torch lead set, follow the cable installation procedure. 1. Use a shielded, twisted pair of 22-24 gauge wire (stranded). Belden # 8761 is recommended. 2. At the upper limit switch, connect the common wire (black) and signal wire (clear) to the upper limit switch. Cut the shield drain wire (uninsulated). Wrap the cut end with tape to ensure the cut end does not contact the cutting machine frame (see Figure 3-15). 3. At the IHS Control Module, loosen the two (2) latches and open the front cover. 4. Route the cable in through the strain relief in order to connect the cable wires to 1TB. 5. Connect the shield drain wire (uninsulated) to 1TB-10 (#S). Be sure the drain wire does not contact the IHS Control Module case. Note that the cable shield is now electrically connected to the MAX200 frame.

14 SETUP 6. Connect the common wire (black) to 1TB-11 (#4). 7. Connect the signal wire (clear) to 1TB-12 (#67). Note: If the upper limit switch signal comes from an interface on the cutting machine, exactly the same wiring (using twisted shielded pair) must be provided from the limit switch. This shield must be electrically isolated from other shields in other cables. A separate cable is recommended to avoid ground – loop problems. Connect the MAX200 Machines Together with Machine Hold Cables To connect MAX200 machines with the IHS option together with hold interconnecting cables: 1. Pass the hold interconnection cable through the feed-through at the rear of the MAX200. See Figure 3-18 for the cable layout, cable part numbers and lengths, socket pin configurations and wire colors and signal names. 2. Connect lead 87 (red) to TB3-87 (+12 VDC), lead 86 (black) to TB3-86 (neutral) and shield lead to shield terminal. See Figure 3-15. 3. Repeat Steps 1 and 2 to connect the hold cable at the other MAX200s.

3-39 14 SETUP Red X FT, 047125, Belden #9320–20 AWG, 1 Pair Overall Shielded, CSA Certified Qty 6, 074027 Terminal–Insulated Locking Fork, 22–18 AWG #6: T&B RA2217 MAX200 End OtherMAX200 End Blk Shield Red Blk Shield LEGEND – MAX200 END WIRE # COLOR FUNCTION 86 Blk Hold Signal 87 Red Hold Common Shield Shld Hold Shield LEGEND – OTHER MAX200 END WIRE # COLOR FUNCTION 86 Blk Hold Signal 87 Red Hold Common Shield Shld Hold Shield Figure 3-18 Machine Hold Interconnection Cable Part No. Length 023340 15 ft (4.6 m) 023341 25 ft (7.6 m) 023342 50 ft (15 m) 023343 100 ft (30.5 m) 023344 150 ft (46 m)

14 SETUP WARNING Disconnect all power to the MAX200 before adjusting the torch. Failure to do so could result in eye or bodily injury due to accidental firing or movement of the torch. Adjust the Torch Position Before using the machine torch system, the torch must be adjusted for the torch-to-work distance for the metal to be cut. To adjust the torch, perform the following procedure. Note: Two people may be required to perform the torch position adjustment. 1. Retract the torch from the work at least 3-4 inches. 2. Manually extend probes fully by pulling down on the plastic mounting yoke. 3. Adjust the position of the torch in the mounting bracket by loosening the securing bolt and positioning the torch so that the torch shield is within 1/16 to 1/8 inch of the extended probe plastic caps. Use a straight edge to determine this (see Figure 3-19). Secure the torch in the mounting bracket by tightening the securing bolt. Figure 3-19 Torch Standoff Adjustment Setup Torch Torch Shield Inductor Probe

3-41 14 SETUP Install the Water Muffler Option The Water Muffler option can be used with the 1.75 inch (44.5 mm) diameter torch bodies only. The 2 inch (51 mm) diameter torch body can not support the Water Muffler option. To install the Water Muffler option, refer to the MAX200 Water Muffler Instruction Manual IM-205 (P/N 802050).

4-1 14 Section 4 OPERATION In this section: Front Panel Controls.................................................................................................................................................4-2 Power ..............................................................................................................................................................4-2 Status...............................................................................................................................................................4-2 Status Indicators Before Startup ......................................................................................................................4-2 Gas...................................................................................................................................................................4-3 Pre-operation ............................................................................................................................................................4-4 Operation ..................................................................................................................................................................4-4 Operating Tips ..........................................................................................................................................................4-5 Changing Consumable Parts ...........................................................................................................................4-5 Cutting Techniques...........................................................................................................................................4-7 Torch Alignment............................................................................................................................................4-7 Cutting..........................................................................................................................................................4-8 Piercing ........................................................................................................................................................4-8 Common Cutting Faults ...............................................................................................................................4-9 Duty Cycle....................................................................................................................................................4-9 Claims and Technical Questions...............................................................................................................................4-9 Cut Charts...............................................................................................................................................................4-10

14 OPERATION Front Panel Controls Power • ON (1) pusbutton/indicator switch Activates the power supply and its control circuits. • OFF (0) pushbutton switch Shuts the power supply down. • DC ON LED Illuminates when main contactor closes, indicating that DC power is present at the torch. • AMPS thumbwheel switch (supplied on units w/o THC) Adjusts output current. • MACHINE DELAY dial Adjusts the machine motion delay from 0.1 seconds to 6.0 seconds. Status The STATUS indicators are all extinguished during normal operation. • INTERLOCK LED (Spare interlock for future use) When illuminated, indicates that the interlock jumper on TB4-34 & 35 has been removed. For assistance in reinstalling the jumper, refer to Claims and Technical Questions later in this section. • TRANSFORMER LED When illuminated, indicates that either the main transformer or one of the choppers has overheated. • COOLANT LEVEL LED When illuminated, indicates the coolant level is too low. • SHIELD GAS/CAP LED When illuminated, indicates the shield gas pressure is too low or the cap is not installed properly on the torch. • PLASMA GAS LED When illuminated, indicates that the plasma gas pressure is too low. • COOLANT TEMP LED When illuminated, indicates that the torch coolant temperature is too high (above 70° C, 160° F). • COOLANT FLOW LED When illuminated, indicates that the coolant flow from the torch is inadequate. Status Indicators Before Startup When power is applied from the line disconnect switch and before the POWER ON (I) button is pushed, the COOLANT FLOW LED will be illuminated. Once the POWER ON button is pushed, this LED will extinguish if the system is in the proper working condition. Other fault conditions may also be indicated when the line power is switched on. Correct any other fault conditions before pressing the the POWER ON (I) button. See Troubleshooting in Section 3 of MAX200 Service Manual, IM-162 (801620).

4-3 15 OPERATION Gas • TEST/RUN switch Sets dynamic (flowing) gas flow. • PLASMA pressure gauge/plasma gas needle valve Adjusts and displays the plasma gas flow pressure. • SHIELD pressure gauge/shield gas needle valve Adjusts and displays the shield gas flow pressure. Figure 4-1 Front Panel Controls Machine System with THC Machine System without THC MACHINE DELAY 6 SEC AMPS 0 3 20 E Z R O 100 80 60 40 O E Z R 20 100 80 40 60 ON POWER OFF 0 2 DC ON 0 -COOLANT FLOW -COOLANT TEMP -PLASMA GAS -COOLANT LEVEL -TRANSFORMER -SHIELD GAS/CAP STATUS -INTERLOCK RUN TEST PLASMA SHIELD GAS MACHINE DELAY 6 SEC 0 3 20 E Z R O 100 80 60 40 O E Z R 20 100 80 40 60 ON POWER OFF DC ON -COOLANT FLOW -COOLANT TEMP -PLASMA GAS -COOLANT LEVEL -TRANSFORMER -SHIELD GAS/CAP STATUS -INTERLOCK RUN TEST PLASMA SHIELD GAS

14 OPERATION Pre-operation 1. Ensure that your cutting environment and your clothing meet the safety requirements outlined in the Safety section. 2. Refer to Cut Charts (page 4-10) for the type and width of material you plan to cut. Select the gas combination that will create the desired results. Ensure the gas supplies are adequate for the amount of cutting to be done and are input to the power supply at the proper pressure. Caution: Input gas pressures below 60 psi (plasma) and 70 psi (shield/cap will cause the safety interlock circuit to shut down the power supply. If the low pressure interlocks are bypassed for any reason and low gas pressures occur, the consumables and torch can burn out. 3. Select the proper torch parts from the Cut Chart. Install the parts in the torch. (See Changing Consumable Parts for proper installation, page 4-5.) 4. Attach the MAX200 work clamp to the workpiece. Do not attach work clamp to the section of the workpiece that will drop off. Make sure that there is good metal-to-metal contact between the work clamp and the workpiece. 5. Apply power to the MAX200 power supply via the wall disconnect switch. See Status Indicators Before Startup earlier in this section. Operation Note: When using the MAX200 machine torch with extended torch leads (100, 125 or 150 feet) be aware that the 40A consumable parts cannot be used. There is also a slight chance that the following conditions could occur during cutting with extended torch leads over 75 feet: • High ambient operating temperature or high volume production cutting may increase the heat load on the torch cooling system enough to cause the system to shutdown. If this occurs, allow the system to cool down. Reduce the ambient temperature, if possible or the cutting “arc on” time. • The gas pressure response time will increase at the torch at preflow, plasma on and plasma off. The user may have to increase the lead in of the cut and/or increase the time between successive cuts. • There may be a slight incidence of the torch misfiring due to the high frequency energy from the start circuit being dissipated.

4-5 14 OPERATION 1. Refer to the cutting charts (page 4-10) to find the required operating parameters for the metal you plan to cut. 2. If you are using a machine torch system without a THC, set the torch-to-work distance and set the AMPS thumbwheel switch on the power supply (arc current) according to the charts. 3. When using a machine torch system with a THC, set the torch-to-work distance and set the arc voltage and current on the remote control according to the charts. 4. Select the proper travel speed from the charts and adjust the cutting machine speed accordingly. 5. Adjust the MACHINE DELAY on the power supply to meet the recommended motion delay time in the charts. 6. Square the torch with the workpiece if you are straight cutting, or angle the torch as required to accomplish your cut. Operating Tips Changing Consumable Parts The consumable parts in the torch need to be monitored periodically for signs of wear. A good rule of thumb is to check the parts after every 150 starts. To remove the consumables: 1. Unscrew the retaining cap. First bring the torch to the edge of the machine, with the lifter raised to its highest point. Positioning the torch in this way prevents the danger of dropping the consumables into the water in the water table. 2. Remove the retaining cap. 3. Check the shield for external signs of wear. The shield should be clean and clear of metal debris. The gas holes along the edge of the shield should not be blocked with debris. The center hole should not have any nicks or gouges, and should show no signs of arcing activity. WARNING Always unplug the power supply before inspecting or changing the torch parts.

15 OPERATION 4. Using the 7/8" side of the wrench (supplied in the spare parts kit), remove the shield. Inspect the gas holes from the inside. The holes should be clear of metal or other debris which will cause arcing. If the shield is still good, screw it back on to the retaining cap and tighten it with the wrench. Replace ifdamaged. 5. Inspect the two O-rings on the torch. They should be lubricated and undamaged. If they are dry, lubricate them lightly with a very thin film of the lubricant provided in the spare parts kit. If they are damaged, replace them. 6. Remove the nozzle with the 3/4" side of the wrench. Inspect it for damage or signs of wear. The inside of the nozzle should be clean and bright, with no deposits from the electrode. You can clean the inside of the nozzle with steel wool, but be sure to remove any remnants of the steel wool afterward. The hole in the nozzle should not be worn or oval-shaped. 7. Remove the electrode with the center hole in the wrench and inspect it. An all copper electrode should be replaced when the pit depth exceeds .040 inch (1 mm). A SilverPlus electrode should be replaced when the pit depth exceeds approximately two times the recommended depth of an all copper electrode. If the electrode is still good, inspect its O-ring – it should be lubricated and undamaged. If it is dry, lubricate it lightly with a very thin film of lubricant provided in the spare parts kit. If it is damaged, replace it. 8. Remove the swirl ring from the electrode and inspect it. It should be clean, and the holes on the top and sides should not be plugged. If the swirl ring is still good, inspect its O-ring. It should be lubricated and undamaged. If it is dry, lubricate it lightly with a very thin film of lubricant provided in the spare parts kit. If it is damaged, replace it. 9. Inspect the inside of the torch body by using a mirror, or by looking carefully inside. The inside of the torch body should be clean and undamaged. Check for loose or damaged water tube. A loose or damaged tube can cause: • shortened electrode life • the flow switch interlock to shut the system down • humming or rattling sound to come from the torch Use the water tube removal tool (027347) to loosen or replace the water tube. When installing the water tube, do not overtighten! Snug down by hand only. 10. Replace the electrode and tighten it with the wrench. Do not overtighten. 11. Install the swirl ring with the bottom O-ring facing the inside of the torch – it won't fit in properly if it is installed in the wrong direction. Push it into place. Hold the swirl ring in place until the nozzle is installed to avoid dropping it into the water. 12. Install nozzle until finger-tight, then tighten with wrench. Do not overtighten. 13. Replace the retaining cap. Make sure that it is tightened snugly; if it is loose, it can affect the shield gas flow.

4-7 14 OPERATION Cutting Techniques Torch Alignment Prior to cutting with a machine torch, ensure that the torch is at right angles to the workpiece to get a clean, vertical cut. Use a square to align the torch. The torch should be aligned at 90° increments (0°, 90°, 180°, and 270°). See Figure 4-2. Figure 4-2 Torch Alignment

14 OPERATION Cutting • Start cutting from the edge of the workpiece, unless you must pierce. For tips on piercing, refer to the Piercing section. • When cutting, make sure that the sparks are coming out of the bottom of the workpiece. If not, check for the following: – If the sparks are spraying on top of the workpiece, the torch may be moving too fast. Check the Cut Charts for the correct travel speeds. The optimum travel speed is generally just slightly under the speed that causes the arc to “rooster tail” off of the workpiece. – If there is not sufficient power to fully penetrate the workpiece, reduce the travel speed. If this does not work, stop cutting and re-check the cutting chart specifications. Piercing Note: The MAX200 can pierce metals up to a thickness of one (1) inch. • Set the torch-to-work distance (standoff) so that the shield cap is 1/8 inch or more away from the workpiece. (Refer to the Adjust the Torch Position procedure, page 3-40.) • Ensure the MACHINE DELAY on the power supply is set to the recommended motion time delay (refer to cutting charts) in order for the metal to be pierced completely before the travel motion begins. • Position the torch directly over the workpiece juncture/cut line to be pierced. • The workpiece can now be pierced.

4-9 14 OPERATION Common Cutting Faults • The workpiece is not totally penetrated. Causes can be: – The current is too low. – The cut speed is too high. – The torch parts are worn. – The metal being cut is too thick. • Dross forms on the bottom of the cut. Causes can be: – The cutting speed is too slow or too fast. – The torch parts are worn. Duty Cycle The duty cycle is reduced if: • The input line voltage is less than nominal, due to a long power cord, poor utility supply, etc. • You are cutting material greater than two inches thick. • The work clamp is not making a good electrical contact to the workpiece due to paint, rust, etc. • Arc voltage is greater than 150 volts (at 200 amps). Claims and Technical Questions Claims for damage during shipment — If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. Claims for defective merchandise — All units shipped from Hypertherm undergo rigorous quality control testing. However, if your unit does not function correctly: 1. Read the Troubleshooting section of this manual. ou may find the problem is quite easy to fix, such as a loose connection. 2. If you are unable to solve the problem, call your distributor. He will be able to help you, or refer you to an authorized Hypertherm repair facility. 3. If you need additional assistance, call our Customer Service or Field Service group at 1-800-643-0030.

15 OPERATION Cut Charts The following Cut Charts provide the necessary information in order for the operator using the MAX200 machine torch system to be successful in plasma arc cutting. The Cut Charts are divided into two areas: (1) above water cutting (pages 4-11 through 4-33) and (2) under water cutting, where the water table water is 3" above the top surface of the workpiece (pages 4-34 through 4-45). The following table provides the operator with a quick reference of the consumables used for all cutting and gouging applications with the MAX200 machine torch. Also listed are the consumables used with the water-muffler. Part Numbers Plasma Gas/ Nozzle Type Retaining Shield Gas (Amps) Shield Cap Nozzle Swirl Ring Electrode Air/Air 200 020424 120837 020608 020607 220021 100 020448 120837 020611 020607 120547 40 020688 020423 020689 020613 220021 200 gouging 020485 020423 020615 020607 220021 O2/Air 200 020424 120837 020605 020604 220021 100 020448 120837 020616 020617 120547 H35/N2 200 020602 120837 020608 020607 020415 100 020448 120837 020611 020607 020415 200 gouging 020485 020423 020615 020607 020415 N2/CO2 200 020424 120837 020608 020607 020415 N2/Air 200 020424 120837 020608 020607 020415 Beveling Consumables O2/Air 200 beveling 120260 020423 120259 120833 120258 Water Tube 120257 Consumables Used with MAX200 Water-Muffler Air/Air 200 020566 020423 020608 020607 220021 100 020618 020423 020611 020607 120547 O2/Air 200 020566 020423 020605 020604 220021 100 020618 020423 020616 020617 120547 N2/CO2 200 020566 020423 020608 020607 020415 N2/Air 200 020566 020423 020608 020607 020415 MAX200 Machine Torch Consumables

4-11 14 OPERATION Mild Steel – Above Water 200 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriting can occur. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1 inch (25 mm) not recommended. 020424 Shield 020608 Nozzle 120837 Retaining cap 220021 Electrode 020607 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 3/32 2.5 125 185 4700 0.5 3/16 1/8 3 125 175 4450 0.5 1/4 1/8 3 130 125 3175 0.5 3/8 1/8 3 135 50 1270 1.0 1/2 1/8 3 140 35 890 * 5/8 .16 4 145 25 635 * 3/4 3/16 5 150 20 510 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 125 4700 185 0.5 5 3 1/8 125 4450 175 0.5 6 3 1/8 130 3175 125 0.5 10 3 1/8 135 1270 50 1.0 12 3 1/8 140 890 35 * 15 4 .16 145 635 25 * 20 5 3/16 150 510 20 * Metric – 80 amps • Air Plasma / Air Shield Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 17 1.5-1.8 3.3-3.6 127 4.0 2 2.5 3/32 120 6050 0.0 Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 17 1.5-1.8 127 4.0 3.7-4.0 270 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) 37 22-26 54-58 Torch-to-Work Distance 60 Torch-to-Work Distance Torch-to-Work Distance Travel Speed Travel Speed Travel Speed Mild Steel – Above Water 100 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross level and is very economical. Some surface nitriting can occur. While this process may be used on thicker materials, optimal recommended range is to 3/8 inch (10 mm). Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 020448 Shield 020611 Nozzle 120837 Retaining cap 120547 Electrode 020607 Swirl ring

4-13 15 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) .050 (18GA.) 3/32 2.5 110 320 8100 0.0 1/16 3/32 2.5 110 300 7600 0.0 .075 3/32 2.5 110 220 5600 0.0 1/8 3/32 2.5 110 140 3550 0.5 .158 3/32 2.5 115 120 3050 * .197 3/32 2.5 115 50 1250 * 1/4 3/32 2.5 120 35 850 * 3/8 3/32 2.5 125 20 500 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 2 2.5 3/32 110 5600 220 0.0 3 2.5 3/32 110 3550 140 0.5 4 2.5 3/32 115 3050 120 * 5 2.5 3/32 115 1250 50 * 6 2.5 3/32 120 850 35 * 10 2.5 3/32 125 500 20 * Travel Speed Travel Speed Torch-to-Work Distance Torch-to-Work Distance Shield Gas Flowrate (SCFH) Plasma Gas Pressure Plasma Gas Flowrate (SCFH) English Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 4.0 25 16-20 56-60 275 60 12 1.1-1.4 3.9-4.1 129 Mild Steel – Above Water 40 amps • Air Plasma / Air Shield This gas combination gives good cut speeds, low dross levels and is very economical. Some surface nitriting can occur. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1/8 inch (3 mm) not recommended. 020514 Shield 020689 Nozzle 020423 Retaining cap 120547 Electrode 020613 Swirl ring

15 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/4 1/8 3 120 160 4060 0.5 3/8 1/8 3 125 100 2540 1.0 1/2 .16 4 125 80 2030 2.0 5/8 .16 4 130 70 1780 2.0 3/4 3/16 5 135 55 1400 2.5 7/8 1/4 6 135 45 1140 2.5 1 1/4 6 140 35 890 2.5 1-1/4 1/4 6 150 22 560 * 1-1/2 1/4 6 155 15 380 * 1-3/4 5/16 8 165 10 250 * 2 5/16 8 170 7 180 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 6 3 1/8 120 4060 160 0.5 8 3 1/8 125 3000 120 0.5 10 3 1/8 125 2540 100 1.0 12 4 .16 125 2030 80 2.0 15 4 .16 130 1780 70 2.0 20 5 3/16 135 1400 55 2.5 25 6 1/4 140 890 35 2.5 32 6 1/4 150 560 22 * 50 8 5/16 170 180 7 * 4.0 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 72 48-52 64-68 270 34 3.3-3.6 4.4-4.7 127 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Torch-to-Work Distance Travel Speed Travel Speed Mild Steel – Above Water 200 amps • O2 Plasma / Air Shield This gas combination gives superior cut speed, minimum dross, minimum amount of surface nitriting and excellent weldability. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) + SilverPlus provides increased life to high duty cycle users in most applications. The hafnium wears to approximately two times the depth of a standard electrode (220021). Arc voltage may need to be increased by 5-10 volts throughout the electrode life to maintain proper cut height parameters. If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. Production cutting above 1 inch (25 mm) not recommended. 020424 Shield 020605 Nozzle 120837 Retaining cap 220021 (standard) Electrode 220083 (optional) SilverPlus electrode+ 020604 Swirl ring

4-15 14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 3/32 2.5 105 240 6100 0.0 3/16 1/8 3 110 180 4550 0.0 1/4 1/8 3 110 110 3050 0.5 3/8 1/8 3 115 70 1780 0.5 1/2 1/8 3 115 50 1270 * 5/8 .16 4 125 40 1020 * 3/4 3/16 5 130 30 760 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 105 6100 240 0.0 5 3 1/8 110 4550 180 0.0 6 3 1/8 110 3050 110 0.5 10 3 1/8 115 1780 70 0.5 12 3 1/8 115 1270 50 * 15 4 .16 125 1020 40 * 20 5 3/16 130 760 30 * Torch-to-Work Distance Travel Speed 19 0.8-1.1 3.6-3.9 127 4.0 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 40 12-16 52-56 270 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Mild Steel – Above Water 100 amps • O2 Plasma / Air Shield This gas combination gives good cut speed, low dross level and is very economical. Some surface nitriting can occur. While this process may be used on thicker materials, optimal recommended range is to 3/8 inch (10 mm). Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 020448 Shield 020616 Nozzle 120837 Retaining cap 120547 Electrode 020617 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 120 130 3300 0.5 1/4 1/8 3 125 110 2800 1.0 3/8 1/8 3 130 85 2160 1.5 1/2 1/8 3 130 55 1400 2.0 5/8 .16 4 135 45 1140 2.0 3/4 3/16 5 145 25 635 2.5 7/8 1/4 6 150 20 510 3.0 1 1/4 6 160 15 380 3.0 1-1/4 1/4 6 165 10 250 * 1-1/2 1/4 6 175 5 130 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 120 3300 130 0.5 6 3 1/8 125 2800 110 1.0 10 3 1/8 130 2160 85 1.5 12 3 .16 130 1400 55 2.0 15 4 .16 135 1140 45 2.0 20 5 3/16 145 635 25 2.5 25 6 1/4 160 380 15 3.0 32 6 1/4 165 250 10 * 4.0 Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 210 28 2.5-2.8 3.6-3.9 99 60 Metric 36-40 52-56 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed Travel Speed 60 Torch-to-Work Distance Mild Steel – Above Water 200 amps • N2 Plasma / CO2 Shield This gas combination is used when cut edge quality and surface nitriting are less important. Electrode life is extended when this combination is used. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1 inch (25 mm) not recommended. 020424 Shield 020608 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

4-17 14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 125 220 5600 0.0 1/4 1/8 3 130 195 5000 0.5 3/8 1/8 3 130 145 3700 1.0 1/2 1/8 3 135 105 2700 2.0 5/8 .16 4 140 75 1900 2.0 3/4 3/16 5 140 55 1400 2.5 7/8 1/4 6 145 40 1000 3.0 1 1/4 6 150 30 760 * 1-1/4 1/4 6 160 15 380 * 1-1/2 1/4 6 170 10 250 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 125 5600 220 0.0 6 3 1/8 130 5000 195 0.5 10 3 1/8 130 3700 145 1.0 12 3 .16 135 2700 105 2.0 15 4 .16 140 1900 75 2.0 20 5 3/16 140 1400 55 2.5 25 6 1/4 150 760 30 * 32 6 1/4 160 380 15 * Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 66 44-48 58-62 270 60 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 31 3.0-3.3 4.0-4.3 127 4.0 Stainless Steel – Above Water 200 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriting and surface oxidation of alloying elements can occur. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 020424 Shield 020608 Nozzle 120837 Retaining cap 220021 Electrode 020607 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 3/32 2.5 125 140 3560 0.0 3/16 1/8 3 130 110 2800 0.5 1/4 1/8 3 130 80 2030 0.5 3/8 1/8 3 135 55 1400 0.5 1/2 1/8 3 140 35 890 * 5/8 .16 4 145 25 635 * 3/4 3/16 5 150 20 510 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 125 3560 140 0.0 5 3 1/8 130 2800 110 0.5 6 3 1/8 130 2030 80 0.5 10 3 1/8 135 1400 55 0.5 12 3 1/8 140 890 35 * 15 4 .16 145 635 25 * 20 5 3/16 150 510 20 * Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 37 22-26 54-58 270 60 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 17 1.5-1.8 3.7-4.0 127 4.0 Stainless Steel – Above Water 100 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriting and surface oxidation of alloying elements can occur. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 020448 Shield 020611 Nozzle 120837 Retaining cap 120547 Electrode 020607 Swirl ring

4-19 15 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) .050 (18GA.) 3/32 2.5 120 145 3700 0.0 1/16 3/32 2.5 120 120 3050 0.0 1/8 3/32 2.5 125 75 1900 0.5 1/4 1/8 3 135 30 750 * 3/8 1/8 3 140 12 300 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 125 1900 75 0.5 6 3 1/8 135 750 30 * 10 3 1/8 140 300 12 * Torch-to-Work Distance Travel Speed English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 4.0 25 16-20 56-60 275 60 12 1.1-1.4 3.9-4.1 129 Stainless Steel – Above Water 40 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriting and surface oxidation of alloying elements can occur. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 020514 Shield 020689 Nozzle 020423 Retaining cap 220021 Electrode 020613 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 125 135 3430 0.0 1/4 1/8 3 130 120 3050 0.5 3/8 1/8 3 130 100 2540 1.0 1/2 1/8 3 135 75 1900 2.0 5/8 .16 4 140 60 1520 2.0 3/4 3/16 5 140 45 1140 2.5 7/8 1/4 6 145 35 890 2.5 1 1/4 6 150 20 510 * 1-1/4 1/4 6 160 15 380 * 1-1/2 1/4 6 160 10 250 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 125 3430 135 0.0 6 3 1/8 130 3050 120 0.5 10 3 1/8 130 2540 100 1.0 12 3 .16 135 1900 75 2.0 15 4 .16 140 1520 60 2.0 20 5 3/16 140 1140 45 2.5 25 6 1/4 150 510 20 * 32 6 1/4 160 380 15 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 60 34-38 50-54 270 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 28 2.3-2.6 3.4-3.7 127 4.0 Stainless Steel – Above Water 200 amps • N2 Plasma / Air Shield This gas combination is used when cut edge quality, surface nitriting and surface oxidation of alloying elements are less important. Electrode life is extended when this combination is used. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 020424 Shield 020608 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

4-21 14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 125 190 4800 0.5 1/4 1/8 3 130 170 4300 1.0 3/8 1/8 3 130 125 3200 1.5 1/2 1/8 3 135 95 2400 2.0 5/8 .16 4 140 70 1800 2.0 3/4 3/16 5 140 50 1250 2.5 7/8 1/4 6 145 40 1000 3.0 1 1/4 6 150 30 760 * 1-1/4 1/4 6 160 15 380 * 1-1/2 1/4 6 170 10 250 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 125 4800 190 0.5 6 3 1/8 130 4300 170 1.0 10 3 1/8 130 3200 125 1.5 12 3 .16 135 2400 95 2.0 15 4 .16 140 1800 70 2.0 20 5 3/16 140 1250 50 2.5 25 6 1/4 150 760 30 * 32 6 1/4 160 380 15 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 60 36-40 52-56 210 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 28 2.5-2.8 3.6-3.9 99 4.0 Stainless Steel – Above Water 200 amps • N2 Plasma / CO2 Shield This gas combination is used when surface nitriting and surface oxidation of alloying elements is less important. Electrode life is extended when using this gas combination. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 020424 Shield 020608 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/4 3/16 5 135 62 1600 1.0 3/8 3/16 5 140 52 1300 1.0 1/2 3/16 5 140 42 1100 2.0 5/8 1/4 6 145 37 940 2.0 3/4 1/4 6 150 32 810 2.5 7/8 5/16 8 155 27 690 2.5 1 5/16 8 155 22 560 * 1-1/4 5/16 8 165 16 400 * 1-1/2 5/16 8 170 11 280 * 1-3/4 5/16 8 180 8 200 * 2 5/16 8 185 6 150 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 6 5 3/16 135 1600 62 1.0 10 5 3/16 140 1300 52 1.0 12 5 3/16 140 1100 42 2.0 15 6 1/4 145 940 37 2.0 20 6 1/4 150 810 32 2.5 25 8 5/16 155 560 22 * 32 8 5/16 165 400 16 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 70 36-40 62-66 275 60 Torch-to-Work Distance Travel Speed Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 4.0 33 2.5-2.8 4.3-4.5 129 Stainless Steel – Above Water 200 amps • H35 Plasma / N2 Shield This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives maximum thickness cutting capability, minimum dross levels, minimum amount of surface contamination, excellent weldability and excellent cut quality on thicknesses greater than 1/2". On thicknesses less than 1/2", excessive dross levels may be experienced. Electrode life is extended when this combination is used. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Note: Maximum piercing thickness 3/4" (20 mm) and IHS recommended. If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. WARNING Do not use water muffler when cutting with argon-hydrogen! 020602 Shield 020608 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

4-23 14 OPERATION Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) Note: Maximum piercing thickness 3/8-inch (10 mm) and IHS recommended. If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 3/32 2.5 130 50 1260 0.0 3/16 1/8 3 135 40 1060 0.5 1/4 1/8 3 140 35 890 0.5 3/8 1/8 3 140 30 750 0.5 1/2 1/8 3 145 25 630 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 130 1260 50 0.0 5 3 1/8 135 1060 40 0.5 6 3 1/8 140 890 35 0.5 10 3 1/8 140 750 30 0.5 12 3 1/8 145 630 25 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 20 32-36 56-60 270 60 Torch-to-Work Distance Travel Speed Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) 4.0 9 2.2-2.5 3.9-4.1 127 Stainless Steel – Above Water 100 amps • H35 Plasma / N2 Shield This gas combination gives good cut speed, but may result in severe dross. Some surface nitriting and surface oxidation of alloying elements can occur. WARNING Do not use water muffler when cutting with argon-hydrogen! 020448 Shield 020611 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 130 220 5600 0.5 1/4 1/8 3 140 190 4800 1.0 3/8 1/8 3 140 145 3700 2.0 1/2 1/8 3 145 110 2800 2.5 5/8 .16 4 150 85 2200 2.5 3/4 3/16 5 155 65 1650 2.5 7/8 1/4 6 160 50 1300 2.5 1 1/4 6 165 35 900 * 1-1/4 1/4 6 170 20 500 * 1-1/2 1/4 6 175 12 300 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 130 5600 220 0.5 6 3 1/8 140 4800 190 1.0 10 3 1/8 140 3700 145 2.0 12 3 .16 145 2800 110 2.5 15 4 .16 150 2200 85 2.5 20 5 3/16 155 1650 65 2.5 25 6 1/4 165 900 35 * 32 6 1/4 170 500 20 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 66 44-48 58-62 270 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 31 3.0-3.3 4.0-4.3 127 4.0 Aluminum – Above Water 200 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 020448 Shield 020608 Nozzle 120837 Retaining cap 220021 Electrode 020607 Swirl ring

4-25 14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 3/32 2.5 135 110 2800 0.0 3/16 1/8 3 140 90 2290 0.5 1/4 1/8 3 145 70 1780 0.5 3/8 1/8 3 145 50 1270 0.5 1/2 1/8 3 150 40 1010 * 5/8 .16 4 155 30 760 * 3/4 3/16 5 160 25 635 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 135 2800 110 0.0 5 3 1/8 140 2290 90 0.5 6 3 1/8 145 1780 70 0.5 10 3 1/8 145 1270 50 0.5 12 3 1/8 150 1010 40 * 15 4 .16 155 760 30 * 20 5 3/16 160 635 25 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 37 22-26 54-58 270 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 17 1.5-1.8 3.7-4.0 127 4.0 Aluminum – Above Water 100 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 020448 Shield 020611 Nozzle 120837 Retaining cap 120547 Electrode 020607 Swirl ring

15 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/32 3/32 2.5 120 140 3550 0.0 1/8 3/32 2.5 130 100 2550 0.5 1/4 1/8 3 140 35 900 * 3/8 1/8 3 150 15 350 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 130 2550 100 0.5 6 3 1/8 140 900 35 * 10 3 1/8 150 350 15 * Torch-to-Work Distance Travel Speed English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 12 1.1-1.4 3.9-4.1 129 4.0 60 25 16-20 56-60 275 Aluminum – Above Water 40 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 1/8 inch (3 mm) not recommended. 020514 Shield 020689 Nozzle 020423 Retaining cap 220021 Electrode 020613 Swirl ring

4-27 14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 130 180 4570 0.5 1/4 1/8 3 135 160 4060 1.0 3/8 1/8 3 135 120 3050 1.5 1/2 1/8 3 140 80 2030 2.0 5/8 .16 4 140 70 1780 2.0 3/4 3/16 5 150 50 1270 2.5 7/8 1/4 6 160 35 890 2.5 1 1/4 6 165 25 635 * 1-1/4 1/4 6 175 20 510 * 1-1/2 1/4 6 185 10 250 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 130 4570 180 0.5 6 3 1/8 135 4060 160 1.0 10 3 1/8 135 3050 120 1.5 12 3 .16 140 2030 80 2.0 15 4 .16 140 1780 70 2.0 20 5 3/16 150 1270 50 2.5 25 6 1/4 165 635 25 * 32 6 1/4 175 510 20 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 60 34-38 54-54 270 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 28 2.3-2.6 3.7-3.7 127 4.0 Aluminum – Above Water 200 amps • N2 Plasma / Air Shield This gas combination is used when cut edge quality is less important. Electrode life is extended when this combination is used. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 020424 Shield 020611 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 1/8 3 130 185 4700 0.5 1/4 1/8 3 135 160 4050 1.0 3/8 1/8 3 135 120 3050 2.0 1/2 1/8 3 140 95 2400 2.5 5/8 .16 4 140 70 1800 2.5 3/4 3/16 5 150 55 1400 3.0 7/8 1/4 6 160 42 10580 3.0 1 1/4 6 165 33 840 * 1-1/4 1/4 6 175 20 510 * 1-1/2 5/16 8 185 11 280 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 5 3 1/8 130 4700 185 0.5 6 3 1/8 135 4050 160 1.0 10 3 1/8 135 3050 120 2.0 12 3 .16 140 2400 95 2.5 15 4 .16 140 1800 70 2.5 20 5 3/16 150 1400 55 3.0 25 6 1/4 165 840 33 * 32 6 1/4 175 510 20 * English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 60 36-40 52-56 210 60 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 28 2.5-2.8 3.6-3.9 99 4.0 Aluminum – Above Water 200 amps • N2 Plasma / CO2 Shield This gas combination is used when cut edge quality is less important. Electrode life is extended when this combination is used. Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. 020424 Shield 020608 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

4-29 14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 3/16 3/16 5 130 170 4300 0.5 1/4 3/16 5 130 155 4000 1.0 3/8 1/4 6 135 120 3000 2.0 1/2 1/4 6 140 100 2550 2.0 5/8 1/4 6 145 80 2000 2.5 3/4 5/16 8 150 60 1500 2.5 7/8 5/16 8 155 50 1250 2.5 1 5/16 8 155 40 1000 * 1-1/4 5/16 8 165 26 660 * 1-1/2 5/16 8 170 18 460 * 1-3/4 5/16 8 180 12 300 * 2 5/16 8 185 7 180 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 6 5 3/16 130 4000 155 1.0 10 6 1/4 135 3000 120 2.0 12 6 1/4 140 2550 100 2.0 15 6 1/4 145 2000 80 2.5 20 6 5/16 150 1500 60 2.5 25 8 5/16 155 1000 40 * 32 8 5/16 165 660 26 * 50 8 5/16 185 180 7 * 4.0 33 2.5-2.8 4.3-4.5 129 Torch-to-Work Distance Travel Speed Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 70 36-40 62-66 275 60 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 7/8 inch (21 mm) not recommended. Aluminum – Above Water 200 amps • H35 Plasma / N2 Shield This gas combination (Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas) gives maximum thickness cutting capability, excellent cut quality and excellent weldability. Electrode life is extended when this combination is used. WARNING Do not use water muffler when cutting with argon-hydrogen! 020602 Shield 020608 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

14 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 3/32 2.5 135 95 2440 0.0 3/16 1/8 3 140 85 2200 0.5 1/4 1/8 3 145 80 1980 0.5 3/8 1/8 3 145 60 1530 0.5 1/2 1/8 3 150 50 1280 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2.5 3/32 135 2440 95 0.0 5 3 1/8 140 2200 85 0.5 6 3 1/8 145 1980 80 0.5 10 3 1/8 145 1530 60 0.5 12 3 1/8 150 1280 50 * Torch-to-Work Distance Travel Speed 9 2.2-2.5 3.9-4.1 127 4.0 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 20 32-36 56-60 270 60 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Set plasma gas inlet pressure to 120 psi (8.3 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. Aluminum – Above Water 100 amps • H35 Plasma / N2 Shield This gas combination gives good cut speed, low dross levels and is very economical. WARNING Do not use water muffler when cutting with argon-hydrogen! 020448 Shield 020611 Nozzle 120837 Retaining cap 020415 Electrode 020607 Swirl ring

4-31 15 OPERATION 49-51 50-52 50 90 90 3.4-3.5 3.4-3.6 3.4 6.2 6.2 Shield Gas Pressure (psi) Plasma Gas Inlet Pressure (psi) TEST (psi) RUN (psi) English Shield Gas Inlet Pressure (psi) Shield Gas Inlet Pressure (bar) RUN (bar) Metric Plasma Gas Pressure Shield Gas Pressure (bar) Plasma Gas Inlet Pressure (bar) TEST (bar) Plasma Gas Pressure Mild Steel – Gouging 200 amps • Air Plasma / Air Shield If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 020485 Shield 020615 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring

15 OPERATION 49-51 50-52 50 120 120 3.4-3.5 3.4-3.6 3.4 8.3 8.3 Shield Gas Inlet Pressure (psi) TEST (psi) RUN (psi) Shield Gas Inlet Pressure (bar) TEST (bar) RUN (bar) Metric Plasma Gas Pressure Shield Gas Pressure (bar) Plasma Gas Inlet Pressure (bar) English Plasma Gas Pressure Shield Gas Pressure (psi) Plasma Gas Inlet Pressure (psi) Stainless Steel – Gouging 200 amps • H35 Plasma / N2 Shield Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. 020485 Shield 020615 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length.

4-33 15 OPERATION 49-51 50-52 50 120 120 3.4-3.5 3.4-3.6 3.4 8.3 8.3 Shield Gas Inlet Pressure (psi) TEST (psi) RUN (psi) Shield Gas Inlet Pressure (bar) TEST (bar) RUN (bar) Metric Plasma Gas Pressure Shield Gas Pressure (bar) Plasma Gas Inlet Pressure (bar) English Plasma Gas Pressure Shield Gas Pressure (psi) Plasma Gas Inlet Pressure (psi) Aluminum – Gouging 200 amps • H35 Plasma / N2 Shield Hypertherm recommends a mixture of 35% hydrogen and 65% argon for the plasma gas. 020485 Shield 020615 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length.

15 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/4 1/8 3 130 130 3300 0.5 3/8 1/8 3 135 95 2400 1.0 1/2 1/8 3 140 75 1900 2.0 5/8 .16 4 145 50 1200 2.0 3/4 3/16 5 150 35 850 2.5 7/8 1/4 6 155 20 530 3.0 1 1/4 6 165 15 400 3.0 Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 6 3 1/8 130 3300 130 0.5 8 3 1/8 135 2700 110 0.5 10 3 1/8 135 2400 95 1.0 12 3 1/8 140 1900 75 2.0 15 4 .16 145 1200 50 2.0 20 5 3/16 150 850 35 2.5 25 6 1/4 165 400 15 3.0 English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Torch-to-Work Distance Travel Speed 66 44-48 58-62 280 70 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed 31 3.0-3.3 4.0-4.3 132 4.8 Mild Steel – 3" Under Water 200 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross levels and is very economical. Some surface nitriting can occur. Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. 020424 Shield 020608 Nozzle 020423 Retaining cap 220021 Electrode 020607 Swirl ring

4-35 15 OPERATION Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (psi) Run (psi) (psi) (Inches) (Inches) (mm) (Volts) (ipm) (mm/min) (sec) 1/8 5/64 2 130 120 3050 0.0 3/16 1/8 3 135 90 2300 0.5 1/4 1/8 3 140 70 1730 0.5 3/8 1/8 3 145 42 1050 0.5 1/2 1/8 3 145 28 700 * Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 3 2 5/64 130 3050 120 0.0 5 3 1/8 135 2300 90 0.5 6 3 1/8 140 1730 70 0.5 10 3 1/8 145 1050 42 0.5 12 3 1/8 145 700 28 * Metric – 80 amps • Air Plasma / Air Shield Shield Gas Pressure Material Thickness Arc Voltage Setting Approx. Motion Delay Time Test (bar) Run (bar) (bar) (mm) (mm) (Inches) (Volts) (mm/min) (ipm) (sec) 17 1.5-1.8 3.3-3.6 132 4.8 2 2 5/64 120 6050 240 0.0 Travel Speed 37 22-26 54-58 280 70 17 1.5-1.8 3.7-4.0 132 Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Torch-to-Work Distance Travel Speed 4.8 Metric Plasma Gas Flowrate (l/min) Plasma Gas Pressure Shield Gas Flowrate (l/min) Torch-to-Work Distance Travel Speed English Plasma Gas Flowrate (SCFH) Plasma Gas Pressure Shield Gas Flowrate (SCFH) Mild Steel – 3" Under Water 100 amps • Air Plasma / Air Shield This gas combination gives good cut speed, low dross level and is very economical. Some surface nitriting can occur. While this process may be used on thicker materials, optimal recommended range is to 3/8 inch (10 mm). Set plasma gas inlet pressure to 90 psi (6.2 bar) Set shield gas inlet pressure to 90 psi (6.2 bar) If leads are greater than 50 feet, increase TEST pressure 5 psi for every extra 50 feet of torch lead length. * Production cutting above 3/8 inch (10 mm) not recommended. 020448 Shield 020611 Nozzle 020423 Retaining cap 120547 Electrode 020607 Swirl ring