Hypertherm MAX200 Instruction sheet

© Copyright 1998 Hypertherm, Inc.
All Rights Reserved
HYPERTHERM, HT and LongLife are trademarks of Hypertherm, Inc. and may be
registered in the United States and/or other countries
MAX200
Plasma Arc Cutting System
Product Configuration Manual
PM-345
(P/N 803450)
Revision 0 December, 1998
HYPERTHERM, Inc.
P.O. Box 5010
Hanover, New Hampshire 03755-5010
Tel.: [phone]
Fax: [phone]
http://www.hypertherm.com
email:[email protected]
®

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MAX200 Product Configuration Manual 1-1
SPECIFICATIONS
Section 1
SPECIFICATIONS
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 (U0)......................................280 VDC
Output Current (I2)........................................40-200 amps
Output Voltage (U2) ......................................150 VDC
Duty Cycle Rating (X)...................................100% up to 30kW
Input Power (Input Voltage (U1) x Input Current (I1):
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, 98/57/52
073023** amps
073026*........................................................200 VAC, 3Ø, 50 Hz, 108 amps
073024**
073200*........................................................400 VAC - CE, 3Ø, 50 Hz, 56 amps
073213**
073036*........................................................500 VAC, 3Ø, 50 Hz, 43 amps
073039**
* MAX200 Power Supply - comes without THC Configuration
** MAX200 Power Supply for use with the machine torch - comes with THC Configuration

MAX200 Product Configuration Manual
1-2
SPECIFICATIONS
Dimensions:
Width ............................................................28-1/4" (71 cm)
Height...........................................................35-1/2" (90 cm) w/o casters; 40-3/4" (104 cm) -CE
43" (109 cm) w/casters; 48-1/4" (122 cm) -CE
Depth............................................................41-1/4" (104 cm) w/o handle
50" (127 cm) w/handle
Weight ..........................................................780 pounds (351 kg); 800 pounds (363 kg) -CE
Cooling .........................................................ForcedAir (Class F)
Torch Coolant Tank Capacity .......................2.9 gallons (11 liters)
Torch Coolant Requirements and
Coolant Safety Data .....................................SeeAppendix section of instruction manual
Gas Requirements:
Gas Type/Quality..........................................Air (compressed)/clean, dry, oil-free
Oxygen (O2)/99.5% (liquid)
Nitrogen (N2)/99.995% (liquid)
Carbon Dioxide (CO2 )/99.5% (compressed or
liquid)
Argon/Hydrogen (H35 = 35% Hydrogen/65%
Argon)
Plasma Gases..............................................Air, O2, N2, H35
Shield Gases................................................Air, CO2, 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 (6.2/8.3 bar) (flowing)
Shield Gas Inlet Pressure ............................90 psi (6.2 bar) (flowing)
Plasma Gas Pressure (Test/Run).................See Cut Charts in Operation section of IM87
(#800870) or IM98 (#800980)
Shield Gas Pressure ....................................70 psi (4.8 bar)
PAC200T (90°& 65°) Cutting/PAC200E (65°) Gouging/MAX200 Rev 1 (90°) Hand
Torches
Maximum cutting thickness ..........................2 inches (50 mm)
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 (3.0 l/min)
Weight ..........................................................3 lbs (1.4 kg - MAX200 Rev 1 90°) 2-1/2 lbs.
(1.1 kg - PAC200T/E)

MAX200 Product Configuration Manual 1-3
SPECIFICATIONS
MAX200 Machine Torch
Maximum cutting thickness ..........................2 inches (50 mm)
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 (3.0 l/min)
Weight ..........................................................2-1/2 lbs. (1.1 kg)
Switch Remote (SR) V/C Control - Optional
Controls........................................................Start button:
Activates IHS (if on) and initializes
pilot arc. Stop button:
Deactivates main contactor in
power supply. IHS On/Off switch:
Turns IHS system on or off.
Auto Height On/Off switch:
Activates THC in power supply.
Voltage adjust pot:
Adjusts arc cutting voltage and
displays value on LEDs. Current adjust pot:
Adjusts arc cutting current and
displays value on LEDs.
Control Range ..............................................Current: 40 to 200 Amps
Voltage: 100 to 200 Volts
Control Resolution........................................Current: 20 Amps
Voltage: 5 Volts
Dimensions:
Width ............................................................11-1/2" ( 29 cm)
Height...........................................................5" (13 cm)
Depth............................................................13-1/4" (34 cm)
Weight ..........................................................6 pounds (2.7 kg)
Digital Remote (DR) V/C Control - Optional
Controls........................................................Voltage adjust pot:
Adjusts arc cutting voltage and
displays value on LEDs. Current adjust pot:
Adjusts arc cutting current and
displays value on LEDs.
Dimensions:
Width ............................................................11-1/2" (29 cm)
Height...........................................................3" (7.6 cm)
Depth............................................................13-3/8" (34 cm)
Weight ..........................................................5 pounds-5 oz. (2.4 kg)

MAX200 Product Configuration Manual
1-4
SPECIFICATIONS
Programmable Remote (PR) V/C Control - Optional
Controls........................................................None. Controlled through guidance
machinery computer.
Dimensions:
Width ............................................................11-1/2" (29 cm)
Height...........................................................3" (7.6 cm)
Depth............................................................12-1/2" (31.8 cm)
Weight ..........................................................5 pounds-5 oz. (2.4 kg)
Remote Current (RCC) Control - Optional
Dimensions and Weight:
Width ............................................................6-1/2" (16.5 cm)
Height...........................................................2-1/2" (6.2 cm)
Depth............................................................8-1/2" (21.6 cm)
Weight ..........................................................3 pounds (1.4 kg)
Initial Height Sensing - Optional
Input Power ..................................................120 VAC from power supply
Air Pressure .................................................20 psi (1.4 bar) regulated shop air input
to solenoid.
Dimensions:
Width ............................................................9" (23 cm)
Height...........................................................4-1/2" (11 cm)
Depth............................................................11-1/2" (29 cm)
Weight ..........................................................13 pounds (6 kg)
Water Muffler - Optional - (not used with the stainless steel torch)
Refer to Water Muffler Instruction Manual (P/N 802050).

MAX200 ProductConfigurationManual 2-1
Section 2
MAX200 MACHINE SYSTEM ORDER FORM

MAX200 ProductConfigurationManual2-2
Programmable
Remote V/C
CNC
Interface
(customer
supplied)
Torch
WM
IHS
Console
Air Reg.
Second
MAX200
Power
Supply
WM
Pump
Digital
Remote V/C Switch Remote V/C
Remote
Current
Control
MAX200
Power
Supply
1 MAX200 Power Supply (PS)
2 Machine Torch Assembly
3 Leads Between Power Supply and Torch
4 Machine Interface Cable Between Power Supply and
CNC Interface
5 Programmable Remote Voltage & Current Control
6 Cable Between Power Supply and Programmable Remote or
Digital Remote
7 Cable Between Programmable Remote and CNC Interface
8 Digital Remote Voltage & Current Control
9 Switch Remote Voltage & Current Control
10 Cable Between Power Supply and Switch Current
11 Remote Current Control
12 Cable Between Power Supply and Current Remote
13 Inductive IHS System
14 IHS Pressure Regulator Assembly
15 Inductive IHS Lead Set
16 Water Muffler System (not used with the stainless steel torch)
17 Additional Length WM Hose
18 Cable Between Water Muffler Pump and Power Supply
19 Work Cable Between Power Supply and Work Table
20 Hold Cable Between Power Supplies
MAX200 Machine System Block Diagram

MAX200 ProductConfigurationManual 3-1
Section 3
MAX200 HAND SYSTEM ORDER FORM

MAX200 ProductConfigurationManual3-2
1 MAX200 Hand Cutting System
2 MAX200 Hand Gouging System
3 MAX200 Power Supply
4 PAC200T 90°Cutting Torch Assembly with
25 ft (7.6 m) Leads MAX200 Hand Systems and Options
5 PAC200T 65°Cutting Torch Assembly with 25 ft (7.6 m) Leads
6 PAC200E Gouging Torch Assembly with 25 ft (7.6 m) Leads
7 Extended Leads
1
2
3
4
5
6
MAX200
Power
Supply
MAX200
Power
Supply
MAX200
Power
Supply
7