Hypertherm Powermax 900 User manual

230 Volt CE Conversion
Installation Manual
803210 - Rev. 0

230 Volt CE Conversion
Kit: 128313
Installation Manual
IM-321
(P/N 803210)
© Copyright 1998 Hypertherm, Inc.
All Rights Reserved
HYPERTHERM and POWERMAX are trademarks of Hypertherm, Inc. and may be
registered in the United States and/or other countries
Revision 0 September, 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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1-1
230V CE Installation Manual
SPECIFICATIONS
Section 1 SPECIFICATIONS
In this section:
Introduction ........................................................................................1-2
Specifications ..................................................................................... 1-2
230 Volt CE Powermax900 Power Supply ....................................1-2

1-2 230V CE Installation Manual
SPECIFICATIONS
INTRODUCTION
The instructions in this manual will enable a qualified electronics technician to convert the
400 volt CE Powermax900 into a 230 volt CE power supply. The kit (128313) contains a transformer
and case, wheels, castors, and 2 line cords - one to hook up to a line disconnect box or 3-phase plug,
and a shorter cord to connect from the transformer case to the link box at the rear of the Powermax -
See Figure 2-1. See also Section 3 for a list of parts for the 230 volt CE conversion kit.
When installation is complete, refer to the Operator Manual for setup, operating instructions and
maintenance of the Powermax system.
SPECIFICATIONS
230 Volt CE Powermax900 Power Supply
Rated Open Circuit Voltage (OCV) (U0) ..............300VDC
Rated Output Current (I2) ....................................20-50 amps
Rated Output Voltage (U2) ..................................120VDC
Duty Cycle (X) @ 40°C .......................................50% (I2=55A, U2=120V) See data tag on power
supply for more information on duty cycle
Ambient temperature/duty cycle..........................Power supplies will operate between +14°
and 104°F (-10°and +40°C). Power
supplies operated in an ambient
temperature above 86°F (30°C) may show
some decrease in duty cycle.
Apparent Input Power (S1) ..................................11.4kVA (U1I1)
Input Voltage (U1)/Input Current (I1)
@ 6.6 kw Output .................................................230V/30A - 3φ, 50/60 Hz
Dimensions and Weight:
Depth...................................................................23.1" (590 mm)
Width ...................................................................15.25" (390 mm)
Height..................................................................27.7" (700 mm)
Weight .................................................................128 pounds (58 kg)
Gas Type.............................................................Air or Nitrogen
Gas Quality, Air ...................................................Clean, dry, oil-free
Gas Quality, Nitrogen..........................................99.995% pure
Gas Inlet Pressure ..............................................90 psi (6.2 bar)
Gas Flow .............................................................360 scfh/6 scfm at 90 psi (170 l/min
at 6.2 bar) supplied to power supply
pressure regulator
Power Supply pressure regulator setting ............70 psi (4.8 bar) flowing

230V CE INSTALLATION
230V CE Installation Manual 2-1
Section 2 230V INSTALLATION
In this section:
Installation ........................................................................................... 2-2
Installation of Wheels and Casters to Transformer Case.................... 2-4
Wheel Installation ........................................................................... 2-4
Caster Installation........................................................................... 2-4
Attaching Power Supply Bracket to Powermax900 CE Chassis. ........ 2-6
Attaching 230V Transformer Case Assembly to Powermax900
CE Chassis ......................................................................................... 2-9
Hooking up the Three-Phase Transformer Secondary Power Cord
from 230V Transformer Case Assembly to
Powermax900 CE Power Unit........................................................... 2-10
Choosing Plug, Power Cord and Line Disconnect Box Fuse ............ 2-11
Power Cord Plug .......................................................................... 2-11
Power Cord - 230V ....................................................................... 2-11
Line Voltage Disconnect Box and Fuse........................................ 2-12

230V CE INSTALLATION
2-2 230V CE Installation Manual
WARNING
INSTALLATION MUST BE PERFORMED ONLY BY HYPERTHERM DISTRIBUTORS OR
QUALIFIED ELECTRONICS TECHNICIANS!!
SHOCK HAZARD: Always turn off power, unplug cord from wall and wait 5 minutes before
removing any cover of the power supply! If power unit is directly connected to a line
disconnect box, place line disconnect switch to OFF position. Lock out and tag out switch
before proceeding!
INSTALLATION
The installation of the 230V kit to the 400V CE Powermax900 involves 5 basic steps:
1. Installation of wheels and casters to the transformer case.
2. Attaching the power supply bracket to the Powermax900 chassis.
3. Attaching the 230V case assembly to the Powermax900 bracket and chassis.
4. Hooking up the three-phase transformer secondary power cord from the 230V
transformer case assembly to the Powermax900.
5. Choosing the plug, power cord and line disconnect box fuse.
See Section 3 for a parts list of the 128313 Powermax900 230V conversion kit.

230V CE INSTALLATION
230V CE Installation Manual 2-3
Figure 2-1 Powermax900 230V CE Power Supply Assembled

230V CE INSTALLATION
2-4 230V CE Installation Manual
INSTALLATION OF WHEELS AND CASTERS TO TRANSFORMER
CASE
Wheel Installation
1. Carefully turn transformer case assembly upside down.
2. Snap an 027249 retaining ring on one end of the 004672 wheel axle.
3. Slide one 027057 wheel on the axle.
4. Slide 008973 shoulder washer over the end of the axle with the larger diameter end of
the washer facing the mounted wheel.
5. Slide the axle through both holes in the rear of the transformer case assembly.
6. Slide the second 008973 shoulder washer over the end of the axle with the smaller
diameter end of the washer facing the transformer case.
7. Slide the second 027057 wheel onto the axle.
8. Snap the second 027249 retaining ring on the end of the axle to secure the second
wheel.
Caster Installation
1. Attach the 027299 casters to the case with the 075470 10-32 screws and 075174 star
washers as shown in Figure 2-2.
2. Turn transformer case back over on to wheels - Figure 2-3.
Wheel and caster installation complete.

230V CE INSTALLATION
230V CE Installation Manual 2-5
Figure 2-3 Wheels and Casters Installed on 230V Transformer Case
Figure 2-2 Wheel and Caster Installation
027249
Retaining
ring
008973
Shoulder
washer
027299
Caster
075470
10-32 screws (8)
004672
Axle
075174
10-32 star washers (8)
027057
Wheel 027057 Wheel

230V CE INSTALLATION
2-6 230V CE Installation Manual
ATTACHING POWER SUPPLY BRACKET TO POWERMAX900 CE
CHASSIS.
1. If torch is connected to power supply, disconnect it.
WARNING
INSTALLATION MUST BE PERFORMED ONLY BY HYPERTHERM DISTRIBUTORS OR
QUALIFIED ELECTRONICS TECHNICIANS!!
SHOCK HAZARD: Always turn off power, unplug cord from wall and wait 5 minutes before
removing any cover of the power supply! If power unit is directly connected to a line
disconnect box, place line disconnect switch to OFF position and remove power cord from
line disconnect box.
Figure 2-4 Removal of Power Cord from Powermax900 CE Power Supply - 1 of 2
Remove screws to remove
line cord rear panel and
expose filter board and TB1.
2. Remove power cord from line disconnect box or from receptacle.
3. Remove power cord from power supply. See Figure 2-4.
3.1.Loosen the power cord strain relief.
3.2.Remove the screws securing the line cord rear panel.
3.3.Slide rear panel down on power cord to expose filter board and TB1.
3.4.Disconnect power cord from TB1 and ground stud. See Figure 2-5.
Loosen power cord
strain relief.

230V CE INSTALLATION
230V CE Installation Manual 2-7
U V W Remove power
cord wires from
TB1 and ground
stud.
Green/
Yellow
Black
Blue
Brown
TB1
Figure 2-5 Removal of Power Cord from Powermax900 CE Power Supply - 2 of 2
GND
3.5.Remove toroid from power cord wires. Save the toroid. See Figure 2-6.
3.5.Remove the power cord from the rear panel.
Figure 2-6 Removal of Toroid from Power Cord
Unwind power cord
wires from toroid.
Save toroid
Toroid

230V CE INSTALLATION
2-8 230V CE Installation Manual
Figure 2-7 Attaching 230V Power Supply Bracket to Powermax CE Chassis
001568
Power supply
bracket
075160
Kepnuts (on inside)
(12)
075174
Star washers (12)
075470
Screws (12)
4. Remove the power supply cover.
5. Carefully tilt the Powermax over onto its front handle as shown in Figure 2-7.
6. Place the 001568 power supply bracket against the bottom of the power supply as shown
in Figure 2-7 and fasten with the 075470 10-32 screws, 075174 star washers and
075160 kepnuts in 12 locations.

230V CE INSTALLATION
230V CE Installation Manual 2-9
ATTACHING 230V TRANSFORMER CASE ASSEMBLY TO
POWERMAX900 CE CHASSIS
1. Lift Powermax over transformer case assembly with the rear of the power supply lined up
over the power cord side of the transformer case.
2. Carefully set down the Powermax onto the transformer case assembly.
3. Fasten the Powermax to the transformer case assembly by screwing in the 075467
8-32 screws in 10 locations.
4. Thread the transformer secondary power cord (shorter cord) through the strain relief of
the line cord rear panel.
Figure 2-6 Attaching 230V Transformer Case Assembly to Powermax900 CE Chassis
075467
8-32 screw
Transformer
Secondary
Power Cord

230V CE INSTALLATION
2-10 230V CE Installation Manual
Caution: The toroid must be installed as shown to maintain European EMC compliance.
1. Prepare the power cord wires as shown in Figure 2-9. Note that all 4 wires must loop
through the toroid.
HOOKING UP THE THREE-PHASE TRANSFORMER SECONDARY
POWER CORD FROM 230V TRANSFORMER CASE ASSEMBLY TO
POWERMAX900 CE POWER UNIT
WARNING
BE CERTAIN THAT WIRES ARE CONNECTED AS SHOWN IN FIGURE 2-10. AS A
PRECAUTION, CHECK CONTINUITY FROM POWER SUPPLY ENCLOSURE TO INCOMING
GROUND WIRE BEFORE CONNECTING TO POWER.
Figure 2-9 Power Cord Preparation
2. Connect the power cord wires and the ground wire as shown in Figure 2-10. Be certain
that all wires are fastened securely! Pull on wires after fastening to verify that they
will not come loose.
3. Connect the rear panel to the Powermax900 power supply and secure with screws.
4. Tighten the strain relief around the power cord. Be certain that the strain relief grips the
outer insulation of the power cord and not the individual wires.
5. Replace the power supply cover. See completed assembly in Figure 2-1.
Loop all 4 wires 1 turn
through toroid
Toroid
0.5" (13 mm)
3.75" (95 mm)
4.75" (120 mm)

230V CE INSTALLATION
230V CE Installation Manual 2-11
U V W Connect power
cord wires to
TB1 and ground
stud.
Green/
Yellow
Black
Blue
Brown
TB1
Figure 2-10 Connecting Power Cord to Powermax900 CE Power Supply
GND
CHOOSING PLUG, POWER CORD AND LINE DISCONNECT BOX
FUSE
Power Cord Plug
The 230V CE Powermax900 kit is shipped with a three-phase power cord and no plug. The
user must obtain a plug that is certified by national or local electrical codes. The plug should be
connected to the power cord by a licensed electrician.
Power Cord - 230V
If the three-phase power cord length needs to be changed, use the table below to choose the proper
gauge size for the appropriate length. Use cords that are certified by national or local codes. The
cord should be installed only by a licensed electrician.
Input Input Recommended Power Cord Gauge Size (mm2)
Voltage Current < 3 m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45 m
230 VAC 21 amps 2.5 4 6 10 16

230V CE INSTALLATION
2-12 230V CE Installation Manual
The 230 Volt CE conversion is now complete. See the Powermax Operator Manual for further
instructions to setup, operate and maintain the Powermax system.
Line Voltage Disconnect Box and Fuse
Use a line disconnect box for each power supply. This disconnect box allows the operator 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. Use slow-blow fuses according to the power
requirements listed below.
Input Input Current Recommended
Voltage Phase @ 6.6 kw Output Slow-Blow Fuse Size
230 VAC 3 30 amps 40 amp

PARTS LIST
3-1
230V CE Installation Manual
Section 3 PARTS LIST
In this section:
Powermax900 230 Volt CE Conversion Kit - 128313........................3-2

PARTS LIST
230V CE Installation Manual
3-2
Figure 3-1 Powermax900 230V CE Panel, Wheels and Casters
Index No. Part No. Description Quantity
1 001568 Panel:Powermax800 600V 1
2 004672 Axle:Powermax800 Power Unit 1
3 008973 Shoulder Washer:1/2" X 27/64 Nylon 2
4 027057 Wheel:8" X 1.75" 2
5 027249 Retaining Ring:1/2" Shaft Extension 2
6 027299 Caster:MAX70 Swivel 2
7 075467 M/S:8-32 X 3/8 Phillips Head Round SSB 10
8 075470 M/S:10-32 X 3/4 Phillips Head Pan 20
9 075174 Lockwasher :#10 Internal 20
075160 Kepnut:10-32 S/Z 12
129365 Powermax900 230V CE Conversion SA 1
10 001672 Cover:Powermax900 600V 1
11 001570 Bracket:Powermax800 600V 2
12 008752 Fuseblock:3Position 30A600V 13/32X1-1/2 1
13 008949 Terminal board:3-Terminal 1
14 108092 Fuse:32A 400V 10mm X 38mm 3
15 008963 Strain relief:3/4" X .625-.750 2
16 014236 Transformer:Powermax900 230V Input 1
17 123383 Cable:Powermax900 230V Conv. Fuses 1
18 123384 Cable:Powermax900 230V Conv. Term. Block 1
POWERMAX900 230 VOLT CONVERSION KIT - 128313
1
3
10
89
66
3
4
5
25
4

PARTS LIST
3-3
230V CE Installation Manual
7
10 11
12
13
14
15
16
Figure 3-2 Powermax900 230V CE Conversion Subassembly - 129369
17
18