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