Hypertherm powermax800 User manual

600 Volt Conversion
Installation Manual
803200 - Rev. 0

600 Volt Conversion
Kit: 128312
Installation Manual
IM-320
(P/N 803200)
© 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 June, 1998
HYPERTHERM, Inc.
P.O. Box 5010
Hanover, New Hampshire 03755-5010
Tel.: [phone]
Fax: [phone]
http://www.hypertherm.com
email:[email protected]
®
®

Hypertherm Offices Worldwide :
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
Tel.: [phone] (Main Office)
Fax: [phone] (All Departments)
Tel.: [phone] (Technical Service)
Tel.: [phone] (Customer Service)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]
European Technical Support Organization (ETSO)
Technologiepark Hanau
Rodenbacher Chaussee 6
D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]
Hypertherm Singapore Pte Ltd
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
Tel.: [phone]
Fax: [phone]
Hypertherm U.K.
9 Berkeley Court • Manor Park
Runcorn, Cheshire, England WA7 1TQ
Tel.: [phone]
Fax: [phone]
Hypertherm France
10, Allée de I’lsara
F-95000 Cergy-Pontoise, France
Tel.: [phone]
Fax: [phone]
Hypertherm Italy
Via Stilicone 18
20154 Milan, Italy
Tel.: [phone]
Fax: [phone]

1-1
600V Installation Manual
SPECIFICATIONS
Section 1 SPECIFICATIONS
In this section:
Introduction ........................................................................................1-2
Specifications ..................................................................................... 1-2
600 Volt Powermax900 Power Supply ..........................................1-2

1-2 600V Installation Manual
SPECIFICATIONS
INTRODUCTION
The instructions in this manual will enable a qualified electronics technician to convert the
208/240/480 volt Powermax900 or 208/240/480 volt Powermax800 power supply into a 600 volt
power supply. The kit (128312) 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 600 volt conversion kit.
When installation is complete, refer to the Operator Manual for setup, operating instructions and
maintenance of the Powermax system.
SPECIFICATIONS See the operator manual for Powermax800 specifications
600 Volt 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 .................................................600V/12A - 3φ, 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

600V INSTALLATION
600V Installation Manual 2-1
Section 2 600V 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 Chassis .............2-6
Attaching 600V Transformer Case Assembly to
Powermax900 Chassis .....................................................................2-8
Switching Voltage Configuration to 480V ..........................................2-9
Hooking Up the Three-Phase Transformer Secondary Power Cord
from 600V Transformer Case Assembly to Powermax900 ...............2-10
Choosing Plug, Power Cord and Line Disconnect Box Fuse ............2-11
Power Cord Plug......................................................................2-11
Power Cord - 600V ..................................................................2-11
Line Voltage Disconnect Box and Fuses .................................2-11

600V INSTALLATION
2-2 600V 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 600V kit to the 208/240/480V Powermax900 involves 6 basic steps:
1. Installation of wheels and casters to the transformer case.
2. Attaching the 600V power supply bracket to the Powermax900 chassis.
3. Attaching the 600V case assembly to the Powermax900 chassis.
4. Switching the power supply voltage configuration to 480V.
5. Hooking up the three-phase transformer secondary power cord from the 600V
transformer case assembly to the Powermax900.
6. Choosing the plug, power cord and line disconnect box fuse.
WARNING
THE 208/240/480V POWERMAX900 POWER SUPPLY IS SET UP TO OPERATE AT 240V WITH
A SINGLE-PHASE INPUT. WHEN CONVERTED TO A 600V POWER SUPPLY, THE VOLT-
AGE CONFIGURATION IN THE POWER SUPPLY MUST BE SWITCHED TO 480V, AND THE
POWER CORD MUST BE HOOKED UP FOR THREE-PHASE OPERATION. See pages 2-9 to
2-10.
See Section 3 for a parts list of the 128312 Powermax 600V conversion kit.
Note: All graphics and text in this document refer to the Powermax900. Unless otherwise noted, all
instructions apply to either the Powermax800 or Powermax900.

600V INSTALLATION
600V Installation Manual 2-3
Figure 2-1 Powermax900 600V Power Supply Assembled

600V INSTALLATION
2-4 600V 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.

600V INSTALLATION
600V Installation Manual 2-5
Figure 2-3 Wheels and Casters Installed on 600V 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