MAXPRO200

Instruction Manual

807700 – Revision 1
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 MAXPRO200

Instruction Manual
807700 – Revision 1

English

March 2013

Hypertherm, Inc.
Hanover, NH 03755 USA
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9
Hanover, NH 03755 USA 4704 SE
603-643-3441 Tel (Main Office) Roosendaal, Nederland
603-643-5352 Fax (All Departments) 31 165 596907 Tel
[email protected] (Main Office Email) 31 165 596901 Fax
800-643-9878 Tel (Technical Service) 31 165 596908 Tel (Marketing)
[email protected] (Technical Service Email) 31 165 596900 Tel (Technical Service)
800-737-2978 Tel (Customer Service) 00 800 4973 7843 Tel (Technical Service)
[email protected] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization) Hypertherm Japan Ltd.
877-371-2876 Fax (Return Materials Authorization) Level 9, Edobori Center Building
[email protected] (RMA email) 2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
Hypertherm Plasmatechnik GmbH 81 6 6225 1183 Tel
Technologiepark Hanau 81 6 6225 1184 Fax
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland Hypertherm Brasil Ltda.
49 6181 58 2100 Tel Rua Bras Cubas, 231 – Jardim Maia
49 6181 58 2134 Fax Guarulhos, SP - Brasil
49 6181 58 2123 (Technical Service) CEP 07115-030
55 11 2409 2636 Tel
Hypertherm (S) Pte Ltd. 55 11 2408 0462 Fax
82 Genting Lane
Media Centre Hypertherm México, S.A. de C.V.
Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1,
Singapore 349567, Republic of Singapore Colonia Olivar de los Padres
65 6841 2489 Tel Delegación Álvaro Obregón
65 6841 2490 Fax México, D.F. C.P. 01780
65 6841 2489 (Technical Service) 52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building Hypertherm Korea Branch
495 ShangZhong Road #3904 Centum Leaders Mark B/D,
Shanghai, 200231 1514 Woo-dong, Haeundae-gu, Busan
PR China Korea, 612-889
86-21-60740003 Tel 82 51 747 0358 Tel
86-21-60740393 Fax 82 51 701 0358 Fax

07/18/12
 Contents

Safety ..........................................................................................................................................................9
Recognize safety information ............................................................................................................................................................. 9
Follow safety instructions .................................................................................................................................................................... 9
Electrical hazards .................................................................................................................................................................................. 9
Electric shock can kill ....................................................................................................................................................................... 10
Cutting can cause fire or explosion ............................................................................................................................................... 11
Fire prevention ............................................................................................................................................................................ 11
Explosion prevention ................................................................................................................................................................. 11
Toxic fumes can cause injury or death .......................................................................................................................................... 12
Grounding safety ............................................................................................................................................................................... 13
Static electricity can damage circuit boards ............................................................................................................................... 13
Compressed gas equipment safety .............................................................................................................................................. 14
Gas cylinders can explode if damaged ........................................................................................................................................ 14
A plasma arc can cause injury and burns .................................................................................................................................... 14
Arc rays can burn eyes and skin .................................................................................................................................................... 15
Pacemaker and hearing aid operation .......................................................................................................................................... 16
Noise can damage hearing .............................................................................................................................................................. 16
A plasma arc can damage frozen pipes ....................................................................................................................................... 16
Dry dust collection information ....................................................................................................................................................... 17
Laser radiation .................................................................................................................................................................................... 18
Symbols and marks ........................................................................................................................................................................... 19
Additional safety information ........................................................................................................................................................... 20
Warning labels ................................................................................................................................................................................... 20
Electromagnetic Compatibility (EMC) .............................................................................................23
Introduction ......................................................................................................................................................................................... 23
Installation and use ............................................................................................................................................................................ 23
Assessment of area ........................................................................................................................................................................... 23
Methods of reducing emissions ..................................................................................................................................................... 23
Mains supply ............................................................................................................................................................................... 23

MAXPRO200 Instruction Manual 807700 Revision 1 1

Contents

Maintenance of cutting equipment .................................................................................................................................................24

Cutting cables .....................................................................................................................................................................................24
Equipotential bonding ................................................................................................................................................................24
Earthing of the workpiece .........................................................................................................................................................24
Screening and shielding ...................................................................................................................................................................24
Warranty .................................................................................................................................................. 25
Attention ...............................................................................................................................................................................................25
General .................................................................................................................................................................................................25
Patent indemnity .................................................................................................................................................................................26
Limitation of liability ............................................................................................................................................................................26
National and local codes ..................................................................................................................................................................26
Liability cap ..........................................................................................................................................................................................26
Insurance ..............................................................................................................................................................................................26
Transfer of rights .................................................................................................................................................................................26
Product Stewardship ........................................................................................................................... 27
Introduction ..........................................................................................................................................................................................27
National and local safety regulations .............................................................................................................................................27
Certification test marks .....................................................................................................................................................................27
Differences in national standards ...................................................................................................................................................27
Safe installation and use of shape cutting equipment ...............................................................................................................28
Procedures for periodic inspection and testing ..........................................................................................................................28
Qualification of test personnel .........................................................................................................................................................28
Residual current devices (RCDs) ...................................................................................................................................................28
Higher-level systems .........................................................................................................................................................................29
Environmental Stewardship .............................................................................................................. 31
Introduction ..........................................................................................................................................................................................31
National and local environmental regulations ...............................................................................................................................31
The RoHS directive ............................................................................................................................................................................31
Proper disposal of Hypertherm products .....................................................................................................................................31
The WEEE directive ...........................................................................................................................................................................31
The REACH regulation ......................................................................................................................................................................32
Proper handling and safe use of chemicals .................................................................................................................................32
Fumes emission and air quality .......................................................................................................................................................32
Specifications ........................................................................................................................................ 33
System description ............................................................................................................................................................................33
General .........................................................................................................................................................................................33
Power supply ...............................................................................................................................................................................33
Ignition console ...........................................................................................................................................................................33
Torch ..............................................................................................................................................................................................33
Gas system ..................................................................................................................................................................................33

2 MAXPRO200 Instruction Manual 807700 Revision 1

 Contents

Cooling system ........................................................................................................................................................................... 35

System gas requirements ................................................................................................................................................................ 35
Power supply ...................................................................................................................................................................................... 36
Mechanized torches .......................................................................................................................................................................... 37
Straight torch – 428024 .......................................................................................................................................................... 37
Quick-disconnect torch – 428027 or 428028 .................................................................................................................. 38
Hand torches ...................................................................................................................................................................................... 39
90 degree hand torch – 420108 ........................................................................................................................................... 39
65 degree hand torch – 420107 ........................................................................................................................................... 40
Installation .............................................................................................................................................. 41
Upon receipt ....................................................................................................................................................................................... 41
Claims .................................................................................................................................................................................................. 41
Installation requirements .................................................................................................................................................................. 41
Noise levels ......................................................................................................................................................................................... 41
Placement of system components ................................................................................................................................................. 42
Recommended grounding and shielding practices ................................................................................................................... 44
Introduction ................................................................................................................................................................................. 44
Types of grounding .................................................................................................................................................................... 44
Grounding practices ................................................................................................................................................................. 44
Placement of the power supply ...................................................................................................................................................... 48
Torch lead connections .................................................................................................................................................................. 49
Work lead connections .................................................................................................................................................................. 52
Torch connections ........................................................................................................................................................................... 53
Connect the torch to the quick-disconnect receptacle ............................................................................................................ 54
Torch mounting and alignment ....................................................................................................................................................... 55
Mounting the torch .................................................................................................................................................................... 55
Torch alignment .......................................................................................................................................................................... 55
CNC interface cable ....................................................................................................................................................................... 56
Notes to CNC interface cable run list ................................................................................................................................... 56
Remote ON/OFF switch (provided by customer) ...................................................................................................................... 58
Power requirements .......................................................................................................................................................................... 60
General ......................................................................................................................................................................................... 60
Line disconnect switch ............................................................................................................................................................. 61
Main power cable .................................................................................................................................................................... 61
Connect the power ........................................................................................................................................................................... 62
Torch coolant requirements ............................................................................................................................................................ 63
Premixed coolant for standard operating temperatures ................................................................................................... 63
Custom Coolant mix for cold operating temperatures (below -12° C / 10° F) ........................................................... 64
Custom Coolant mix for hot operating temperatures (above 38° C / 100° F) ............................................................ 65
Water purity requirements ....................................................................................................................................................... 65

MAXPRO200 Instruction Manual 807700 Revision 1 3

Contents

Fill the power supply with coolant ..................................................................................................................................................66

Connect the supply gases ...............................................................................................................................................................67
Air/air cutting ...............................................................................................................................................................................67
N2/N2 supply gas connection ..................................................................................................................................................67
O2/Air Supply gas hook up ......................................................................................................................................................67
Gas requirements ...............................................................................................................................................................................71
Setting the supply gas regulators ...........................................................................................................................................71
Gas regulators .....................................................................................................................................................................................72
Supply gas plumbing .........................................................................................................................................................................73
Supply gas hoses ...............................................................................................................................................................................74
Air .................................................................................................................................................................................................74
Oxygen ........................................................................................................................................................................................74
Nitrogen ......................................................................................................................................................................................74
Operation ................................................................................................................................................ 75
Daily start-up .......................................................................................................................................................................................75
Controls and indicators .....................................................................................................................................................................76
Power supply operation ....................................................................................................................................................................77
General .........................................................................................................................................................................................77
3-digit display functions ............................................................................................................................................................78
Choosing a cutting process .....................................................................................................................................................79
Handheld cutting ................................................................................................................................................................................80
Specifications ..............................................................................................................................................................................80
Consumable selection and gas settings ...............................................................................................................................80
Starting a cut ...............................................................................................................................................................................80
Piercing .........................................................................................................................................................................................81
Gouging ................................................................................................................................................................................................82
Specifications ..............................................................................................................................................................................82
Gouging safety ............................................................................................................................................................................82
Gouge a workpiece ....................................................................................................................................................................82
Gouging techniques ..................................................................................................................................................................83
Straight gouging .................................................................................................................................................................83
Side gouging .......................................................................................................................................................................84
Gouge profiles and metal removal rates ...............................................................................................................................85
Varying the gouge profile ..........................................................................................................................................................86
Cutting parameters ............................................................................................................................................................................86
Mechanized consumables ................................................................................................................................................................86
Hand held torch consumables ........................................................................................................................................................86
Hand held cutting and gouging consumable selection .....................................................................................................87
Mild steel ...............................................................................................................................................................................87
Stainless steel .....................................................................................................................................................................88

4 MAXPRO200 Instruction Manual 807700 Revision 1

 Contents

Aluminum ............................................................................................................................................................................. 89
Install and inspect consumables .................................................................................................................................................... 90
Install consumables ................................................................................................................................................................... 90
Inspect consumables ................................................................................................................................................................ 91
Torch maintenance ............................................................................................................................................................................ 92
Routine maintenance ................................................................................................................................................................ 92
Quick-disconnect maintenance .............................................................................................................................................. 92
Maintenance kit .......................................................................................................................................................................... 92
Torch connections ..................................................................................................................................................................... 93
Quick-disconnect torch .................................................................................................................................................... 93
Straight torch ...................................................................................................................................................................... 93
Replace the torch water tube ................................................................................................................................................. 94
Common cutting faults ..................................................................................................................................................................... 95
Machine torch ............................................................................................................................................................................. 95
Hand torch ................................................................................................................................................................................... 95
Optimizing cut quality ....................................................................................................................................................................... 96
Tips for table and torch ............................................................................................................................................................ 96
Plasma setup tips ...................................................................................................................................................................... 96
Maximize the life of consumable parts .................................................................................................................................. 96
Additional factors of cut quality .............................................................................................................................................. 97
Cut angle ............................................................................................................................................................................. 97
Dross .................................................................................................................................................................................... 98
Straightness of the cut surface ....................................................................................................................................... 98
How to increase cutting speed ...................................................................................................................................... 98
Estimated kerf-width compensation ...................................................................................................................................... 99
Metric .................................................................................................................................................................................... 99
English ................................................................................................................................................................................100
Cut charts ..........................................................................................................................................................................................101
Maintenance ........................................................................................................................................119
Introduction .......................................................................................................................................................................................119
Preventive maintenance .................................................................................................................................................................119
Power supply status ........................................................................................................................................................................120
Sequence of operation and power supply status ....................................................................................................................121
PCB block diagram .........................................................................................................................................................................126
Error codes .......................................................................................................................................................................................127
Diagnostic functions .......................................................................................................................................................................128
Troubleshooting table .....................................................................................................................................................................129
Initial checks .....................................................................................................................................................................................137
Power measurement .......................................................................................................................................................................138

MAXPRO200 Instruction Manual 807700 Revision 1 5

Contents

Power supply coolant system servicing ..................................................................................................................................... 139

Draining the coolant system .................................................................................................................................................. 139
Coolant flow test ...................................................................................................................................................................... 140
Coolant system filter replacement ....................................................................................................................................... 142
Air filter element replacement ....................................................................................................................................................... 143
Control board ................................................................................................................................................................................... 144
Control board LED list ............................................................................................................................................................ 144
Control board test points ....................................................................................................................................................... 144
Gas leak tests ................................................................................................................................................................................... 147
Start circuit ........................................................................................................................................................................................ 148
Operation ................................................................................................................................................................................... 148
Start circuit functional schematic ......................................................................................................................................... 148
Start circuit troubleshooting .................................................................................................................................................. 149
Pilot arc current levels .................................................................................................................................................................... 151
Transfer current ........................................................................................................................................................................ 151
Chopper tests .................................................................................................................................................................................. 152
Automatic chopper and current sensor tests during power-up .................................................................................... 152
Using a meter to measure open circuit voltage (OCV) ........................................................................................... 153
Phase loss detection .............................................................................................................................................................. 154
Torch lead test ......................................................................................................................................................................... 155
Preventive maintenance ................................................................................................................................................................. 156
Introduction ............................................................................................................................................................................... 156
Preventive maintenance protocol ......................................................................................................................................... 156
The power supply .................................................................................................................................................................... 156
Cooling system ........................................................................................................................................................................ 157
Torch main body ...................................................................................................................................................................... 157
Gas flows .................................................................................................................................................................................. 157
Cable connections .................................................................................................................................................................. 158
Ignition enclosure .................................................................................................................................................................... 158
System grounding ................................................................................................................................................................... 158
............................................................................................................................................................................................................. 158
Preventive Maintenance Master Schedule ................................................................................................................................ 159
Daily: ........................................................................................................................................................................................... 159
Weekly: ...................................................................................................................................................................................... 159
Semi-annually: .......................................................................................................................................................................... 159
Annually: .................................................................................................................................................................................... 159
Preventive Maintenance Protocol Checklist .............................................................................................................................. 160
Year 1 preventive maintenance (PM) kits .................................................................................................................................. 161
Maintenance kits parts list ..................................................................................................................................................... 161
Service parts replacement schedule .......................................................................................................................................... 161

6 MAXPRO200 Instruction Manual 807700 Revision 1

 Contents

Parts List ...............................................................................................................................................165

Control panel ....................................................................................................................................................................................165
Power supply ....................................................................................................................................................................................166
Ignition enclosure ............................................................................................................................................................................172
Height control connection kits ......................................................................................................................................................173
Sensor THC connection kit – 428023 ...............................................................................................................................173
Sensor PHC connection kit – 428022 ..............................................................................................................................173
Wire groups and harnesses ..........................................................................................................................................................173
USB cables for software updates ................................................................................................................................................173
Cable for USB update – 223291 ........................................................................................................................................173
Cable for USB update – 223273 ........................................................................................................................................173
Power supply gas hose kit – 228862 ......................................................................................................................................173
Machine torches ..............................................................................................................................................................................174
Straight torch ............................................................................................................................................................................174
Quick-disconnect torch ..........................................................................................................................................................174
Leads and cables ............................................................................................................................................................................175
Machine torch leads ................................................................................................................................................................175
CNC cables ..............................................................................................................................................................................175
Work leads ................................................................................................................................................................................175
Work clamp ...............................................................................................................................................................................175
Hand torch leads .....................................................................................................................................................................175
Inline valve kit ....................................................................................................................................................................................175
Hand torch heat shield – 127389 .............................................................................................................................................175
90 degree hand torch .....................................................................................................................................................................176
65 degree hand torch .....................................................................................................................................................................177
Consumable parts kits ....................................................................................................................................................................178
Mechanized torch consumable kit – 428013 ...................................................................................................................178
Hand torch consumable kit – 428014 ...............................................................................................................................179
Supply gas hoses ............................................................................................................................................................................180
Oxygen .......................................................................................................................................................................................180
Nitrogen .....................................................................................................................................................................................180
Air ................................................................................................................................................................................................180
Recommended spare parts ...........................................................................................................................................................181
Wiring Diagrams .................................................................................................................................183
Wiring diagram symbols ................................................................................................................................................................184

MAXPRO200 Instruction Manual 807700 Revision 1 7

Contents

Material Safety Data Sheet (MSDS) — Torch Coolant 30% PG Mixture .............................197
1 - Identification of the substance/mixture and of the company undertaking ................................................................... 197
2 - Hazards identification ............................................................................................................................................................... 198
3 - Composition/information on ingredients ............................................................................................................................. 198
4 - First aid measures ..................................................................................................................................................................... 198
5 - Fire-fighting measures ............................................................................................................................................................. 198
6 - Accidental release measures ................................................................................................................................................. 199
7 - Handling and storage ............................................................................................................................................................... 199
8 - Exposure controls/personal protection ................................................................................................................................ 199
9 - Physical and chemical properties .......................................................................................................................................... 200
10 - Stability and reactivity ............................................................................................................................................................ 200
11 - Toxicological information ...................................................................................................................................................... 201
12 - Ecological information ........................................................................................................................................................... 201
13 - Disposal considerations ........................................................................................................................................................ 201
14 - Transport information ............................................................................................................................................................. 202
15 - Ecological information ........................................................................................................................................................... 202
16 - Other information .................................................................................................................................................................... 202

8 MAXPRO200 Instruction Manual 807700 Revision 1

 Safety

RECOGNIZE SAFETY DANGER WARNING CAUTION

INFORMATION Hypertherm uses American National Standards Institute
guidelines for safety signal words and symbols. A signal
The symbols shown in this section are used to identify word DANGER or WARNING is used with a safety
potential hazards. When you see a safety symbol in this symbol. DANGER identifies the most serious hazards.
manual or on your machine, understand the potential
for personal injury, and follow the related instructions to • DANGER and WARNING safety labels are located on
avoid the hazard. your machine near specific hazards.
• DANGER safety messages precede related
instructions in the manual that will result in serious
FOLLOW SAFETY injury or death if not followed correctly.
INSTRUCTIONS • WARNING safety messages precede related
instructions in this manual that may result in injury or
Read carefully all safety messages in this manual and death if not followed correctly.
safety labels on your machine. • CAUTION safety messages precede related
instructions in this manual that may result in minor
• Keep the safety labels on your machine in good injury or damage to equipment if not followed correctly.
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.

ELECTRICAL HAZARDS
• Only trained and authorized personnel may open this • If the equipment must have power when the enclosure
equipment. is open for servicing, arc flash explosion hazards may
• If the equipment is permanently connected, turn it off, exist. Follow ALL local requirements (NFPA 70E in the
and lock out/tag out power before the enclosure is USA) for safe work practices and for Personal
opened. Protective Equipment when servicing energized
equipment.
• If power is supplied to the equipment with a cord,
unplug the unit before the enclosure is opened. • The enclosure shall be closed and the proper earth
ground continuity to the enclosure verified prior to
• Lockable disconnects or lockable plug covers must be
operating the equipment after moving, opening, or
provided by others.
servicing.
• Wait 5 minutes after removal of power before entering
• Always follow these instructions for disconnecting
the enclosure to allow stored energy to discharge.
power before inspecting or changing torch
consumable parts.

MAXPRO200 Instruction Manual 807700 Revision 1 9

Safety

ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause a fatal shock or • Install and ground this equipment according to the
severe burn. instruction manual and in accordance with national
• Operating the plasma system completes an electrical and local codes.
circuit between the torch and the workpiece. The • Inspect the input power cord frequently for damage or
workpiece and anything touching the workpiece are cracking of the cover. Replace a damaged power cord
part of the electrical circuit. immediately. Bare wiring can kill.
• Never touch the torch body, workpiece or the water in • Inspect and replace any worn or damaged torch leads.
a water table when the plasma system is operating. • Do not pick up the workpiece, including the waste
Electric shock prevention cutoff, while you cut. Leave the workpiece in place or
on the workbench with the work cable attached during
All Hypertherm plasma systems use high voltage the cutting process.
in the cutting process (200 to 400 VDC are • Before checking, cleaning or changing torch parts,
common). Take the following precautions when disconnect the main power or unplug the power
operating this system: supply.
• Never bypass or shortcut the safety interlocks.
• Wear insulated gloves and boots, and keep your body
• Before removing any power supply or system
and clothing dry.
enclosure cover, disconnect electrical input power.
• Do not stand, sit or lie on – or touch – any wet surface Wait 5 minutes after disconnecting the main power to
when using the plasma system. allow capacitors to discharge.
• Insulate yourself from work and ground using dry • Never operate the plasma system unless the power
insulating mats or covers big enough to prevent any supply covers are in place. Exposed power supply
physical contact with the work or ground. If you must connections present a severe electrical hazard.
work in or near a damp area, use extreme caution.
• When making input connections, attach proper
• Provide a disconnect switch close to the power supply grounding conductor first.
with properly sized fuses. This switch allows the
• Each Hypertherm plasma system is designed to be
operator to turn off the power supply quickly in an
used only with specific Hypertherm torches. Do not
emergency situation.
substitute other torches which could overheat and
• When using a water table, be sure that it is correctly present a safety hazard.
connected to earth ground.

10 MAXPRO200 Instruction Manual 807700 Revision 1

 Safety

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention WARNING

• Be sure the area is safe before doing any cutting. Explosion Hazard
Keep a fire extinguisher nearby. Argon-Hydrogen and Methane
• Remove all flammables within 35 feet (10 m) of the Hydrogen and methane are flammable gases that
cutting area. present an explosion hazard. Keep flames away from
• Quench hot metal or allow it to cool before handling cylinders and hoses that contain methane or hydrogen
or before letting it touch combustible materials. mixtures. Keep flames and sparks away from the torch
• Never cut containers with potentially flammable when using methane or argon-hydrogen plasma.
materials inside – they must be emptied and properly
cleaned first. WARNING
• Ventilate potentially flammable atmospheres before Explosion Hazard
Underwater Cutting with Fuel Gases
cutting.
• When cutting with oxygen as the plasma gas, an • Do not cut aluminum underwater or with water
exhaust ventilation system is required. touching the underside of the aluminum.
• Cutting aluminum underwater or with the water
Explosion prevention touching the underside of the aluminum can result in
• Do not use the plasma system if explosive dust or an explosive condition that can detonate during
vapors may be present. plasma cutting operations.
• Do not cut pressurized cylinders, pipes, or any
closed container. WARNING
• Do not cut containers that have held combustible Hydrogen Detonation with
Aluminum Cutting
materials.
• Do not cut under water with fuel gases containing
hydrogen.
• Cutting under water with fuel gases containing
hydrogen can result in an explosive condition that
can detonate during plasma cutting operations.

MAXPRO200 Instruction Manual 807700 Revision 1 11

Safety

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for The air quality level in any relevant workplace depends
cutting. Accordingly, although the plasma arc has not on site-specific variables such as:
been identified as a source of toxic fumes, the material • Table design (wet, dry, underwater).
being cut can be a source of toxic fumes or gases that
• Material composition, surface finish, and composition
deplete oxygen.
of coatings.
Fumes produced vary depending on the metal that is • Volume of material removed.
cut. Metals that may release toxic fumes include, but are • Duration of cutting or gouging.
not limited to, stainless steel, carbon steel, zinc • Size, air volume, ventilation and filtration of the work
(galvanized), and copper. area.
• Personal protective equipment.
In some cases, the metal may be coated with a
substance that could release toxic fumes. Toxic coatings • Number of welding and cutting systems in operation.
include, but are not limited to, lead (in some paints), • Other site processes that may produce fumes.
cadmium (in some paints and fillers), and beryllium.
If the workplace must conform to national or local
regulations, only monitoring or testing done at the site
Gases produced by plasma cutting vary based on the
can determine whether the site is above or below
material to be cut and the method of cutting, but may
allowable levels.
include ozone, oxides of nitrogen, hexavalent chromium,
hydrogen, and other substances if such are contained in
To reduce the risk of exposure to fumes:
or released by the material being cut.
• Remove all coatings and solvents from the metal
Caution should be taken to minimize exposure to fumes before cutting.
produced by any industrial process. Depending upon • Use local exhaust ventilation to remove fumes from
the chemical composition and concentration of the the air.
fumes (as well as other factors, such as ventilation), • Do not inhale fumes. Wear an air-supplied respirator
there may be a risk of physical illness, such as birth when cutting any metal coated with, containing, or
defects or cancer. suspected to contain toxic elements.
• Assure that those using welding or cutting
It is the responsibility of the equipment and site owner
equipment, as well as air-supplied respiration
to test the air quality in the area where the equipment is
devices, are qualified and trained in the proper use of
used and to ensure that the air quality in the workplace
such equipment.
meets all local and national standards and regulations.
• Never cut containers with potentially toxic materials
inside. Empty and properly clean the container first.
• Monitor or test the air quality at the site as needed.
• Consult with a local expert to implement a site plan
to ensure safe air quality.

12 MAXPRO200 Instruction Manual 807700 Revision 1

 Safety

GROUNDING SAFETY

Work cable Attach the work cable securely to the Input power
workpiece or the work table with good metal-to-metal • Be sure to connect the power cord ground wire to
contact. Do not connect it to the piece that will fall away the ground in the disconnect box.
when the cut is complete.
• If installation of the plasma system involves
connecting the power cord to the power supply, be
Work table Connect the work table to an earth
sure to connect the power cord ground wire properly.
ground, in accordance with appropriate national and
local electrical codes. • 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.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

Use proper precautions when handling printed circuit boards:
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling PC boards.

MAXPRO200 Instruction Manual 807700 Revision 1 13

Safety

COMPRESSED GAS EQUIPMENT

SAFETY GAS CYLINDERS CAN
• Never lubricate cylinder valves or regulators with oil
EXPLODE IF DAMAGED
or grease.
• Use only correct gas cylinders, regulators, hoses and Gas cylinders contain gas under high pressure.
fittings designed for the specific application. If damaged, a cylinder can explode.
• Maintain all compressed gas equipment and
associated parts in good condition. • Handle and use compressed gas cylinders in
accordance with applicable national and local codes.
• Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national • Never use a cylinder that is not upright and secured
and local codes. 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.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-on torches The plasma arc will cut quickly through gloves and skin.
Plasma arc comes on immediately when the torch • Keep away from the torch tip.
switch is activated. • Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.

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 Safety

ARC RAYS CAN BURN EYES AND SKIN

Eye protection Plasma arc rays produce intense • Cuffless trousers to prevent entry of sparks and slag.
visible and invisible (ultraviolet and infrared) rays that • Remove any combustibles, such as a butane lighter
can burn eyes and skin. or matches, from your pockets before cutting.
• Use eye protection in accordance with applicable
national and local codes. Cutting area Prepare the cutting area to reduce
• Wear eye protection (safety glasses or goggles with reflection and transmission of ultraviolet light:
side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s • Paint walls and other surfaces with dark colors to
ultraviolet and infrared rays. reduce reflection.
• Use protective screens or barriers to protect others
Skin protection Wear protective clothing to protect from flash and glare.
against burns caused by ultraviolet light, sparks, and hot • Warn others not to watch the arc. Use placards or
metal. signs.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.

Minimum Suggested shade

Arc current protective shade number for OSHA 29CFR Europe
(amps) number comfort 1910.133(a)(5) EN168:2002
(ANSI Z49.1:2005) (ANSI Z49.1:2005)
Less than 40 A 5 5 8 9
41 to 60 A 6 6 8 9
61 to 80 A 8 8 8 9
81 to 125 A 8 9 8 9
126 to 150 A 8 9 8 10
151 to 175 A 8 9 8 11
176 to 250 A 8 9 8 12
251 to 300 A 8 9 8 13
301 to 400 A 9 12 9 13
401 to 800 A 10 14 10 N/A

MAXPRO200 Instruction Manual 807700 Revision 1 15

Safety

PACEMAKER AND HEARING AID OPERATION

Pacemaker and hearing aid operation can be affected To reduce magnetic field hazards:
by magnetic fields from high currents. • Keep both the work cable and the torch lead to one
side, away from your body.
Pacemaker and hearing aid wearers should consult a
• Route the torch leads as close as possible to the
doctor before going near any plasma arc cutting and
work cable.
gouging operations.
• Do not wrap or drape the torch lead or work cable
around your body.
• Keep as far away from the power supply as possible.

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise Use ear protectors if the noise is disruptive or if there is
levels as defined by local codes in many applications. a risk of hearing damage after all other engineering and
Prolonged exposure to excessive noise can damage administrative controls have been implemented. If
hearing. Always wear proper ear protection when hearing protection is required, wear only approved
cutting or gouging, unless sound pressure level personal protective devices such as ear muffs or ear
measurements taken at the installed site have verified plugs with a noise reduction rating appropriate for the
personal hearing protection is not necessary per situation. Warn others in the area of possible noise
relevant international, regional, and local codes. hazards. In addition, ear protection can prevent hot
splatter from entering the ear.
Significant noise reduction can be obtained by adding
simple engineering controls to cutting tables such as
barriers or curtains positioned between the plasma arc
and the workstation; and/or locating the workstation
away from the plasma arc. Implement administrative
controls in the workplace to restrict access, limit
operator exposure time, screen off noisy working areas
and/or take measures to reduce reverberation in
working areas by putting up noise absorbers.

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.

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 Safety

DRY DUST COLLECTION INFORMATION

At some sites, dry dust can represent a potential Note 1 – Hypertherm’s interpretation of these new
explosion hazard. requirements is that unless a site-specific evaluation
has been completed to determine that all dust
The U.S. National Fire Protection Association’s 2007 generated is not combustible, the 2007 edition of
edition of NFPA standard 68, “Explosion Protection by NFPA 68 requires the use of explosion vents designed
Deflagration Venting,” provides requirements for the to the worst-case Kst value (see annex F) that could be
design, location, installation, maintenance, and use of generated from dust so that the explosion vent size and
devices and systems to vent combustion gases and type can be designed. NFPA 68 does not specifically
pressures after any deflagration event. Consult with the identify plasma cutting or other thermal cutting
manufacturer or installer of any dry dust collection processes as requiring deflagration venting systems,
system for applicable requirements before you install a but it does apply these new requirements to all dry dust
new dry dust collection system or make significant collection systems.
changes in the process or materials used with an
existing dry dust collection system. Note 2 – Users of Hypertherm manuals should consult
and comply with all applicable federal, state, and local
Consult your local “Authority Having Jurisdiction” (AHJ) laws and regulations. Hypertherm does not, by the
to determine whether any edition of NFPA 68 has been publication of any Hypertherm manual, intend to urge
“adopted by reference” in your local building codes. action that is not in compliance with all applicable
regulations and standards, and this manual may never
Refer to NFPA68 for definitions and explanations of be construed as doing so.
regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other
terms.

MAXPRO200 Instruction Manual 807700 Revision 1 17

Safety

LASER RADIATION
Exposure to the laser output can result in serious eye injury. Avoid direct eye exposure.

For your convenience and safety, on Hypertherm products that use a laser, one of the following laser radiation labels
has been applied on the product near where the laser beam exits the enclosure. The maximum output (mV),
wavelength emitted (nM) and, if appropriate, the pulse duration is also provided.

Additional laser safety instructions: • Modifying the laser or product in any way can
increase the risk of laser radiation.
• Consult with an expert on local laser regulations. • Use of adjustments or performance of procedures
Laser safety training may be required. other than those specified in this manual may result
• Do not allow untrained persons to operate the laser. in hazardous laser radiation exposure.
Lasers can be dangerous in the hands of untrained • Do not operate in explosive atmospheres, such as in
users. the presence of flammable liquids, gases, or dust.
• Do not look into the laser aperture or beam at any • Use only laser parts and accessories that are
time. recommended or provided by the manufacturer for
• Position the laser as instructed to avoid unintentional your model.
eye contact. • Repairs and servicing MUST be performed by
• Do not use the laser on reflective workpieces. qualified personnel.
• Do not use optical tools to view or reflect the laser • Do not remove or deface the laser safety label.
beam.
• Do not disassemble or remove the laser or aperture
cover.

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 Safety

SYMBOLS AND MARKS

Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.

S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments
with increased hazard of electrical shock according to IEC 60674-1.

CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety.
The products were evaluated, tested, and certified by CSA-International. Alternatively, the product may have
a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United
States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.

CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and
standards. Only those versions of Hypertherm products with a CE marking located on or near the data plate
have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European
EMC Directive are incorporated within versions of the product with a CE marking.

GOST-TR mark
CE versions of Hypertherm products that include a GOST-TR mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.

c-Tick mark
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale in
Australia and New Zealand.

CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.

UkrSEPRO mark
The CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product
safety and EMC requirements for export to the Ukraine.

MAXPRO200 Instruction Manual 807700 Revision 1 19

Safety

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
American Welding Society, 550 LeJeune Road P.O. Box Cylinders, Compressed Gas Association 1235 Jefferson Davis
351020, Miami, FL 33135 Highway, Arlington, VA 22202
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting 7. CSA Standard W117.2, Code for Safety in Welding and
and Welding Processes, American National Standards Institute Cutting, Canadian Standards Association Standard Sales
1430 Broadway, New York, NY 10018 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada
3. ANSI Standard Z87.1, Safe Practices for Occupation and 8. NFPA Standard 51B, Cutting and Welding Processes,
Educational Eye and Face Protection, American National National Fire Protection Association 470 Atlantic Avenue,
Standards Institute, 1430 Broadway, New York, NY 10018 Boston, MA 02210
4. AWS F4.1, Recommended Safe Practices for the Preparation 9. NFPA Standard 70–1978, National Electrical Code, National
for Welding and Cutting of Containers and Piping That Have Fire Protection Association, 470 Atlantic Avenue, Boston, MA
Held Hazardous Substances, American Welding Society 550 02210
LeJeune Road, P.O. Box 351040, Miami, FL 33135 10. OSHA, Safety and Health Standards, 29FR 1910 U.S.
5. AWS F5.2, Recommended Safe Practices for Plasma Arc Government Printing Office, Washington, D.C. 20402
Cutting, American Welding Society 550 LeJeune Road, P.O. 11. AWS Safety and Health Fact Sheets, American Welding
Box 351040, Miami, FL 33135 Society 550 LeJeune Road, P.O. Box 351040, Miami, FL
33135 www.aws.org/technical/facts/

WARNING LABELS
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.

Read and follow these instructions, employer safety

practices, and material safety data sheets. Refer to WARNING AVERTISSEMENT
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society Plasma cutting can be injurious to operator and persons Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
(http://www.aws.org) and OSHA Safety and Health in the work area. Consult manual before operating. Failure trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
Standards, 29 CFR 1910 (http://www.osha.gov). to follow all these safety instructions can result in death. non respect des ces instructions de sécurité peut entraîner la mort.

1. Cutting sparks can cause explosion or fire. 1. Les étincelles de coupage peuvent provoquer une explosion
1.1 Do not cut near flammables. ou un incendie.
1.2 Have a fire extinguisher nearby and ready to use. 1.1 Ne pas couper près des matières inflammables.
1.3 Do not use a drum or other closed container as a cutting table. 1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. Plasma arc can injure and burn; point the nozzle away 2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
from yourself. Arc starts instantly when triggered. Il s’allume instantanément quand on l’amorce;
2.1 Turn off power before disassembling torch. 2.1 Couper l’alimentation avant de démonter la torche.
2.2 Do not grip the workpiece near the cutting path. 2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Wear complete body protection. 2.3 Se protéger entièrement le corps.

3. Hazardous voltage. Risk of electric shock or burn. 3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged. 3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
3.2 Protect from shock by insulating yourself from work and ground. endommagés.
3.3 Disconnect power before servicing. Do not touch live parts. 3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Plasma fumes can be hazardous. 4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes. 4.1 Ne pas inhaler les fumées
4.2 Use forced ventilation or local exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Do not operate in closed spaces. Remove fumes with ventilation. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin. 5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Wear correct and appropriate protective equipment to protect 5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
head, eyes, ears, hands, and body. Button shirt collar. Protect ears oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
from noise. Use welding helmet with the correct shade of filter. contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained. Only qualified personnel should operate this 6. Suivre une formation. Seul le personnel qualifié a le droit de faire
equipment. Use torches specified in the manual. Keep non-qualified fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
personnel and children away. manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette.
Replace if it is missing, damaged, or worn (PN 110584 Rev C). La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).

20 MAXPRO200 Instruction Manual 807700 Revision 1

 Safety

WARNING LABELS 1. Cutting sparks can cause explosion

or fire.
This warning label is affixed to some power supplies. It is important that the 1.1 Do not cut near flammables.
operator and maintenance technician understand the intent of these
warning symbols as described. The numbered text corresponds to the 1.2 Have a fire extinguisher nearby and
numbered boxes on the label. ready to use.
1.3 Do not use a drum or other closed
container as a cutting table.
2. Plasma arc can injure and burn; point
the nozzle away from yourself. Arc
starts instantly when triggered.
2.1 Turn off power before disassembling
torch.
2.2 Do not grip the workpiece near the
cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric
shock or burn.
3.1 Wear insulating gloves. Replace
gloves when wet or damaged.
3.2 Protect from shock by insulating
yourself from work and ground.
3.3 Disconnect power before servicing.
Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust
to remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure
skin.
5.1 Wear correct and appropriate
protective equipment to protect head,
eyes, ears, hands, and body. Button
shirt collar. Protect ears from noise.
Use welding helmet with the correct
shade of filter.
6. Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in
the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this
label. Replace if it is missing,
damaged, or worn.

MAXPRO200 Instruction Manual 807700 Revision 1 21

Safety

22 MAXPRO200 Instruction Manual 807700 Revision 1

 Electromagnetic Compatibility (EMC)

Introduction a. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the
Hypertherm’s CE-marked equipment is built in compliance cutting equipment.
with standard EN60974-10. The equipment should be
installed and used in accordance with the information b. Radio and television transmitters and receivers.
below to achieve electromagnetic compatibility.
c. Computer and other control equip.
The limits required by EN60974-10 may not be adequate
to completely eliminate interference when the affected d. Safety critical equipment, for example guarding of
equipment is in close proximity or has a high degree of industrial equipment.
sensitivity. In such cases it may be necessary to use other
measures to further reduce interference. e. Health of the people around, for example the use of
pacemakers and hearing aids.
This cutting equipment is designed for use only in an
industrial environment. f. Equipment used for calibration or measurement.

Installation and use g. Immunity of other equipment in the environment. User

shall ensure that other equipment being used in the
The user is responsible for installing and using the plasma environment is compatible. This may require additional
equipment according to the manufacturer’s instructions. protection measures.

If electromagnetic disturbances are detected then it shall h. Time of day that cutting or other activities are to be
be the responsibility of the user to resolve the situation carried out.
with the technical assistance of the manufacturer. In some
cases this remedial action may be as simple as earthing The size of the surrounding area to be considered will
the cutting circuit, see Earthing of the work piece. In other depend on the structure of the building and other activities
cases, it could involve constructing an electromagnetic that are taking place. The surrounding area may extend
screen enclosing the power source and the work beyond the boundaries of the premises.
complete with associated input filters. In all cases,
electromagnetic disturbances must be reduced to the
point where they are no longer troublesome.
Methods of reducing emissions

Assessment of area Mains supply

Cutting equipment must be connected to the mains
Before installing the equipment, the user shall make an
supply according to the manufacturer’s recommendations.
assessment of potential electromagnetic problems in the
If interference occurs, it may be necessary to take
surrounding area. The following shall be taken into
additional precautions such as filtering of the mains
account:
supply.

MAXPRO200 Instruction Manual 807700 Revision 1 23

Electromagnetic Compatibility (EMC)

Consideration should be given to shielding the supply Earthing of the workpiece

cable of permanently installed cutting equipment, in
metallic conduit or equivalent. Shielding should be Where the workpiece is not bonded to earth for electrical
electrically continuous throughout its length. The shielding safety, nor connected to earth because of its size and
should be connected to the cutting mains supply so that position, for example, ship’s hull or building steel work, a
good electrical contact is maintained between the conduit connection bonding the workpiece to earth may reduce
and the cutting power source enclosure. 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
Maintenance of cutting equipment equipment. Where necessary, the connection of the
The cutting equipment must be routinely maintained workpiece to earth should be made by a direct connection
according to the manufacturer’s recommendations. All to the workpiece, but in some countries where direct
access and service doors and covers should be closed connection is not permitted, the bonding should be
and properly fastened when the cutting equipment is in achieved by suitable capacitances selected according to
operation. The cutting equipment should not be modified national regulations.
in any way, except as set forth in and in accordance with
the manufacturer’s written instructions. For example, the Note: The cutting circuit may or may not be earthed for
spark gaps of arc striking and stabilizing devices should safety reasons. Changing the earthing arrangements
be adjusted and maintained according to the should only be authorized by a person who is competent
manufacturer’s recommendations. to assess whether the changes will in crease the risk of
injury, for example, by allowing parallel cutting current
Cutting cables return paths which may damage the earth circuits of other
equipment. Further guidance is provided in IEC 60974-9,
The cutting cables should be kept as short as possible Arc Welding Equipment, Part 9: Installation and Use.
and should be positioned close together, running at or
close to the floor level. Screening and shielding
Equipotential bonding Selective screening and shielding of other cables and
equipment in the surrounding area may alleviate problems
Bonding of all metallic components in the cutting of interference. Screening of the entire plasma cutting
installation and adjacent to it should be considered. installation may be considered for special applications.

However, metallic components bonded to the workpiece

will increase the risk that the operator could receive a
shock by touching these metallic components and the
electrode (nozzle for laser heads) at the same time.

The operator should be insulated from all such bonded

metallic components.

24 MAXPRO200 Instruction Manual 807700 Revision 1

 Warranty

Attention Hypertherm provides repair, replacement or adjustment of

the Product as the sole and exclusive remedy, if and only if
Genuine Hypertherm parts are the factory-recommended the warranty set forth herein properly is invoked and
replacement parts for your Hypertherm system. Any applies. Hypertherm, at its sole option, shall repair,
damage or injury caused by the use of other than genuine replace, or adjust, free of charge, any defective Products
Hypertherm parts may not be covered by the Hypertherm covered by this warranty which shall be returned with
warranty, and will constitute misuse of the Hypertherm Hypertherm’s prior authorization (which shall not be
Product. unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
You are solely responsible for the safe use of the Product. authorized Hypertherm repair facility, all costs, insurance
Hypertherm does not and cannot make any guarantee or and freight pre paid by the customer. Hypertherm shall not
warranty regarding the safe use of the product in your be liable for any repairs, replacement, or adjustments of
environment. Products covered by this warranty, except those made
pursuant to this paragraph and with Hypertherm’s prior
General written consent.

Hypertherm, Inc. warrants that its Products shall be free The warranty set forth above is exclusive and is in lieu of all
from defects in materials and workmanship for the specific other warranties, express, implied, statutory, or otherwise
periods of time set forth herein and as follows: if with respect to the Products or as to the results which
Hypertherm is notified of a defect (i) with respect to the may be obtained therefrom, and all implied warranties or
plasma power supply within a period of two (2) years from conditions of quality or of merchantability or fitness for a
the date of its delivery to you, with the exception of particular purpose or against infringement. The foregoing
Powermax brand power supplies, which shall be within a shall constitute the sole and exclusive remedy for any
period of three (3) years from the date of delivery to you, breach by Hypertherm of its warranty.
and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, and with Distributors/OEMs may offer different or additional
respect to torch lifter assemblies within a period of one (1) warranties, but Distributors/OEMs are not authorized to
year from its date of delivery to you, and with respect to give any additional warranty protection to you or make any
Automation products one (1) year from its date of delivery representation to you purporting to be binding upon
to you, with the exception of the EDGE Pro CNC and Hypertherm.
ArcGlide THC, which shall be within a period of two (2)
years from the date of delivery to you, and (iii) with respect
to HyIntensity fiber laser components within a period of
two (2) years from the date of its delivery to you, with the
exception of laser heads and beam delivery cables, which
shall be within a period of one (1) year from its date of
delivery to you.

This warranty shall not apply to any Powermax brand

power supplies that have been used with phase
converters. In addition, Hypertherm does not warranty
systems that have been damaged as a result of poor
power quality, whether from phase converters or incoming
line power. This warranty shall not apply to any product
which has been incorrectly installed, modified, or
otherwise damaged.

MAXPRO200 Instruction Manual 807700 Revision 1 25

Warranty

Patent indemnity Insurance

Except only in cases of products not manufactured by At all times you will have and maintain insurance in such
Hypertherm or manufactured by a person other than quantities and types, and with coverage sufficient and
Hypertherm not in strict conformity with Hypertherm’s appropriate to defend and to hold Hypertherm harmless in
specifications and in cases of designs, processes, the event of any cause of action arising from the use of the
formulae, or combinations not developed or purported to products.
be developed by Hypertherm, Hypertherm will have the
right to defend or settle, at its own expense, any suit or Transfer of rights
proceeding brought against you alleging that the use of
the Hypertherm product, alone and not in combination You may transfer any remaining rights you may have
with any other product not supplied by Hypertherm, hereunder only in connection with the sale of all or
infringes any patent of any third party. You shall notify substantially all of your assets or capital stock to a
Hypertherm promptly upon learning of any action or successor in interest who agrees to be bound by all of the
threatened action in connection with any such alleged terms and conditions of this Warranty. Within thirty (30)
infringement (and in any event no longer than fourteen days before any such transfer occurs, you agree to notify
(14) days after learning of any action or threat of action), in writing Hypertherm, which reserves the right of
and Hypertherm’s obligation to defend shall be approval. Should you fail timely to notify Hypertherm and
conditioned upon Hypertherm’s sole control of, and the seek its approval as set forth herein, the Warranty set forth
indemnified party’s cooperation and assistance in, the herein shall be null and void and you will have no further
defense of the claim. recourse against Hypertherm under the Warranty or
otherwise.
Limitation of liability
In no event shall Hypertherm be liable to any
person or entity for any incidental, consequential
direct, indirect, punitive or exemplary damages
(including but not limited to lost profits) regardless
of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty,
failure of essential purpose, or otherwise, and even
if advised of the possibility of such damages.

National and local codes

National and local codes governing plumbing and
electrical installation shall take precedence 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.

Liability cap
In no event shall Hypertherm’s liability, if any,
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 (whether in court,
arbitration, regulatory proceeding or otherwise)
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.

26 MAXPRO200 Instruction Manual 807700 Revision 1

 Product Stewardship

Introduction been tested for compliance with the European Low

Voltage Directive and the European EMC Directive. EMC
Hypertherm maintains a global Regulatory Management filters needed to comply with the European EMC Directive
System to ensure that products comply with regulatory are incorporated within versions of the power supply with
and environmental requirements. a CE Marking.

National and local safety regulations Certificates of compliance for Hypertherm products are
available from the Downloads Library on the Hypertherm
National and Local safety regulations shall take web site at https://www.hypertherm.com.
precedence over any instructions provided with the
product. The product shall be imported, installed,
operated and disposed of in accordance with national and
Differences in national standards
local regulations applicable to the installed site. Nations may apply different performance, safety or other
standards. National differences in standards include, but
Certification test marks are not limited to:

Certified products are identified by one or more • Voltages

certification test marks from accredited testing
• Plug and cord ratings
laboratories. The certification test marks are located on or
near the data plate. • Language requirements
• Electromagnetic compatibility requirements
Each certification test mark means that the product and its
These differences in national or other standards may make
safety-critical components conform to the relevant
it impossible or impractical for all certification test marks to
national safety standards as reviewed and determined by
be placed on the same version of a product. For example,
that testing laboratory. Hypertherm places a certification
the CSA versions of Hypertherm’s products do not
test mark on its products only after that product is
comply with European EMC requirements, and therefore
manufactured with safety-critical components that have
do not have a CE marking on the data plate.
been authorized by the accredited testing laboratory.
Countries that require CE marking or have compulsory
Once the product has left the Hypertherm factory, the
EMC regulations must use CE versions of Hypertherm
certification test marks are invalidated if any of the
products with the CE marking on the data plate. These
following occurs:
include, but are not limited to:
• The product is modified in a manner that creates a
• Australia
hazard or non-conformance with the applicable
standards. • New Zealand
• Safety-critical components are replaced with • Countries in the European Union
unauthorized spare parts. • Russia
• Any unauthorized assembly, or accessory that uses or It is important that the product and its certification test
generates a hazardous voltage is added. mark be suitable for the end-use installation site. When
• There is any tampering with a safety circuit or other Hypertherm products are shipped to one country for
feature that is designed into the product as part of the export to another country; the product must be configured
certification, or otherwise. and certified properly for the end-use site.
CE marking constitutes a manufacturer’s declaration of
conformity to applicable European directives and
standards. Only those versions of Hypertherm products
with a CE Marking located on or near the data plate have

MAXPRO200 Instruction Manual 807700 Revision 1 27

Product Stewardship

Safe installation and use of shape Hypertherm recommends that only visual inspection be
performed unless the electrical safety tests are specifically
cutting equipment required by local national regulations in the country where
IEC 60974-9, titled Arc Welding Equipment – Installation the equipment is installed.
and use, provides guidance in the safe installation and use
of shape cutting equipment and the safe performance of Residual current devices (RCDs)
cutting operations. The requirements of national and local
regulations shall be taken into consideration during In Australia and some other countries, local codes may
installation, including, but not limited to, grounding or require the use of a Residual Current Devices (RCD)
protective earth connections, fuses, supply disconnecting when portable electrical equipment is used in the
device, and type of supply circuit. Read these instructions workplace or at construction sites to protect operators
before installing the equipment. The first and most from electrical faults in the equipment. RCDs are
important step is the safety assessment of the installation. designed to safely disconnect the mains electrical supply
when an imbalance is detected between the supply and
The safety assessment must be performed by an expert, return current (there is a leakage current to earth). RCDs
and determines what steps are necessary to create a safe are available with both fixed and adjustable trip currents
environment, and what precautions should be adopted between 6 to 40 milliamperes and a range of trip times up
during the actual installation and operation. to 300 milliseconds selected for the equipment
installation, application and intended use. Where RCDs
are used, the trip current and trip time on RCDs should be
Procedures for periodic inspection selected or adjusted high enough to avoid nuisance
and testing tripping during normal operation of the plasma cutting
equipment and low enough in the extremely unlikely event
Where required by local national regulations,
of an electrical fault in the equipment to disconnect the
IEC 60974-4 specifies test procedures for periodic
supply before the leakage current under a fault condition
inspection and after repair or maintenance, to ensure
can pose a life threatening electrical hazard to operators.
electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the
To verify that the RCDs continue to function properly over
continuity of the protective circuit and insulation
time, both the trip current and the trip time should be
resistance tests in the factory as non-operating tests. The
tested periodically. Portable electrical equipment and
tests are performed with the power and ground
RCDs used in commercial and industrial areas in Australia
connections removed.
and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma
Hypertherm also removes some protective devices that
cutting equipment to AS/NZS 3760, measure the
would cause false test results. Where required by local
insulation resistance according to Appendix B of the
national regulations, a label shall be attached to the
standard, at 250 VDC with the power switch in the ON
equipment to indicate that it has passed the tests
position to verify proper testing and to avoid the false
prescribed by IEC60974-4. The repair report shall
failure of the leakage current test. False failures are
indicate the results of all tests unless an indication is made
possible because the metal oxide varistors (MOVs) and
that a particular test has not been performed.
electromagnetic compatibility (EMC) filters, used to
reduce emissions and protect the equipment from power
Qualification of test personnel surges, may conduct up to 10 milliamperes leakage
Electrical safety tests for shape cutting equipment can be current to earth under normal conditions.
hazardous and shall be carried out by an expert in the field
of electrical repair, preferably someone also familiar with If you have any questions regarding the application or
welding, cutting, and allied processes. The safety risks to interpretation of any IEC standards described here, you
personnel and equipment, when unqualified personnel are are required to consult with an appropriate legal or other
performing these tests, may be much greater than the advisor familiar with the International Electrotechnical
benefit of periodic inspection and testing. standards, and shall not rely on Hypertherm in any respect
regarding the interpretation or application of such
standards.

28 MAXPRO200 Instruction Manual 807700 Revision 1

 Product Stewardship

Higher-level systems
When a system integrator adds additional equipment;
such as cutting tables, motor drives, motion controllers or
robots; to a Hypertherm plasma cutting system, the
combined system may be considered a higher-level
system. A higher-level system with hazardous moving
parts may constitute industrial machinery or robotic
equipment, in which case the OEM or end-use customer
may be subject to additional regulations and standards
than those relevant to the plasma cutting system as
manufactured by Hypertherm.

It is the responsibility of the end-use customer and the

OEM to perform a risk assessment for the higher-level
system, and to provide protection against hazardous
moving parts. Unless the higher-level system is certified
when the OEM incorporates Hypertherm products into it,
the installation also may be subject to approval by local
authorities. Seek advice from legal counsel and local
regulatory experts if you are uncertain about compliance.

External interconnecting cables between component parts

of the higher level system must be suitable for
contaminants and movement as required by the final end
use installation site. When the external interconnecting
cables are subject to oil, dust, water, or other
contaminants, hard usage ratings may be required.

When external interconnecting cables are subject to

continuous movement, constant flexing ratings may be
required. It is the responsibility of the end-use customer or
the OEM to ensure the cables are suitable for the
application. Since there are differences in the ratings and
costs that can be required by local regulations for higher
level systems, it is necessary to verify that any external
interconnecting cables are suitable for the end-use
installation site.

MAXPRO200 Instruction Manual 807700 Revision 1 29

Product Stewardship

30 MAXPRO200 Instruction Manual 807700 Revision 1

 Environmental Stewardship

Introduction “CE Marking” on the data plate of CE versions of

Powermax series units shipped since 2006. Parts
The Hypertherm Environmental Specification requires used in CSA versions of Powermax and other products
RoHS, WEEE and REACH substance information to be manufactured by Hypertherm that are either out of scope
provided by Hypertherm’s suppliers. or exempt from RoHS are continuously being converted to
RoHS compliance in anticipation of future requirements.
Product environmental compliance does not address the
indoor air quality or environmental release of fumes by the Proper disposal of Hypertherm
end user. Any materials that are cut by the end user are
not provided by Hypertherm with the product. The end products
user is responsible for the materials being cut as well as Hypertherm plasma cutting systems, like all electronic
for safety and air quality in the workplace. The end user products, may contain materials or components, such
must be aware of the potential health risks of the fumes as printed circuit boards, that cannot be discarded with
released from the materials being cut and comply with all ordinary waste. It is your responsibility to dispose of any
local regulations. Hypertherm product or component part in an
environmentally acceptable manner according to national
National and local environmental and local codes.
regulations
• In the United States, check all federal, state, and local
National and local environmental regulations shall take laws.
precedence over any instructions contained in this
• In the European Union, check the EU directives,
manual.
national, and local laws. For more information, visit
www.hypertherm.com/weee.
The product shall be imported, installed, operated and
disposed of in accordance with all national and local • In other countries, check national and local laws.
environmental regulations applicable to the installed site. • Consult with legal or other compliance experts when
appropriate.
The European Environmental regulations are discussed
later in The WEEE Directive. The WEEE directive
On January 27, 2003, the European Parliament and
The RoHS directive the Council of the European Union authorized Directive
Hypertherm is committed to complying with all applicable 2002/96/EC or WEEE (Waste Electrical and Electronic
laws and regulations, including the European Union Equipment).
Restriction of Hazardous Substances (RoHS) Directive
that restricts the use of hazardous materials in electronics As required by the legislation, any Hypertherm product
products. Hypertherm exceeds RoHS Directive covered by the directive and sold in the EU after August
compliance obligations on a global basis. 13, 2005 is marked with the WEEE symbol. This directive
encourages and sets specific criteria for the collection,
Hypertherm continues to work toward the reduction of handling, and recycling of EEE waste. Consumer and
RoHS materials in our products, which are subject to the business-to-business wastes are treated differently
RoHS Directive, except where it is widely recognized that (all Hypertherm products are considered
there is no feasible alternative. business-to-business). Disposal instructions for the
CE versions of Powermax plasma systems can be found
Declarations of RoHS Conformity have been prepared for at www.hypertherm.com/weee.
the current CE versions of Powermax plasma cutting
systems manufactured by Hypertherm. There is also a
“RoHS mark” on the Powermax CE versions below the

MAXPRO200 Instruction Manual 807700 Revision 1 31

Environmental Stewardship

The URL is printed on the symbol-only warning label for Hypertherm does not manufacture or provide the materials
each of these CE version Powermax series units shipped that are cut and has no knowledge whether the fumes
since 2006. The CSA versions of Powermax and other released from materials that are cut will pose a physical
products manufactured by Hypertherm are either out of hazard or health risk. Please consult with your supplier
scope or exempt from WEEE. or other technical advisor if you need guidance
concerning the properties of the material you will cut
The REACH regulation using a Hypertherm product.

The REACH regulation (1907/2006), in force since Fumes emission and air quality
June 1, 2007, has an impact on chemicals available to the
European market. The REACH regulation requirements for Note: The following information on air quality is intended
component manufacturers states that the component shall for general information only and should not be used as
not contain more than 0.1% by weight of the Substances a substitute for reviewing and implementing applicable
of Very High Concern (SVHC). government regulations or legal standards in the country
where the cutting equipment will be installed and
Component manufacturers and other downstream users, operated.
such as Hypertherm, are obligated to obtain assurances
from its suppliers that all chemicals used in or on In the USA, the National Institute for Occupational Safety
Hypertherm products will have a European Chemical and Health (NIOSH) Manual of Analytical Methods
Agency (ECHA) registration number. To provide (NMAM) is a collection of methods for sampling and
chemical information as required by the REACH analyzing contaminants in workplace air. Methods
regulation, Hypertherm requires suppliers to provide published by others, such as OSHA, MSHA, EPA, ASTM,
REACH declarations and identify any known use of ISO or commercial suppliers of sampling and analytical
REACH SVHC. Any use of SVHC in amounts exceeding equipment, may have advantages over NIOSH methods.
0.1% w/w of the parts has been eliminated. The MSDS
contains a full disclosure of all substances in the chemical For example, ASTM Practice D 4185 is a standard
and can be used to verify REACH SVHC compliance. practice for the collection, dissolution, and determination
of trace metals in workplace atmospheres. The sensitivity,
The lubricants, sealants, coolants, adhesives, solvents, detection limit, and optimum working concentrations for
coatings and other preparations or mixtures used by 23 metals are listed in ASTM D 4185. An industrial
Hypertherm in, on, for, or with its shape cutting equipment hygienist should be used to determine the optimum
are used in very small quantities (except the coolant) and sampling protocol, considering analytical accuracy, cost,
are commercially available with multiple sources that can and optimum sample number. Hypertherm uses a third
and will be replaced in the event of a supplier problem party industrial hygienist to perform and interpret air
associated with REACH Registration or REACH quality testing results taken by air sampling equipment
Authorization (SVHCs). positioned at operator stations in Hypertherm buildings
where plasma cutting tables are installed and operated.
Proper handling and safe use of
Where applicable, Hypertherm also uses a third party
chemicals industrial hygienist to obtain air and water permits.
Chemical Regulations in the USA, Europe, and other
locations require that Material Safety Data Sheets If you are not fully aware and up to date on all applicable
(MSDS) be made available for all chemicals. The list of government regulations and legal standards for the
chemicals is provided by Hypertherm. The MSDS are for installation site, you should consult a local expert prior
chemicals provided with the product and other chemicals to purchasing, installing, and operating the equipment.
used in or on the product. MSDS can be downloaded
from the Downloads Library on the Hypertherm web site
at https://www.hypertherm.com. On the Search screen,
insert MSDS in the document title and click on Search.

In the USA, OSHA does not require Material Safety

Data Sheets for articles such as electrodes, swirl rings,
retaining caps, nozzles, shields, deflectors and other solid
parts of the torch.

32 MAXPRO200 Instruction Manual 807700 Revision 1

 Specifications

System description
General
The MAXPRO200 plasma system is designed to cut a wide range of thicknesses of mild steel, stainless steel, and
aluminum.

Power supply
The power supply is a 200 A, 165 VDC constant-current supply. It contains the circuitry to ignite a torch, plus a heat
exchanger and a pump to cool the chopper and torch. The power supply has a discrete machine interface to provide
communication with a CNC.

Ignition console
The ignition console is attached to the outside of the rear panel of the power supply enclosure. The ignition console uses
a spark-gap assembly. The ignition console converts 120 VAC control voltage from the power supply into high-frequency
and high-voltage pulses (9–10 kV) to initiate the pilot arc at the torch electrode-nozzle gap. The high-voltage,
high-frequency signal is coupled to the pilot arc lead.

Torch
• The maximum production cutting capacity is the maximum thickness that can be cut with a 100% duty
cycle. The maximum production cutting capacity of the MAXPRO200 torch is 32 mm (1-1/4 inches)
for mild steel using the 200 amp O2/Air process, 22 mm (7/8 inch) for stainless steel, and 19 mm (5/8
inch) for aluminum using the 200 amp Air/Air process.
• Maximum pierce capacity is 32 mm (1.25 inches) for mild steel, 25 mm (1 inch) for stainless steel, and
32 mm (1.25 inch) for aluminum.
• The maximum severance capacity is the maximum thickness that can be severed without regard for
speed and cut quality. This thickness should only be cut occasionally and cannot be cut with a 100%
duty cycle. The maximum severance capacity of the MAXPRO200 torch is 75 mm (3 inches) for mild
steel, 63 mm (2-1/2 inches) for stainless steel, and 75 mm (3 inches) for aluminum.

Gas system
The gas system manages the pressure and timing of the gas supplied to the torch. It consists of a regulator, proportional
valves, pressure transducers, and an inline valve located in the torch lead.

MAXPRO200 Instruction Manual 807700 Revision 1 33

Specifications

34 MAXPRO200 Instruction Manual 807700 Revision 1

 Specifications

Cooling system
The cooling system uses a liquid-to-air cooled heat exchanger and a pump to reduce the temperature of the coolant. The
coolant cools the chopper, torch lead and torch. The cooling system also contains flow and temperature sensors that
verify the cooling system is working properly.

System gas requirements

Gas quality and pressure requirements
Gases Quality Pressure +/- 10% Flow rate
O2 oxygen 99.5% pure (liquid gas recommended) 621 kPa / 6.2 bar / 90 psi 3400 l/h 120 scfh
Clean, dry, and oil free
N2 nitrogen 99.9% pure (liquid gas recommended) 621 kPa / 6.2 bar / 90 psi 11330 l/h 400 scfh
Clean, dry, and oil free
Air Clean, dry, and oil free (ISO 8573-1 class 1.4.2) 621 kPa / 6.2 bar / 90 psi 11330 l/h 400 scfh

Gases by process
Mild steel Stainless steel Aluminum
Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas

Amperage
Cutting 50 A Air or O2 Air Air Air Air Air
Cutting 130 A Air or O2 Air Air Air Air Air
Cutting 130 A N2 N2 N2 N2
Cutting 200 A Air or O2 Air Air Air Air Air
Cutting 200 A N2 N2 N2 N2

MAXPRO200 Instruction Manual 807700 Revision 1 35

Specifications

Power supply
Maximum Open Circuit Voltage (OCV) (U0) 360 VDC
Maximum output current (I2) 200 Amps
Output voltage (U2) 50 – 165 VDC
Duty cycle rating (X) 100% @ 33 kW, 40° C (104° F)
Ambient temperature/Duty cycle Power supplies will operate between (-10°C – 40°C)
-10° C and +40° C (+14° and 104° F)
Power factor (cosϕ) 0.98 @ 33 kW output
Cooling Forced air (Class F)
Insulation Class H
AC Power kVA
Power supply Frequency Amperage Regulatory
Voltage Phase (+/- 10%)
part numbers (Hz) l1 approval
(U1) (U1 x l1 x 1.73)
078610 200/208 3 50 108/104 CSA 37.4
078611 220 3 50-60 98 CSA 37.4
078612 240 3 60 90 CSA 37.4
078613 380 3 50 57 CCC 37.4
078614 400 3 50-60 54 CE/GOST-R 37.4
078615 415 3 50 52 CE/GOST-R 37.4
078616 440 3 50-60 49 CSA 37.4
078609 480 3 60 45 CSA 37.4
078617 600 3 60 36 CSA 37.4

1
2
1 63.5 mm (2.5 inches)
2 688 mm (27.1 inches)
3 133 mm (5.25 inches)
4 998 mm (39.3 inches)

5 927 mm (40.1 inches)

335.7 kg
3
(740 lb)

36 MAXPRO200 Instruction Manual 807700 Revision 1

 Specifications

Mechanized torches
Straight torch – 428024
• The outside diameter of the torch mounting sleeve is 50.8 mm (2.0 inches)
• The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)

1
4
2 3

5
7 6

1.02 kg
(2.25 lb)

1 397.15 mm (15.64 inches)

2 279.40 mm (11.00 inches)

3 117.75 mm (4.64 inches)

4 12.70 mm (0.50 inches)

5 44.20 mm (1.74 inches)

6 46 degrees

7 44.20 mm (1.74 inches)

MAXPRO200 Instruction Manual 807700 Revision 1 37

Specifications

Quick-disconnect torch – 428027 or 428028

• The torch mounting sleeve for the quick-disconnect torch is available with an outside diameter of
50.8 mm (2.0 inches) or 44.45 mm (1.75 inches)
• The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)

2 3 4 5

6
9 8 7

1.45 kg
(3.20 lb)

1 435.33 mm (17.14 inches)

2 279.40 mm (11.00 inches)

3 76.98 mm (3.03 inches)

4 78.95 mm (3.11 inches)

5 12.70 mm (0.50 inches)

6 44.20 mm (1.74 inches)

7 46 degrees

8 57.15 mm (2.25 inches)

9 44.20 mm (1.74 inches)

38 MAXPRO200 Instruction Manual 807700 Revision 1

 Specifications

Hand torches
90 degree hand torch – 420108
• The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)

5
2

0.91 kg
(2.0 lb)

1 310.40 mm (12.22 inches)

2 90 degrees

3 44.20 mm (1.74 inches)

4 305.05 mm (12.01 inches)

5 149.10 mm (5.87 inches)

MAXPRO200 Instruction Manual 807700 Revision 1 39

Specifications

65 degree hand torch – 420107

• The minimum bend radius for the torch lead is 152.4 mm (6.0 inches)

0.91 kg 3
(2.0 lb)

1 290.58 mm (11.44 inches)

2 65 degrees

3 44.20 mm (1.74 inches)

4 285.24 mm (11.23 inches)

5 238.51 mm (9.39 inches)

40 MAXPRO200 Instruction Manual 807700 Revision 1

 Installation

Upon receipt
• Verify that all system components on your order have been received. Contact your supplier if any items
are missing.
• Inspect the system components for any physical damage that may have occurred during shipping. If
there is evidence of damage, refer to Claims. All communications regarding claims must include the
model number and serial number located on the rear of the power supply.

Claims
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. If you need additional assistance,
call customer service listed in the front of this manual, or your authorized Hypertherm distributor.

Claims for defective or missing merchandise – If any of the merchandise is defective or missing, contact your
supplier. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized
Hypertherm distributor.

Installation requirements
All installation and service of the electrical and plumbing systems must conform to national and local
electrical and plumbing codes. This work should be performed only by qualified, licensed personnel.

Direct any technical questions to the nearest Hypertherm Technical Service Department listed in the front of this manual,
or your authorized Hypertherm distributor.

Noise levels
Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always wear
proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific
environment in which the system is used. See also Noise can damage hearing in the Safety section of this manual.
Specific information by product can be found in the Hypertherm downloads library at:

https://www.hypertherm.com/Xnet/library/DocumentLibrary.jsp

Select the product you are looking for from the Product Type drop down menu, choose “Regulatory” from the Category
drop down menu, and choose “Acoustical Noise Data Sheets” from the Sub Category drop down menu. Press Submit.

MAXPRO200 Instruction Manual 807700 Revision 1 41

Installation

Placement of system components

• Place all system components in position prior to making electrical, gas, and interface connections.
Use the diagram in this section for component-placement guidelines.
• Ground all system components to earth. See Recommended grounding and shielding practices on
page 44 for details.
• To prevent leaks in the system, tighten all gas connections as shown below.

Torque specifications
Gas or water hose size kgf-cm lbf-in lbf-ft

Up to 10 mm (3/8 in) 8.9–9.8 75–85 6.25–7

12 mm (1/2 in) 41.5–55 360–480 30–40

42 MAXPRO200 Instruction Manual 807700 Revision 1

 Installation

System components
A Power supply

2
B Torch

A Cable and lead

1 Torch lead

2 Work lead

3 CNC interface cable

Supply gas hoses

4 Air

5 N2

6 O2

Customer supplied power cable

7 Main power cable

6 2

5 B
4

MAXPRO200 Instruction Manual 807700 Revision 1 43

Installation

Recommended grounding and shielding practices

WARNING!
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. All work requiring the
removal of the plasma system cover must be performed by a qualified technician.
See the Safety section of your instruction manual for more safety precautions.

Introduction
This section describes practices for grounding and shielding to protect a plasma cutting system against radio frequency
interference (RFI) and electromagnetic interference (EMI) (also called noise). It also describes the DC power ground and
the service ground. The diagram at the end of this section shows these types of grounds in a plasma cutting system.

Note: The grounding practices in this section have been used on many installations with excellent results, and
Hypertherm recommends that these practices be a routine part of the installation process. The actual methods
used to implement these practices may vary from system to system, but should remain as consistent as possible.
However, due to the variation in equipment and installations, these grounding practices may not succeed in every
case to eliminate RFI/EMI noise issues.

Types of grounding
Service ground (also called safety ground or potential earth (PE) ground) is the grounding system that applies to the
incoming line voltage. It prevents a shock hazard to any personnel from any of the equipment or the cutting
table. It includes the service ground coming into the plasma system and other systems such as the CNC
and the motor drives, as well as the supplemental ground rod connected to the cutting table. In the plasma
circuits, the ground is carried from the plasma system chassis to the chassis of each separate console
through the interconnecting cables.

DC power ground (also called cutting current ground) is the grounding system that completes the path of the cutting
current from the torch back to the plasma system. It requires that the positive lead from the plasma system
be firmly connected to the cutting table ground bus with a properly sized cables. It also requires that the
slats, on which the workpiece rests, make firm contact with the table and the workpiece.

RFI and EMI grounding and shielding is the grounding system that limits the amount of electrical noise emitted by
the plasma and motor drive systems. It also limits the amount of noise that is received by the CNC and
other control and measurement circuits. The grounding practices described in this section mainly target
RFI and EMI grounding and shielding.

Grounding practices
1. Unless noted, use only 16 mm2 (6 AWG) welding cable (047040) for the EMI ground cables shown on the diagram.
2. The cutting table is used for the common, or star, EMI ground point and should have threaded studs welded to the
table with a copper bus bar mounted on them. A separate bus bar should be mounted on the gantry as close to
each motor as possible. If there are motors at each end of the gantry, run a separate EMI ground cable from the
far motor to the gantry bus bar. The gantry bus bar should have a separate, heavy EMI ground cable 21.2 mm2
(4 AWG; 047031) to the table bus bar. The EMI ground cables for the torch lifter and the RHF console must each
run separately to the table ground bus.

44 MAXPRO200 Instruction Manual 807700 Revision 1

 Installation

3. A ground rod that meets all applicable local and national electrical codes must be installed within 6 m (20 ft) of the
cutting table. This is a PE ground and should be connected to the cutting table ground bus bar using 16 mm2
(6 AWG) green and yellow grounding cable (047121) or equivalent.
4. For the most effective shielding, use the Hypertherm CNC interface cables for I/O signals, serial communication
signals, between plasma systems in multi-drop connections, and for interconnections between all parts of the
Hypertherm system.
5. All hardware used in the ground system must be brass or copper. While you can use steel studs welded to the
cutting table for mounting the ground bus, no other aluminum or steel hardware can be used in the ground system.
6. AC power, PE, and service grounds must be connected to all equipment according to local and national codes.
7. For a system with a remote high frequency console (RHF), the positive, negative, and pilot arc leads should be
bundled together for as long a distance as possible. The torch lead, work lead, and the pilot arc (nozzle) leads may be
run parallel to other wires or cables only if they are separated by at least 150 mm (6 inches). If possible, run power
and signal cables in separate cable tracks.
8. For a system with an RHF console, the ignition console should be mounted as closely as possible to the torch, and
must have a separate ground cable that connects directly to the cutting table ground bus bar.
9. Each Hypertherm component, as well as any other CNC or motor drive cabinet or enclosure, must have a separate
ground cable to the common (star) ground on the table. This includes the ignition console, whether if it is bolted to
the plasma system or to the cutting table.
10. The metal braided shield on the torch lead must be connected firmly to the ignition console and to the torch. It must
be electrically insulated from any metal and from any contact with the floor or building. The torch lead can be run in a
plastic cable tray or track, or covered with a plastic or leather sheath.
11. The torch holder and the torch breakaway mechanism – the part mounted to the lifter, not the part mounted to the
torch – must be connected to the stationary part of the lifter with copper braid at least 12.7 mm (0.5 inches) wide. A
separate cable must run from the lifter to the gantry ground bus bar. The valve assembly should also have a separate
ground connection to the gantry ground bus bar.
12. If the gantry runs on rails that are not welded to the table, then each rail must be connected with a ground cable from
the end of the rail to the table. The rail ground cables connect directly to the table and do not need to connect to the
table ground bus bar.
13. If you are installing a voltage divider board, mount it as closely as possible to where the arc voltage is sampled.
One recommended location is inside the plasma system enclosure. If a Hypertherm voltage divider board is used, the
output signal is isolated from all other circuits. The processed signal should be run in twisted shielded cable
(Belden 1800F or equivalent). Use a cable with a braided shield, not a foil shield. connect the shield to the chassis of
the plasma system and leave it unconnected at the other end.
14. All other signals (analog, digital, serial, and encoder) should run in twisted pairs inside a shielded cable. Connectors
on these cables should have a metal housing. The shield, not the drain, should be connected to the metal housing of
the connector at each end of the cable. Never run the shield or the drain through the connector on any of the pins.

MAXPRO200 Instruction Manual 807700 Revision 1 45

Installation

The following picture shows an example of a cutting table ground bus. The components shown here may differ from your
system.

1 2 3 4 5 6 7

1 Gantry ground bus

2 Ground rod
3 Plasma system lead (+)
4 Remote high frequency (RHF) console
5 CNC enclosure
6 Torch holder
7 Plasma system chassis

The following picture shows an example of a gantry ground bus. It is bolted to the gantry, close to the motor. All of the
individual ground cables from the components mounted on the gantry go to the bus. A single heavy cable then goes from
the gantry ground bus to the table ground bus,

1 Cable to the cutting table ground bus

2 Ground cables from components on the gantry

1 2

The following diagram shows an example of grounding the components in a plasma cutting system.

46 MAXPRO200 Instruction Manual 807700 Revision 1

 Installation

6 7 8 9 10

12

11

Chassis and RFI ground

3
AC earth and ground

1 Cutting table 7 RHF console (not on all systems). Connect to table

ground bus bar.
2 Gantry 8, 9 System-specific component such as metering
console, gas console, or selection console
3 Plasma system 10 CNC chassis
4 Table ground bus bar 11 Torch height control module
(ArcGlide, CommandTHC)
5 Gantry ground bus bar 12 System-specific component such as a cooler or
chiller
6 Torch height control lifter (ArcGlide, Sensor THC,
Sensor PHC, or other)

MAXPRO200 Instruction Manual 807700 Revision 1 47

Installation

A Placement of the power supply

WARNING!
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. All work requiring the
removal of the plasma system cover must be performed by a qualified technician.
See the Safety section of your instruction manual for more safety precautions.

The power supply can be moved by using the lifting eye or by forklift but the forks must be long enough to extend the
entire length of the base. Take care when lifting so that the underside of the power supply is not damaged. The forks must
also be centered front to back and side to side to prevent tipping while moving. Fork lift speeds should be kept to a
minimum, especially when making a turn or going around a corner.

• Place the power supply in an area that is free of excessive moisture, has proper ventilation and is
relatively clean. Allow 1 m (3 ft) of space on all sides of the power supply for ventilation and service.
• Cooling air is drawn in through the side panel and is exhausted through the rear of the unit by a cooling
fan. Do not place any filter device over the air intake locations, which reduces cooling efficiency and
VOIDS THE WARRANTY.
• Do not place the power supply on an incline greater than 10° to prevent it from toppling.

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1 Torch lead connections

1. Insert the end of the torch lead through the opening of the ignition enclosure as shown below. Secure the collar on
the torch lead to the ignition enclosure by aligning the tabs on the collar with the corresponding openings in the
ignition enclosure, rotate the collar until it stops, and verify that the collar will not detach when released.

2. Connect the CPC connector to the CPC receptacle.

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Note: The plasma gas and coolant return hose connectors mentioned below are push-to-connect fittings.
• To make a connection, push the hose fitting into the appropriate connector until it stops, 12 mm (0.472 in).

Connector-collar

• To disconnect a fitting, push the connector-collar and hose toward the fitting, hold the collar in place and pull the
hose away from the fitting.

3. Connect the coolant return hose (red).

4. Connect the plasma gas hose (black).

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Note: The shield gas/pilot arc and coolant supply/negative lead hose connectors mentioned below are slightly
different push-to-connect fittings. Slide the hose fitting over the connector and press until it clicks into place. To
disconnect a fitting, pull the connector-collar toward the hose, and pull the hose away from the fitting.

5. Connect the pilot arc/shield gas hose (blue).

6. Connect the negative lead/coolant supply hose (blue with green tape).

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2 Work lead connections

Part number Length
223335 7.5 m (25 ft)
223336 15 m (50 ft)
223337 23 m (75 feet)
223338 30 m (100 feet)

Remove the first nut and washer from the work lead terminal and use it to secure the work lead to the terminal.

Lower frame of work table (typical)

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B Torch connections
Note: The connections between the straight torch main body and the torch leads are identical to the connections
between the quick-disconnect receptacle and the torch leads.
Align the quick disconnect receptacle, or the straight torch main body, to the torch leads and secure using the
push-to-connect fittings.

Connect to torch lead

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Connect the torch to the quick-disconnect receptacle

Align the torch body to the quick disconnect receptacle and connect them by screwing completely together. Apply a thin
film of silicone lubricant to each o-ring. The o-rings should look shiny, but there should not be any excess or built-up
lubricant.

Be certain that there is no space between the torch body and the o-ring on the quick-disconnect.

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Torch mounting and alignment

Mounting the torch

1 1 Torch sleeve
2 Mounting bracket
3 Quick-disconnect receptacle

1. Install the torch (with torch leads attached) in the torch mounting bracket.
2. Position the torch below the mounting bracket, so that the bracket is around the lower portion of the torch sleeve but
not touching the torch quick-disconnect.
3. Tighten the securing screws.
Note: The bracket should be as low on the torch sleeve as possible to minimize vibration at the tip of the torch.

Torch alignment
To align the torch at right angles to the workpiece, use a square as shown above.

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3 CNC interface cable

Part Number Length Part Number Length
223327 1.3 m (5 feet) 223330 15 m (50 feet)
223328 3.0 m (10 feet) 223331 23 m (75 feet)
223329 7.5 m (25 feet) 223332 30 m (100 feet)

Power supply end CNC end

Wire Pin Input/ Input/
color number Output Signal name Function Output Notes
Orange 1 Input Start + The CNC initiates preflow, and if the hold input is not active, Output
White 2 Input Start – continues with the plasma arc. The system will stay in preflow if the Output 1
hold input remains active.
Brown 3 Input Hold + The CNC delays plasma arc initiation. This signal is normally used Output
White 4 input Hold – in combination with the start signal to synchronize multiple torches. Output 1 and 3
Black 5 Output Motion + Notifies the CNC that an arc transfer has occurred and to begin Input
machine motion once the CNC’s pierce delay has timed out. 2
White 6 Output Motion – Input
Red 7 Output Error + Notifies the CNC that an error has occurred. Input
2
White 8 Output Error – Input

Notes to CNC interface cable run list

1. Inputs are optically isolated. They require 24 VDC at 12.5 mA, or dry-contact closure at 8 mA.
2. Outputs are optically isolated, open-collector, transistors. The maximum rating is 24 VDC at 10 mA.
3. Although the power supply has an output capability, it is normally used solely as an input.
4. There is no +24 VDC power available at the J6 CNC connector.
5. The wire clips on the center panel should be used to help route the CNC cable from the rear panel opening of the
power supply to J6 on the control board. Open the clips by depressing the release tab, and add the CNC cable to
the wires that are already present in the clip. See the figure on the next page.

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CNC cable routing and connection to control board

from the
CNC

To J6 on the control board

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Remote ON/OFF switch (provided by customer)

WARNING!
ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. All work requiring the removal of
the plasma system cover must be performed by a qualified technician.
See Safety on page 9 of your instruction manual for more safety precautions.

1. Remove the 4 screws that secure the control panel to the power supply and locate terminal block J1.8 on the power
supply control board.

2. Remove the jumper wire between terminal 1 and terminal 2. Use a sturdy tool to depress the corresponding orange
release buttons on the spring clamp connector

1 2 3 4 5 6 7

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3. Connect the switch to terminals 1 and 2 as shown below. Use a sturdy tool to depress the corresponding orange
release buttons on the spring clamp connector.

1 2 3 4 5 6 7

Note: Use a switch, relay, or solid-state relay that is compatible with 24 VDC @ 100 mA.
Wires should be a twisted pair.

Note: The power switch on the power supply must be in the ON position for the remote switch to function and
the remote switch must be in the ON position (closed) for the power switch on the power supply to function.

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Power requirements
General
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to
5.61 MVA at the point between the user’s supply and the public system. It is the responsibility of the installer or user of
the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is
connected only to a supply with a short-circuit power Ssc greater than or equal to 5.61 MVA.

All switches, slow-blow fuses and power cables are customer-supplied and must be chosen as outlined by applicable
national and local electrical codes. Installation must be performed by a licensed electrician. Use a separate, primary, line
disconnect switch for the power supply. Recommendations on fuse and circuit breaker sizing are listed below, however
actual sizes required will vary based on individual site electrical line conditions (including but not limited to: source
impedance, line impedance, and line voltage fluctuation), product inrush characteristics, and regulatory requirements.

The main feed protection device (circuit breaker or fuse) must be sized to handle all branch-feed loads for both inrush and
steady-state current. The power supply must be wired into one of the branch-feed circuits. The power supply has a
steady-state current listed in the table below.

Use a motor-start circuit breaker or equivalent if time delay high inrush fuses are not permitted by local and national
codes. Time delay fuses and circuit breakers must be capable of withstanding inrush current that is up to 30 times the
rated input current (FLA) for 0.01 seconds and up to 12 times the rated input current (FLA) for 0.1 seconds.

Note: The table below is for reference only. All local and national electrical code must be followed.

Rated input Recommended Recommended cable size for 15 m (50 feet)

current @ “X” kW time delay, high maximum length
Input voltage Phase output inrush, fuse size Rated for 60º C (140º F) Rated for 90º C (194º F)
200/208 VAC 3 108/104 amps 175 amps N/A 67.5 mm2 (2/0)
220 VAC 3 98 amps 150 amps 85.2 mm2 (3/0) 42.4 mm2 (1 AWG)
240 VAC 3 90 amps 150 amps 85.2 mm2 (3/0) 42.4 mm2 (1 AWG)
380 VAC 3 57 amps 90 amps 33.6 mm2 (2 AWG) 21.2 mm2 (4 AWG)
400 VAC 3 54 amps 80 amps 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG)
415 VAC 3 52 amps 80 amps 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG)
440 VAC 3 49 amps 80 amps 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG)
480 VAC 3 45 amps 70 amps 21.2 mm2 (4 AWG) 13.3 mm2 (6 AWG)
600 VAC 3 36 amps 50 amps 13.3 mm2 (6 AWG) 8.3 mm2 (8 AWG)

Note: Wire AWG recommendations came from Table 310-16 of the National Electric Code Handbook (USA).

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Line disconnect switch

The line disconnect switch serves as the supply-voltage disconnecting (isolating) device. Install this
switch near the power supply for easy access by the operator.

Installation must be performed by a licensed electrician and according to applicable national and local
codes.

The switch should:

SWITCH BOX

• Isolate the electrical equipment and disconnect all live conductors from the supply voltage when in
the “OFF” position
• Have one “OFF” and one “ON” position clearly marked with “O” (OFF) and “l” (ON)
• Have an external operating handle capable of being locked in the “OFF” position
• Contain a power-operated mechanism that serves as an emergency stop
• Have slow-blow fuses installed for the proper breaking capacity (see table on previous page).

7 Main power cable

Wire sizes vary based on the temperature rating of the cable insulation and the distance of the unit from the main box.
Use a 4-conductor Type SO input power cable with a conductor temperature rating of 60° C (140° F) or 90° C (194° F).
Installation must be performed by a licensed electrician.

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Connect the power

WARNING!
ELECTRIC SHOCK CAN KILL

The line disconnect switch must be in the OFF position before making the power cable connections.
In the U.S., use a “lock-out/tag-out” procedure until installation is complete. In other countries, follow
appropriate national and local safety procedures.

1. Insert the power cable through the strain relief at the rear of the power supply.
2. Connect the ground lead (PE) to the GROUND connector as shown below.
3. Connect the power leads to the contactor terminals as shown below. For models with an EMI filter, connect the
power leads to the EMI filter terminal block. Recommended torque on contactor or EMI filter terminals is 7-8 Nm
(60–70 in-lbs).
4. Verify that the line disconnect switch is in the OFF position and remains in the OFF position for the
remainder of the installation of the system.
5. Connect the power cord leads to the line disconnect switch following national and local electrical codes.

North American wire colors European wire colors

U = Black U = Black
V = White V = Blue
W = Red W = Brown
(PE) Earth ground = Green/yellow (PE) Earth ground = Green/yellow

4 3
2

1 1 Ground
2 L1
3 L2
4 L3

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Torch coolant requirements

The system is shipped without any coolant in the tank. Before filling the coolant system, determine what coolant mix is
correct for your operating conditions.

Observe the warning and cautions below. Refer to the Material Safety Data Sheets appendix for data on safety,
handling and storage of propylene glycol and benzotriazole.

WARNING!
COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF
SWALLOWED.

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, seek immediate medical attention.

CAUTION!

Never use automotive antifreeze in place of propylene glycol. Antifreeze contains corrosion inhibitors
that will damage the torch coolant system.
Always use purified water in the coolant mixture to prevent damage to the pump and corrosion in the
torch coolant system.

Premixed coolant for standard operating temperatures

Use Hypertherm premixed coolant (028872) when operating in a temperature range of -12° C to 40° C (10° F to 104° F).
Refer to the custom coolant mix recommendations, if temperatures during operation are ever outside of this range.

Hypertherm premixed coolant consists of 69.8% water, 30% propylene glycol, and 0.2% benzotriazole.

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Custom Coolant mix for cold operating temperatures (below -12° C / 10° F)

CAUTION!

For operating temperatures colder than the temperature stated above, the percentage of propylene
glycol must be increased. Failure to do so could result in a cracked torch head, hoses or other damage
to the torch coolant system due to freezing.

Use the chart below to determine what percentage of propylene glycol to use in the mixture.

Mix 100% propylene glycol (028873) with the premixed Hypertherm coolant (028872) to increase the percentage of
glycol in the premixed Hypertherm coolant. The 100% glycol solution can also be mixed with purified water (see the chart
below for water purity requirements) to achieve the required protection from freezing.

Note: The maximum percentage of propylene glycol should never exceed 50%.
Freezing Point of Propylene Glycol Solution
°C °F
4 40

-1 30
Hypertherm pre-mix
-7 20
(028872)
-12 10

-18 0
Temperature

-23 -10

-29 -20
Maximum glycol percentage

-34 -30

-40 -40

-46 -50

-51 -60

-57 -70
0 10 20 30 40 50 60
% of Propylene Glycol

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Custom Coolant mix for hot operating temperatures (above 38° C / 100° F)
Treated water (with no propylene glycol) can only be used as coolant when operating temperatures are never below 0° C
(32° F). For operations in very warm temperatures, treated water will provide the best cooling properties.

Treated water refers to a mixture of purified water, that meets the specifications below, and 1 part benzotriazole (BZT) to
300 parts of water. BZT (128020) acts as a corrosion inhibitor for the copper based coolant system contained in the
plasma system.

Water purity requirements

It is critical to maintain a low level of calcium carbonate in the coolant to avoid reduced performance of the torch or
cooling system.

Always use water that meets the minimum and maximum specifications in the table below when using a custom coolant
mix.

Water that does not meet the minimum purity specifications below can cause excessive deposits on the nozzle that will
alter the water flow and produce an unstable arc.

Water that does not meet the maximum purity specifications below can also cause problems. Deionized water that is too
pure will cause leaching problems with the coolant system plumbing.

Use water purified by any method (deionization, reverse osmosis, sand filters, water softeners, etc.) as long as the water
purity meets the specifications in the table below. Contact a water specialist for advice in choosing a water filtration
system.

Water purity measurement method

Water purity Conductivity Resistivity Dissolved solids Grains per gallon
μS/cm mΩ-cm (ppm of NaCl) (gpg of CaCO2)
at 25° C (77° F) at 25° C (77° F)
Pure water (for reference 0.055 18.3 0 0
only)
Maximum purity 0.5 2 0.206 0.010
Minimum purity 18 0.054 8.5 0.43
Maximum potable water 1000 0.001 495 25
(for reference only)

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Fill the power supply with coolant

The system will take 14.2 liters to 17.0 liters (3.75 to 4.5 gallons) of coolant depending on the length of the torch leads.

1. Add coolant to the power supply until the tank is full. 2. Turn ON the power supply, then press and
release the amps selector knob as many times as
needed until the flow symbol is selected. The flow
rate will be shown in the three digit display. There
is a 45 second delay before the system will report
a low coolant flow error. If the flow rate has not
reached 1.9 liters per minute (lpm) (0.5 gallons
per minute [gpm]) the system will turn off the
pump.

3. If the system displays an error, turn OFF the power to the 4. Add coolant to the power supply until the tank is
system and add coolant to the tank until it is full again. full and replace the filler cap.
Repeat steps 2 and 3 until no error is displayed.

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Connect the supply gases

Air/air cutting
Note: Verify that the plasma gas line and the shield gas line are properly connected before connecting the air
supply hose and supplying pressurized gas to the system.
Connect the air supply hose to the filter regulator as shown below.

N2/N2 supply gas connection

1. Disconnect the air supply hose from the filter regulator.
2. Remove the Air fitting 015012 (1/4 inch NPT X #6 MALE) from the filter/regulator.
a. Install an 015103 adaptor to use the nitrogen supply gas hose offered by Hypertherm.
b. Use the 1/4 inch NPT Female port from which the air fitting was removed to connect a user supplied N2 supply
gas hose.
3. Set the gas pressure regulators. See Setting the supply gas regulators on page 71.

O2/Air Supply gas hook up

1. Disconnect the air supply from the system.
2. Remove the plasma supply tube from filter/regulator output port.

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3. Use the supplied plug to block the open plasma outlet port of the filter/regulator.

4. Connect only filtered and regulated oxygen to the plasma gas Inlet. See Gas regulators on page 72 for a suitable
oxygen regulator.
Note: An oxygen fitting kit (428054) with the parts described below is available from Hypertherm.
There are several options for connecting the oxygen supply gas line:

a. Remove the 015811 fitting and put on an 015009 fitting (user must order the part. See the note above). Use the
correct Hypertherm supply gas tubing (046231) to connect to the fitting.

015811 015009

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b. Use a suitable O2 fitting to connect to the 8 mm (5/16 inch) tubing that you removed from the plasma gas Inlet.

c. Remove the plasma gas tubing and 8 mm (5/16 inch) fitting (015811) and connect to the 1/4 inch NPT female
threads.

015811

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d. Remove the bushing and fitting to connect to 1/4 inch “G” female threads.

015810
and
and
051811
5. Reconnect the air supply.
6. Set the gas pressure regulators. See Setting the supply gas regulators on page 71.

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Gas requirements
The system is configured for air/air cutting when it is shipped. Connect an air supply to the filter/regulator that is mounted
on the rear panel of the power supply. If cutting with O2/air or N2/N2 you will have to make changes to the gas
connections. See Connect the supply gases on page 67.

CAUTION!

Gas supply pressures not within the specifications in Section 2 can cause poor cut quality, poor
consumable life, and operational problems.
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

Setting the supply gas regulators

1. Turn OFF the power to the system. Set all the supply gas regulator pressures to 6.2 bar (90 psi).
2. Turn ON the power to the system.
3. After the purge cycle is complete, press the current selection knob to get to the test mode. When the test mode icon
is illuminated, turn the knob to get to test 005, “Flow gas at full pressure”. Set all supply regulators to a system inlet
pressure of 6.2 bar (90 psi).
4. Press and release the current selection knob until the amps icon is illuminated.

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Gas regulators
Note: A separate gas regulator is needed only when cutting with oxygen.
Use a high-quality, 1-stage, gas regulator to maintain consistent gas supply pressure, if using liquid cryogenic or bulk
storage. Use a high-quality, 2-stage, gas regulator to maintain consistent gas supply pressure from high pressure gas
cylinders.

The high-quality gas regulators listed below are available from Hypertherm and meet U.S. Compressed Gas Association
(CGA) specifications. In other countries, select gas regulators that conform to national or local codes.

2-stage regulator 1-stage regulator

Part number Description

128544 Kit: Oxygen 2-stage regulator*
128548 Kit: Oxygen 1-stage regulator (for use with cryogenic liquid nitrogen or oxygen)
022037 2-stage oxygen regulator
* Kit includes the 2-stage regulator (022037) and the appropriate fittings

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Supply gas plumbing

• Rigid copper plumbing or suitable flexible hose may be used for all gas supplies.
• Do not use steel, black iron, or aluminum pipe.
• After installation, pressurize the entire system and check for leaks.
• Recommended hose diameters are 9.5 mm (3/8 in) for lengths < 23 m (75 ft) and 12.5 mm (1/2 in) for
lengths > 23 m (75 ft).
For flexible-hose systems, use a hose designed for inert gas to carry air or nitrogen. See Supply gas hoses on page 74
for part numbers.

Caution: Never use teflon tape

Caution: When connecting oxygen to the power supply, make sure that
all hoses, hose connections, and fittings are acceptable for use with
oxygen. Installation must be made in accordance with national
and local codes.

Note: When cutting with oxygen as the plasma gas, air must also be connected to the filter regulator.

WARNING!
CUTTING WITH OXYGEN CAN CAUSE FIRE OR EXPLOSION

Cutting with oxygen as the plasma gas can cause a potential fire hazard due to the oxygen-enriched
atmosphere that it creates. As a precaution, Hypertherm recommends that an exhaust ventilation
system be installed when cutting with oxygen.
Flashback arrestors are required (unless not available for specific gases or required pressures) to
prevent fire from propagating back to supply gas.

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Supply gas hoses

Caution: Never use teflon tape

4 Air

Part number Length Part number Length

024671 3 m (10 ft) 024740 25 m (82 ft)
024658 4.5 m (15 ft) 024744 35 m (115 ft)
024659 7.5 m (25 ft) 024678 45 m (150 ft)
024765 10 m (35 ft) 024680 60 m (200 ft)
024660 15 m (50 ft) 024767 75 m (250 ft)
024766 20 m (65 ft)

5 Oxygen

Part number Length Part number Length

024607 3 m (10 ft) 024738 25 m (82 ft)
024204 4.5 m (15 ft) 024450 35 m (115 ft)
024205 7.5 m (25 ft) 024159 45 m (150 ft)
024760 10 m (35 ft) 024333 60 m (200 ft)
024155 15 m (50 ft) 024762 75 m (250 ft)
024761 20 m (65 ft)

6 Nitrogen

Part number Length Part number Length

024210 3 m (10 ft) 024739 25 m (82 ft)
024203 4.5 m (15 ft) 024451 35 m (115 ft)
024134 7.5 m (25 ft) 024120 45 m (150 ft)
024211 10 m (35 ft) 024124 60 m (200 ft)
024112 15 m (50 ft) 024764 75 m (250 ft)
024763 20 m (65 ft)

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Daily start-up
Before turning on the power to the system make sure that the cutting environment and clothing worn by users in that
environment meet all the safety requirements outlined in Safety on page 9.

DANGER!
ELECTRIC SHOCK CAN KILL

Before operating this system, you must read the safety section thoroughly. Turn OFF the power
supply’s main disconnect switch before proceeding with the following steps.

1. Turn OFF the main disconnect switch to the power supply.

2. Remove the consumables from the torch and check for worn or damaged parts. Always place the consumables
on a clean, dry, oil-free surface after removing. Dirty consumables can cause the torch to malfunction
and can shorten the life of the coolant pump.
• See Install and inspect consumables on page 90 for details.
• Refer to Cut charts to choose the correct consumables for your cutting needs.
3. Replace consumable parts. See Install and inspect consumables on page 90 for details.
4. Make sure that the torch is perpendicular to the workpiece.

1 2 3 4 5 6

1 Shield 4 Swirl ring

2 Nozzle retaining cap 5 Electrode
3 Nozzle 6 Torch main body (quick-disconnect torch shown)

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Controls and indicators

1 2 3 4 5 6 7

Control panel descriptions

1 Power switch
2 3-digit display area
3 Current selection knob
4 2-digit plasma display area
5 Plasma gas knob
6 2-digit shield display area
7 Shield gas knob

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Power supply operation

General
• The system runs a number of tests automatically when the system is turned ON. See Automatic
chopper and current sensor tests during power-up on page 152.
• There is power to the control board and other non-high power components when the main disconnect
switch is on, even if the switch on the Power Supply is off. The switch is illuminated to indicate that
there is power to the system. Non-high power components include the low power control circuitry in
the chopper, but not the high-power IGBTs which are switched by the contactor.
• The 3-digit display counts from 1 to 6 to indicate the 6 second purge that occurs when you turn ON
the power supply (you will only actually see 1 thru 5). If the system is powered up with the start signal
on, the 3-digit display will continue to count up.
• When you turn ON the power to the system the displays shows the last process used.
• The user can lock out all inputs (current, plasma gas, and shield gas) to the system by pressing and
holding both the amps and shield gas control knobs until LOC appears in the 3-digit display. The same
process unlocks the system and ULC appears in the 3-digit display. The user can still cycle through the
functions in the 3-digit display area (current, fault, coolant flow, and test).
• All three displays show actual values during cutting. The user can make changes to the current, the
plasma gas, and the shield gas settings unless the inputs have been locked out or the system is being
controlled remotely. The displays show the set values when idle.
• A blinking red dot appears in the bottom right corner of each display when the parameters have been
changed from the default setting.

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3-digit display functions

Turn the current selection knob to increase or decrease the amperage. Push and release the current selection knob to
move from one function to the next.

3-digit display icons

1 Name Description
2 The remote icon illuminates when there is serial communication with
3 1 Remote the power supply. You can still cycle through the functions but cut
parameters can only be changed through the CNC.
4
Increase or decrease the amperage by selecting the amps icon and
5 turning the knob. The current increases or decreases in 1 amp
2 Amps
increments when you turn the knob slowly. You can jump from one
process amperage to another when you turn the knob quickly.
6 7
The fault icon illuminates when an error occurs.

If the error code number is 60 or less, press the current selection

knob to navigate to the illuminated fault icon. When the fault icon is
selected the error code appears in the 3-digit display.
3 Fault
If the error code is 60 or greater the system automatically selects the
fault icon and the error code number flashes in the 3-digit display.

Press and hold the current selection knob to see the power supply
status number for both types of error code.
When the coolant flow icon is selected the display shows the coolant
flow in gallons per minute. When you turn ON the power to the
4 Coolant flow system and select the coolant flow icon before the power supply
finishes the purge count, the flow switch is overridden and coolant
will continue to flow for 30 seconds.
When test icon is selected the system is in test mode. A number of
5 Test functions can be accessed by turning the current selection knob. See
the maintenance section for detailed information.
This white lamp illuminates when the plasma start signal is given and
6 Plasma start lamp
stays illuminated until the start signal is removed.
7 Arc transfer lamp This green lamp illuminates when the arc transfers to the workpiece.

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Choosing a cutting process

1. Use the current selection knob to set the amperage. Turning the knob slowly increases or decreases the current
1 amp at a time. Turning the knob fast lets you jump quickly to the next process current (50A, 130A, and 200A).
A blinking red dot appears in the bottom right corner of each display when the parameters have been changed from
the default setting. You can return to the default setting by pressing and releasing the knob until you return to the
original selection.
2. Push and release the plasma gas knob to cycle through the plasma gas selections. The pressure will automatically be
set when you choose a gas. Turning the knob increases or decreases the pressure. A blinking red dot appears in the
bottom right corner of each display when the parameters have been changed from the default setting. You can return
to the default setting by pressing and releasing the knob until you return to the original gas selection.
3. The shield gas pressure is set automatically when you choose a plasma gas. Turning the knob increases or decreases
the pressure. A blinking red dot appears in the bottom right corner of each display when the parameters have been
changed from the default setting. You can return to the default setting by pressing and releasing the knob until you
return to the original gas selection.
Note: The example shown below is the 50 amp, mild steel, air/air process. See the cut chart for details.

1 2

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CAUTION!
SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the
torch, sparks and hot metal will spray out from the nozzle. Point the torch away
from yourself and others. Always use the proper protective equipment. See
Safety on page 9 for more information.

Handheld cutting
Specifications
Materials Mild steel, stainless steel, and aluminum
Current 50A, 130A, and 200A
Plasma gas types Air, O2, N2
Shield gas types Air, N2
Torch weight (without lead) See Specifications on page 33

Consumable selection and gas settings

Refer to Cutting parameters on page 86 for consumable and process information.

Starting a cut
1. Start cutting from the edge of the workpiece (see figure below) unless you must pierce. For the best results, the
nozzle orifice should overlap the edge of the workpiece about halfway, and the torch (arc) axis should be
perpendicular to the cut surface.

Note: When cutting, make sure that the sparks are coming out of the bottom of the workpiece. If they are spraying
on top of the workpiece, you are moving the torch too fast, or you do not have sufficient power to fully penetrate
the workpiece.
2. Hold the torch lightly on the metal or just off the metal and drag the torch across the metal. The arc transfers once the
torch is within 6 mm (1/4 inch) of the workpiece.

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3. Pull the torch through the cut. Pulling it is easier than pushing it.
4. Hold the torch so the arc is vertical and watch the arc as it cuts along the line (see figure below). By lightly dragging
the shield on the workpiece, you can maintain a steady cut. For straight-line cuts, use any straight edge as a guide.

Piercing
1. Start by holding the torch so that the shield is approximately 1.5 mm (1/16 inch) away from the workpiece before
squeezing the trigger switch. This method maximizes the life of the consumables. See figures below.
2. Hold the torch at about a 45º angle to the workpiece pointing away from yourself, then slowly roll it to a vertical
position. This is particularly important when cutting thicker material. Make sure that the torch is pointed away from
you and the people around you to avoid any danger from sparks and hot metal. Starting the pierce at an angle
permits the hot metal to escape to one side rather than splashing back against the shield, protecting the operator
from the sparks and extending the life of the shield.
3. When the pierce is complete, proceed with the cut.

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Gouging
Specifications
Materials Mild steel, stainless steel, and aluminum
Current 200 Amps
Plasma gas types Air, O2
Shield gas types Air
Torch weight (without lead) See the Specification section

Gouging safety
When gouging, it is absolutely necessary to wear full protection:

• A welding helmet with at least a #12 glass

• Welding gloves and a welding jacket.
• A heat shield (127389) can be purchased for further protection.

Gouge a workpiece
Note: To choose the correct consumables see Hand held
cutting and gouging consumable selection on page 87.
1. Hold the torch so that the torch tip is within 1.5 mm
(1/16 inch) from the workpiece before firing the torch.
2. Hold the torch at a 45° angle to the workpiece with a small
gap between the torch tip and the workpiece. Press the
trigger to obtain a pilot arc. Transfer the arc to the work piece.
3. Maintain an approximate 45° angle to the workpiece as you
feed into the gouge. Push the plasma arc in the direction of
the gouge you want to create. Keep a small distance between
the torch tip and the molten metal to avoid reducing
consumable life or damaging the torch.
Note: Changing the torch’s angle changes the dimensions of
the gouge.

Feeding into the gouge

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Gouging techniques

Straight gouging

Straight gouge

Weaving gouge

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Side gouging

Side gouge

Weaving gouge

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Gouge profiles and metal removal rates

1 2 Operating parameters
1 Speed 635 to 1270 mm/minute (25 to 50 ipm)
2 Angle 35 to 45 degrees
3 3 Standoff 12.7 to 19.0 mm (0.5 to 0.75 inches)
Maximum arc stretch 76 mm (3 inches)*
*For infrequent use, not 100% duty cycle

Typical gouge profile for 200A, air

Metal removal rate on mild steel – 18.7 Kg/hr (41.2 lbs/hr)
Speed 1270 mm/min (50 ipm)
Stand off 12.7 mm (0.5 inch)
Angle 35º

4 5

4 10.7 mm (0.42 inches)

5 4.4 mm (0.18 inches)

Typical gouge profile for 200A, O2

Metal removal rate on mild steel – 20.5 Kg/hr (45 lbs/hr)
Speed 1270 mm/min (50 ipm)
Stand off 12.7 mm (0.5 inch)
Angle 35º

6 7

6 10.4 mm (0.41 inches)

7 5.4 mm (0.21 inches)

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Varying the gouge profile

You can vary the gouge profile and the metal removal rate by varying the speed of the torch over the workpiece, varying
the distance between the torch and the workpiece, varying the angle of the torch to the workpiece, and varying the
current output of the power supply.

The following actions have the stated effects on the gouge profile:

• Increasing the speed of the torch will decrease width and decrease depth.
• Decreasing the speed of the torch will increase width and increase depth.
• Increasing the standoff of the torch will increase width and decrease depth.
• Decreasing the standoff of the torch will decrease width and increase depth.
• Increasing the angle of the torch (more vertical) will decrease width and increase depth.
• Decreasing the angle of the torch (less vertical) will increase width and decrease depth.
• Increasing the current of the power supply will increase width and increase depth.
• Decreasing the current of the power supply will decrease width and decrease depth.

Cutting parameters
The cut charts for the MAXPRO200 show the consumable parts, cutting speeds, and the gas and torch settings required
for each process, allowing for differences in the lead length. These parameters are used for cutting with both mechanized
and handheld torches, the consumable part numbers listed with each cut chart are specific to mechanized torches. Refer
to Hand held torch consumables below for the consumables to use with handheld torches.

The cut chart values in this document are recommended to provide high quality cuts with minimal dross. Because of
differences between installations and material composition, adjustments may be required to obtain desired results.

Mechanized consumables
The consumable part numbers listed above each cut chart are specific to mechanized torches.

Hand held torch consumables

The following sets of consumables are intended to be used with handheld torches for cutting mild steel, stainless steel,
and aluminum. Use the cutting parameters detailed in the Cut charts for cutting with the MAXPRO200 handheld torches.
Use the following consumables for each process.

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Hand held cutting and gouging consumable selection

The following sets of consumables are intended to be used with handheld torches for cutting mild steel, stainless steel,
and aluminum. You can use the cutting parameters detailed under Cut charts on page 101 with the MAXPRO200
handheld torches as long as you use the following consumables for each process.

Note: consumable part numbers listed above each cut chart are specific to mechanized torches.

Mild steel

50 A
Air Plasma
Air Shield
420063 220935 220890 220529 220528

50 A
O2 Plasma
Air Shield
420063 220935 220891 220529 220528

130 A
Air Plasma
Air Shield
420061 220935 220892 220488 220487

130 A
O2 Plasma
Air Shield
420062 220935 220893 220488 220487

200 A
Air Plasma
Air Shield
420058 220935 420044 220488 220937

200 A
O2 Plasma
Air Shield
420059 220935 220831 220834 220937

200 A Gouging
Air Plasma
Air Shield
420067 220935 420066 220488 220937

200 A Gouging
O2 Plasma
Air Shield
420067 220935 420066 220834 220937

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Stainless steel

50 A
Air Plasma
Air Shield
420063 220935 220890 220529 220528

130 A
Air Plasma
Air Shield
420061 220935 220892 220488 220487

130 A
N2 Plasma
N2 Shield
420061 220935 220892 220488 020415

200 A
Air Plasma
Air Shield
420058 220935 420044 220488 220937

200 A
N2 Plasma
N2 Shield
420058 220935 420044 220488 020415

200 A Gouging
Air Plasma
Air Shield
420067 220935 420066 220488 220937

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Aluminum

50 A
Air Plasma
Air Shield
420063 220935 220890 220529 220528

130 A
Air Plasma
Air Shield
420061 220935 220892 220488 220487

130 A
N2 Plasma
N2 Shield
420061 220935 220892 220488 020415

200 A
Air Plasma
Air Shield
420058 220935 420044 220488 220937

200 A
N2 Plasma
N2 Shield
420058 220935 420044 220488 020415

200 A Gouging
Air Plasma
Air Shield
420067 220935 420066 220488 220937

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Install and inspect consumables

WARNING!

Always disconnect power to the power supply before inspecting or changing torch consumable parts.
Use gloves when removing consumables. The torch might be hot.

Install consumables
Check the consumable parts daily for wear before cutting. See Inspect consumables on page 91. Before removing
consumables, bring the torch to the edge of the cutting table, with the torch lifter raised to its highest point to prevent the
consumables from dropping into the water of the water table.

Do not overtighten parts! Only tighten until mating parts are seated.

Apply a thin film of silicone lubricant on each o-ring. The o-ring Wipe the internal and external surfaces of the
should look shiny, but there should not be any excess or built-up torch with a clean cloth or paper towel.
lubricant.

Tool: 104119

1. Install the 2. Install the swirl 3. Install the 4. Install the 5. Install the
electrode into ring into the nozzle and swirl nozzle retaining shield onto the
the torch head nozzle ring into the cap onto the nozzle retaining
nozzle retaining torch head cap
cap

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Inspect consumables
Inspect Look for Action
Shield General:
Erosion or missing material Replace the shield
Molten material attached Replace the shield
Blocked gas holes Replace the shield
Center hole:
Must be round Replace the shield when the center hole is no longer round

Nozzle retaining cap General:

Erosion or missing material Replace the nozzle retaining cap
Cracks Replace the nozzle retaining cap
Burn marks Replace the nozzle retaining cap

Nozzle General:
Always replace the nozzle and Erosion or missing material Replace the nozzle
the electrode as a set Blocked gas holes Replace the nozzle
Center hole:
Must be round Replace the nozzle when the center hole is no longer round
Signs of arcing Replace the nozzle
O-rings:
Damage Replace the o-ring
Lubricant Apply a thin film of silicone lubricant if the o-rings are dry

Swirl ring General:

Damage Replace the swirl ring
Dirt or debris Clean and inspect for damage, and replace if damaged
Blocked gas holes Replace the swirl ring
O-rings:
Damage Replace the o-ring
Lubricant Apply a thin film of silicone lubricant if the o-rings are dry

Electrode Center surface:

Always replace the nozzle and Emitter wear – a pit forms as In general, replace the electrode when the pit depth is
the electrode as a set the emitter wears 1 mm (0.04 in.) or greater.
Emitter O-rings:
Damage Replace the o-ring
Lubricant Apply a thin film of silicone lubricant if the o-rings are dry

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Torch maintenance
Poor cut quality and premature failure may occur if the torch is not maintained properly.

The torch is manufactured to very tight tolerances to maximize cut quality. The torch should not be subjected to hard
impacts that can cause critical features to become misaligned.

The torch should be stored in a clean location when not in use, to avoid contamination of critical surfaces and passages.

Routine maintenance
The following steps should be completed each time consumables are changed: O-rings (2)

1. Use a clean cloth to wipe off the torch inside and outside. A cotton swab can be used
to access hard-to-reach internal surfaces.
2. Use compressed air to blow away any remaining dirt and debris from internal and
external surfaces.
3. Apply a thin film of silicone lubricant on each external o-ring. The o-rings should look
shiny, but there should not be any excess or built-up lubricant.
4. If consumables will be reused, use a clean cloth to wipe them off, and use compressed
air to blow them off before they are installed again. This is especially critical for the nozzle retaining cap.

Quick-disconnect maintenance
The following steps should be completed every 5–10
times consumables are changed:
O-rings

1. Remove the torch from the quick-disconnect

assembly.
2. Use compressed air to blow off all internal surfaces
and the external threads.
3. Use compressed air to blow off all internal surfaces
at the rear of the torch.
4. Inspect each of the 4 o-rings at the rear of the torch
and the o-ring on the quick-disconnect receptacle
for damage. Replace any damaged o-rings. If they
are not damaged, apply a thin film of silicone
lubricant on each o-ring. The o-rings should look Rear view of torch
External
shiny, but there should not be any excess or built-up threads
lubricant.

Maintenance kit
Even with proper care, the o-rings at the rear of the torch will need to be replaced periodically. Hypertherm provides a
quick-disconnect torch maintenance kit (228780) with replacement parts. The kit should be kept in stock and be used as
part of your routine maintenance schedule. The straight torch and the hand torches only have two replaceable o-rings.

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Torch connections

Quick-disconnect torch

1 1
2 2
5 3 3 5
4 4

Torch main body Quick-disconnect receptacle

1 Shield gas
2 Pilot arc
3 Coolant return
4 Plasma gas
5 Coolant supply

Straight torch

2
1

3
4

1 Plasma gas
2 Coolant supply (also contains the negative lead)
3 Shield gas (also contains the pilot arc lead)
4 Coolant return

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Replace the torch water tube

WARNING!

DO NOT CHANGE CONSUMABLE PARTS WHILE IN THE IDLE MODE. Always disconnect power to the
power supply before inspecting or changing torch consumable parts. Use gloves when removing
consumables. The torch might be hot.

Note: The water tube may seem loose when correctly inserted, but any side-to-side looseness will disappear after
the electrode is installed.
1. Turn OFF all power to the system.
2. Remove consumables from torch. See Install and inspect consumables on
page 90.
3. Remove the old water tube.
4. Apply a thin film of silicone lubricant on the o-ring, and install a new water
tube. The o-ring should look shiny, but there should not be any excess or
built-up lubricant.
5. Replace consumables. See Install and inspect consumables on page 90.

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Common cutting faults

Machine torch
• Torch pilot arc will initiate, but will not transfer. Causes can be:
• Work cable connection on the cutting table is not making good contact.
• Malfunction in the system. See the Troubleshooting table on page 129 in the Maintenance section of this
manual.
• Torch-to-work distance is too high.
• The workpiece is not totally penetrated, and there is excessive sparking on top of the workpiece.
Causes can be:
• Current is set too low (check cut chart information).
• Cut speed or cut height is too high (check cut chart information).
• Torch parts are worn or incorrect (see Install and inspect consumables on page 90).
• Metal being cut is too thick.
• Dross forms on the bottom of the cut. Causes can be:
• Cutting speed is not correct (check cut chart information).
• Arc current is set too low (check cut chart information).
• Torch parts are worn or incorrect (see Install and inspect consumables on page 90).
• Cut angle is not square. Causes can be:
• Wrong direction of machine travel. High-quality side is on the right with respect to the forward motion of the
torch.
• Torch-to-work distance is not correct (check cut chart information).
• Cutting speed is not correct (check cut chart information).
• Arc current is not correct (check cut chart information).
• Damaged or worn consumable parts (see Install and inspect consumables on page 90).
• Short consumable life. Causes can be:
• Arc current, arc voltage, travel speed, motion delay, gas flow rates, or initial torch height not set as specified in
the Cut charts.
• Attempting to cut highly magnetic metal plate, such as armor plate with a high nickel content, will shorten
consumable life. Long consumable life is difficult to achieve when cutting plate that is magnetized or becomes
magnetized easily.
• Beginning or ending the cut beyond the plate surface. This draws the arc sideways and can damage the nozzle
or shield. To achieve consumable long life, all cuts must begin and end on the plate surface.

Hand torch
• The torch does not cut completely through the workpiece. The causes can be:
• The cut speed is too fast.
• The consumables are worn.
• The metal being cut is too thick for the selected amperage.
• Gouging consumables are installed instead of drag-cutting consumables.
• The work clamp is not attached properly to the workpiece.
• The gas pressure or gas flow rate is too low.

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• Cut quality is poor. The causes can be:

• The metal being cut is too thick for the amperage.
• The wrong consumables are being used (gouging consumables are installed instead of drag-cutting
consumables, for example).
• Moving the torch too quickly or too slowly.
• The arc sputters and consumables life is shorter than expected. The cause can be:
• Moisture in the gas supply.
• Incorrect gas pressure.
• Consumables incorrectly installed.

Optimizing cut quality

The following tips and procedures will help produce square, straight, smooth, and dross-free cuts.

Tips for table and torch

• Use a square to align the torch at right angles to the workpiece.
• The torch may travel more smoothly if you clean, check, and
tune motion on the rails and drive system of the cutting table.
Unsteady machine motion can cause a regular, wavy pattern on
the cut surface.
• The torch must not touch the workpiece during cutting. Contact
can damage the shield and nozzle, and affect the cut surface.

Plasma setup tips

Follow carefully each step in the Daily Start-up procedure described earlier in this section.

Purge the gas lines before cutting.

Maximize the life of consumable parts

Hypertherm’s LongLife® process automatically increases the gas and current flow at the start of each cut and decreases
them at the end to minimize erosion of the electrode’s center surface. The LongLife process also requires that cuts start
and stop on the workpiece.

• The torch should never fire into the air.

• Starting the cut at the edge of the workpiece is acceptable, as long as the arc is not fired in the air.
• To start with a pierce, use a pierce height that is 1.5 to 2 times the cut height. Refer to the cut chart for your
process for more information.
• Each cut should end with the arc still attached to the workpiece to avoid arc blow-outs (ramp-down
errors).
• When cutting small parts that drop down after being cut from the workpiece, check that the arc remains attached
to the edge of the workpiece for proper ramp-down.
• If arc blow-outs occur, try one or more of the following:
• Reduce the cutting speed during the final part of the cut.
• Stop the arc before the part is completely cut to allow completion of the cut during the ramp-down.
• Program the path of the torch into the scrap area for ramp-down.

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Notes:

• Program the path of the torch directly from one cut part into the next, without stopping and starting the
arc. However, do not allow the path to lead off the workpiece and back on.
• It may be difficult to achieve the full benefits of the LongLife process in some conditions.

Additional factors of cut quality

Cut angle
• A cut part whose 4 sides average less than 4° of cut angle is considered acceptable.
• The squarest cut angle will be on the right side with respect to the forward motion of the torch.
• To determine whether a cut-angle problem is being caused by the plasma system or the drive system:
a. Make a test cut and measure the angle of each side.
b. Rotate the torch 90° in its holder and repeat the process.
c. If the angles are the same in both tests, the problem is in the drive system.
• If a cut-angle problem persists after mechanical causes have been eliminated (see Tips for table and
torch), check the cut height, especially if cut angles are all positive or all negative.
• A positive cut angle results when more material is removed from the top of the cut than from the bottom.
• A negative cut angle results when more material is removed from the bottom of the cut.

Cause Solution
Negative angle
The torch is too low. Increase arc voltage to raise the torch

Square

Positive angle The torch is too high. Decrease arc voltage to lower the torch.

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Dross
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly
deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce the dross.

High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of solid
metal attached very closely to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce
high-speed dross:

• Decrease the cutting speed.

• Decrease arc voltage to decrease the torch-to-work distance.
Notes:

• Dross is more likely to form on warm or hot metal than on cool metal. The first cut in a series of cuts will
likely produce the least dross. As the workpiece heats up, more dross may form during subsequent cuts.
• Dross is more likely to form on mild steel than on stainless steel or aluminum.
• Worn or damaged consumables may produce intermittent dross.

Straightness of the cut surface

A typical plasma cut surface is slightly concave.

The cut surface may become more concave, or convex. Correct torch height is required to keep the cut
surface acceptably close to straight.

A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the arc
voltage to increase the torch-to-work distance and straighten the cut surface.

A convex cut surface occurs when the cut height is too great or the cutting current is too high. First,
reduce the arc voltage, then reduce the cutting current. If there is overlap between different cutting
currents for that thickness, try the consumables designed for the lower current.

How to increase cutting speed

To increase cutting speed, you can decrease the torch-to-work distance. However, decreasing this distance will increase
the negative cut angle.

For mechanized applications the torch must not touch the workpiece while piercing or cutting.

For hand held applications the shield can be touching the workpiece to provide stability during cutting.

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The kerf widths in the following charts are for reference. Differences between installations and material composition may cause actual results to vary from
those shown in the tables.

Metric
Thickness (mm)
Mild steel 0.5 0.8 1 1.2 1.5 2 2.5 3 4 5 6 8 10 12 15 20 25 32 38 44 50
50A Air / Air 1.72 1.51 1.46 1.52 1.62 1.58 1.53 1.47 1.44 1.57
50A O2 / Air 1.36 1.35 1.36 1.37 1.39 1.41 1.42 1.44 1.51 1.52
130A Air / Air 2.08 2.21 2.38 2.45 2.48 2.68 3.08 3.46 3.98
130A O2 / Air 2.29 2.35 2.40 2.56 2.63 2.92 3.45 3.82 4.33 4.78
200A Air / Air 2.68 2.90 2.98 2.95 3.12 3.53 3.98 4.20 4.37 5.02 5.69
200A O2 / Air 2.55 2.95 3.11 3.04 3.13 3.44 3.96 4.60 5.15 5.77 6.40
Thickness (mm)
Stainless steel 0.5 0.8 1 1.2 1.5 2 2.5 3 4 5 6 8 10 12 15 20 25 32 38 44 50
50A Air / Air 1.45 1.71 1.77 1.68 1.56 1.52 1.50 1.55 1.66 1.71
130A Air / Air 2.57 2.70 2.74 2.90 3.19
130A N2 / N2 2.56 2.40 2.43 2.40 2.59 2.97
200A Air / Air 3.03 2.76 2.76 2.76 2.98 3.35 3.42 3.64 3.85 4.67
200A N2 / N2 3.36 3.20 2.94 2.95 3.32 3.92 3.71 4.22 4.70
Thickness (mm)
Aluminum 0.5 0.8 1 1.2 1.5 2 2.5 3 4 5 6 8 10 12 15 20 25 32 38 44 50
50A Air / Air 1.40 1.40 1.40 1.40 1.40 1.47 1.50 1.52 1.55 1.58
130A Air / Air 2.84 2.80 2.78 2.76 2.77 2.88
130A N2 / N2 2.73 2.57 2.62 2.46 2.61 3.00
200A Air / Air 3.73 3.94 3.44 3.42 3.51 3.73 4.03 4.29 5.38
200A N2 / N2 3.55 3.35 3.04 3.02 3.16 3.52 4.00 4.57 5.04

Operation
99
 100

Operation
English
Thickness (inches)
Mild steel 0.018 0.020 0.024 0.030 0.036 0.048 0.060 0.075 0.105 0.125 0.135 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1 1-1/4 1-1/2 1-3/4 2
50A Air / Air 0.069 0.065 0.061 0.056 0.060 0.064 0.063 0.059 0.056 0.058 0.063
50A O2 / Air 0.054 0.053 0.053 0.053 0.054 0.055 0.055 0.056 0.057 0.063 0.059
130A Air / Air 0.085 0.090 0.095 0.096 0.098 0.108 0.119 0.137 0.156
130A O2 / Air 0.092 0.093 0.095 0.100 0.105 0.119 0.133 0.151 0.170 0.188
200A Air / Air 0.111 0.114 0.118 0.116 0.126 0.135 0.147 0.158 0.165 0.172 0.200 0.227
200A O2 / Air 0.109 0.123 0.119 0.125 0.132 0.145 0.157 0.180 0.203 0.229 0.255

Stainless Thickness (inches)

steel .018 .020 .024 .030 .036 .048 .060 .075 .105 .125 .135 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1 1-1/4 1-1/2 1-3/4 2
50A Air / Air 0.056 0.061 0.066 0.071 0.066 0.061 0.060 0.059 N/A 0.063 0.068 0.067
130A Air / Air 0.104 0.106 0.108 0.116 0.124
130A N2 / N2 0.101 0.093 0.096 0.094 0.105 0.116
200A Air / Air 0.119 0.105 0.109 0.109 0.120 0.131 0.135 0.134 0.143 0.152 0.184
200A N2 / N2 0.132 0.124 0.116 0.116 0.136 0.156 0.151 0.145 0.165 0.185
Thickness (inches)
Aluminum .018 .020 .024 .030 .036 .048 .060 .075 .105 .125 .135 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1 1-1/4 1-1/2 1-3/4 2
50A Air / Air 0.055 0.055 0.055 0.055 0.055 0.055 0.055 0.055 0.061 0.061 0.062 0.062
130A Air / Air 0.112 0.110 0.109 0.109 0.108 0.114
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130A N2 / N2 0.107 0.099 0.105 0.095 0.106 0.117

200A Air / Air 0.151 0.157 0.136 0.134 0.140 0.145 0.152 0.159 0.167 0.213
200A N2 / N2 0.140 0.130 0.120 0.119 0.127 0.135 0.147 0.159 0.179 0.199
 Operation

Cut charts
The following cut charts for the MAXPRO200 show the consumable parts, cutting speeds, and the gas and torch
settings required for each process, allowing for differences in the lead length. While you can use these parameters for
cutting with both mechanized and handheld torches, the consumable part numbers listed with each cut chart are specific
to mechanized torches. Refer to Hand held cutting and gouging consumable selection on page 87 for the consumables
to use for handheld torches for each process.

The cut chart values in this document are recommended to provide high quality cuts with minimal dross. Because of
differences between installations and material composition, adjustments may be required to obtain desired results.

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