3 4 AMPS 6 1 AC 8 5 6 V 4. 5. 7 8 _ + PSI 6. BAR powermax165 84489 G3 SERIES
powermax165 (P/N 84489) 22 7, Inc. Hanover, NH USA www.hypertherm.com 22 Powermax, Inc. /
, Inc. Etna Road, P.O. Box 51 Hanover, NH 3755 USA 63-643-3441 63-643-5352 8-643-9878 8-737-2978 Automation 5 Technology Drive West Lebanon, NH 3755 USA 63-298-797 63-298-7977 Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 63457 Hanau-Wolfgang, Deutschland 49 6181 58 21 49 6181 58 2134 49 6181 58 2123 Singapore Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 841 2489 65 841 249 65 841 2489 Japan 1952-14 Yata-Natsumegi Mishima City, Shizuoka Pref. 411-81 Japan 81 559 75 7387 81 559 75 7376 UK Ltd 9 Berkeley Court, Manor Park Runcorn, Cheshire, England WA7 1TQ 44 1928 579 74 44 1928 579 64 France 15 Impasse des Rosiers 9561 Eragny, France 85 5 111 85 5 222 S.r.L. Via Torino 2 2123 Milan, Italy 39 2 725 46 312 39 2 725 46 4 39 2 725 46 314 B.V. Burg, Haverkampstraat 13 791 CN Dinxperlo, Nederland 31 315 655 866 31 315 655 886 B.V. (ETSO) Vaartveld 9 474 SE Roosendaal, Nederland 8 49 73 7843 31 165 5969 31 165 59691 Brasil Ltda. Rua Visconde de Santa Isabel, 2 - Sala 611 Vila Isabel, RJ Brasil CEP 256-12 55 21 2278 6162 55 21 2578 947 EN5199
EMC EN5199 CE g. h. EN5199 IEC TC26 (sec)94 IEC TC26/18A/CD Arc Welding Equipment Installation and Use a. b. c. d. e. f. i
, Inc. (i) 2 G3 3 (ii) 1 New Hampshire Hanover / / ii 9-1
...i...ii...1-2...1-2...1-2...1-3...1-3...1-4...1-4...1-4...1-5...1-5...1-5...1-5...1-5...1-5...1-6...2-2...2-3...2-3 - T1...2-4...2-5...2-6...3-2...3-2...3-2...3-3...3-4...3-4...3-5...3-6...3-6...3-7...3-7...3-7...3-8...3-1 powermax165 iii
...3-1...3-11 T1M...3-11 ON /OFF...3-12...3-12...3-13 XFER...3-15...4-2 LED...4-2...4-3...4-4...4-6 ON...4-6...4-6...4-7...4-8...4-8...4-9...4-9...4-1...4-11...4-12...4-13...5-2...5-3...5-4...5-5...5-6...5-9...5-1...5-11...5-11...5-13...5-13...5-14 iv powermax165
powermax165 v
vi powermax165
...1-2...1-2...1-2...1-3...1-3...1-4...1-4...1-4...1-5...1-5...1-5...1-5...1-5...1-5...1-6 1-1
35 1 1-2 11-98
5 2 4 1-3 8-98
AWS ISO 485 1 A No. 8 No. 11 1-2 A No. 1 No. 11-12 2-4 A No. 12 No. 13 4 A No. 14 No. 14 1-4 5/6/2
1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 55 LeJeune Road P.O. Box 3512, Miami, FL 33135 2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 143 Broadway, New York, NY 118 3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 143 Broadway, New York, NY 118 4. AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society 55 LeJeune Road, P.O. Box 3514, Miami, FL 33135 5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 55 LeJeune Road, P.O. Box 3514, Miami, FL 33135 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 2222 7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada 8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 47 Atlantic Avenue, Boston, MA 221 9. NFPA Standard 7 1978, National Electrical Code, National Fire Protection Association, 47 Atlantic Avenue, Boston, MA 221 1. OSHA, Safety and Health Standards, 29FR 191 U.S. Government Printing Office, Washington, D.C. 242 1-5 11-98
1. 1.1 1.2 1.3 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 5. 5.1 6. 7. 11391 Rev A 1-6 8-1
...2-2...2-3...2-3 - T1...2-4...2-5...2-6 powermax9296 l 2-1
* * (U) 3 I2 3 1 16 U2 (X*) 14 F (4 C) U1 X (U1, I1, U2, I2) 2-28 3 6% 23-24 3 7% *X = Ton/Tbase, 38-415 3 8% Ton = 48 3 8% Tbase = 1 6 3 8% 14o 14o F (-1o 4o C) PH Hz PH Hz CE 3 5-6 U1 I1- rms I1 I1 I1 * 2-28 3 53 41 23-24 3 46 38 38-415 3 27 24 *I1 = (I1) X 48 3 22 2 6 3 21 19 U1 2-28 3.94.98 23-24 3.94.98 38-415 3.94.99 48 3.94.99 6 3.78.99 R CE U1 3 Rsce 4 191 23 142 IEC 61-3-12 R min = 191 4 3 142 23 3 IP IP23CS* IP " 2 " > =.5 > = 3 C > =2.5 x 1.1 x 4. S * 15o 6.1 26 / 2-2 powermax165 l
3 4 AMPS 6 1 AC 8 5 6 V 4. 5. 7 8 _ + PSI BAR 6. 1 8% 8 2 26.4 in (671 mm) 16.8 in (427 mm) 124 lb (56.2 kg) 25.8 in (655 mm) powermax165 l 2-3
- T1 1 1-1/4 (32 ) 1-1/2 i (38 ) 1-3/4 i (45 ) 1.4 / T1 3.3 25 7.5 m 6.3 5 15 m 3.8 25 7.5 T1M 5. 35 1.7 6.8 5 15 2-4 powermax165 l
T1 8.9" (226 mm) 4.2" (17 mm) 2.55" (65 mm) 1.5" (38 mm) 1." (25 mm) T1M 1." (25 mm) 15.47" (393 mm) 2.35" (6mm) 8" (23 mm) 32 pitch.125" (3.2 mm) 1.38" (35 mm) powermax165 l 2-5
S S S IEC DC AC TEST l O / " " 2-6 powermax165 l
:...3-2...3-2...3-2...3-3...3-4...3-4...3-5...3-6...3-6...3-7...3-7...3-7...3-8...3-1...3-1...3-11 T1M...3-11 ON /OFF...3-12...3-12...3-13 XFER...3-15 powermax165 3-1
1. 2. " " 3. " " OR Operator Manual 3-2 powermax165
56.2 powermax165 3-3
Powermax165.25 Powermax165 2 6 3 CE 23-4 3 Standard Model Three 3 Phase Input Voltage 2-28 23-24 4 48 6 Input Current 16 at 16kw Output 53 46 27 22 21 Input Current during Arc Stretch 75 72 42 34 33 Recommended Fuse 8 8 5 4 4 CE Model Three 3 Phase Input Voltage 23 4 Input Current 16 at 16kw Output 46 27 Input Current during Arc Stretch 72 42 Recommended Fuse 8 5 " " " " " " 165 3-4 powermax165
Powermax165 1. 3-2. Powermax165 3. CE 3-5/6 2-6 48 CE 3-5/6 23-4 4 PMX165 3 kw 1 A 22.5 kw 1 A 75 A 15 kw 75 A 5 A powermax165 3-5
EMI Powermax165 4 / " " " " AWG (mm 2 ) " " < 1 ft 1-25 ft 25-5 ft 5-1 ft 1-15 ft < 3 m 3 7.5 m 7.5 15 m 15 3 m 3 45 m AWG mm 2 AWG mm 2 AWG mm 2 AWG mm 2 AWG mm 2 2-28 VAC 3 6 (16) 6 (16) 6 (16) 4 (25) 2 (35) 23 VAC 3 6 (16) 6 (16) 6 (16) 4 (25) 2 (35) 4 VAC 3 8 (1) 8 (1) 8 (1) 8 (1) 8 (1) 48 VAC 3 1 (6) 1 (6) 1 (6) 1 (6) 1 (6) 6 VAC 3 1 (6) 1 (6) 1 (6) 1 (6) 1 (6) CE mm 2 mm 2 mm 2 mm 2 mm 2 23 VAC 3 16 16 16 25 35 4 VAC 3 1 1 1 1 1 2 EMC EN5199 3-6 powermax165
3 4 AMPS 6 1 AC 8 5 6 V 4. 5. 7 8 _ + PSI 6. BAR Powermax165 Powermax165 9.5 (241 mm) L1 L2 L3 L1 L2 CE (U) (V) L3 (W) 6 (152 mm) #1 PE / L1 L2 L3 (2) " " PE powermax165 3-7
3 4 AMPS 6 1 AC 8 5 6 V 4. 5. 7 8 _ + PSI 6. BAR ETR ETR 3-8 powermax165
ETR powermax165 3-9
Powermax165 6.1 26 / 8.3 128647 3-128647 Powermax165 Powermax165 3-1 powermax165
1. 1/4 NPT CE G1/4 CE / 2. 9.5 1 " " T1M 9 9 powermax165 3-11
ON /OFF T1M ) ON/OFF 2326 XFER 18 START 12 /1 3, 4 12, 14 2326,, 3-12 powermax165
3 18 AWG 1. 1. 2. 3. powermax165 3-13
4. 1/4" " " J15 J16 3 J15 J16 +VDC -VDC 5. 6. 3-14 powermax165
XFER J19 24 1 / 24 24 4 3 14 12 13 START SIGNAL SHIELD J19 XFER START GND 24VDC BLK YEL RED WHT BLK 1) 24 >24 2) 1 1 "GROUND" IN43 IN42 IN44 powermax165 3-15
4 3 14 12 13 SHIELD START SIGNAL ISOLATED - INPUT MODULE + J19 XFER START GND 24VDC BLK YEL RED WHT 1) - BLK "GROUND" 3-16 powermax165
4 3 14 12 13 SHIELD START SIGNAL + 24VDC J19 XFER START GND 24VDC BLK YEL RED WHT Notes: 1) 24 >24 2) 24 3) 1 1 IN42 IN44 IN43 powermax165 3-17
- 4 3 14 12 13 SHIELD START SIGNAL + 24VDC + J19 XFER START GND 24VDC BLK YEL RED WHT ISOLATED - INPUT MODULE 1) - 2) 24 3-18 powermax165
...4-2 LED...4-2...4-3...4-4...4-6 ON...4-6...4-6...4-7...4-8...4-8...4-9...4-9...4-1...4-11...4-12...4-13 powermax165 4-1
3 4 AMPS 6 1 AC 5 6 8 4. 5. _ + V 7 8 PSI 6. BAR ON (I) / OFF () / LED LED AC LED ON ( I ) LED 4.5 2.8 LED LED LED LED LED V LED 17 68 4-2 powermax165
powermax165 4-3
4A 12929 12928 12932 6A 12929 12928 12931 12926 12925 O 58519 8A 12929 12928 12927 1A 2265 2248 2211 2237 2251 6A 12977 12928 2259 O 58519 8A 12926 12925 12977 12928 12978 1A 12977 2248 2263 2237 2251 4-4 powermax165
4A 1293 12928* 12932 6A 1293 12928* 12931 12926 12925 O 58519 8A 1293 12928* 12927 1A 2247 2248* 2211 2237 2251 4A-8A 1A 2261* 2226* * 4A ** CE 12979 12928 226 ** 6A 12979 12928 227 12926 12925 O 58519 8A 12979 12928 1298 1A 12979 2248 2264 2237 2251 powermax165 4-5
/ ON ON (1) AC POWER ON Gas Pressure LED V 4-6 powermax165
AMPS 4 6 3 8 1 AMPS 4 6 3 8 1 3 5 6 7 8 PSI 4. 5. 6. BAR 35-5 ft 12-15 m 15-25 ft 4.5-7.5 m 15-5 ft 4.5-15 m powermax165 4-7
4-8 powermax165
EMF. powermax165 4-9
5 27668-3 4-1 powermax165
3 powermax165 4-11
1.5 45 45 45 2249 4-12 powermax165
1 3.2 2247 2248 2211 2237 2251 T1M " " powermax165 4-13
8 1293 12928 12927 12926 12925 T1M Mild Steel Arc Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Current Voltage Delay Inches mm IPM mm/min IPM mm/min 132.25 3/16" 4.8 216 5486 14 3556 134 1/4" 6.4 161 489 15 2667 137.5 3/8" 9.5 94 2388 61 1549 8 14 1/2" 12.7 6 1524 39 991 145 1. 5/8" 15.9 4 116 26 66 148 3/4" 19. 31 787 2 58 15 N/A 7/8" 22.2 23 584 15 381 156 1" 25.4 16 46 1 254 Stainless Arc Current 8 Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Voltage Delay Inches mm IPM mm/min IPM mm/min 134.25 3/16" 4.8 216 5486 14 3556 136.5 1/4" 6.4 158 413 13 2616 139 3/8" 9.5 83 218 54 1372.75 142 1/2" 12.7 5 127 33 838 145 5/8" 15.9 34 864 22 559 15 N/A 3/4" 19. 24 61 16 46 153 1" 25.4 14 356 9 229 Aluminum Arc Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Current Voltage Delay Inches mm IPM mm/min IPM mm/min 134 1/8" 3.2 454 11532 295 7493.25 139 1/4" 6.4 176 447 114 2896 8 143 3/8" 9.5 121 373 6 1524.75 146 1/2" 12.7 75 195 37 94 154 N/A 3/4" 19. 37 94 19 483 " " 4-14 powermax165
6 1293 12928 12931 12926 12925 T1M " " powermax165 4-15
4 1293 12928 12932 12926 12925 T1M Mild Steel Arc Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Current Voltage Delay Inches mm IPM mm/min IPM mm/min 147 26 GA.5 638 1625 415 1541 25 148 22 GA.8 5 127 325 8255 149 18 GA 1.3 312 7925 23 5156 152 16 GA 1.5 176 447 114 2896 144.25 14 GA 1.9 64 16256 221 5613 4 146.5 1 GA 3.4 151 3835 98 2489 147.75 3/16 4.7 97 2464 63 16 149 1. 1/4 6.4 74 188 48 1219 Stainless Arc Current 25 4 Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Voltage Delay Inches mm IPM mm/min IPM mm/min 139 26 GA.5 631 1627 41 1414 139 22 GA.8 496 12598 322 8179 142 18 GA 1.3 592 1537 335 859 144.25 16 GA 1.5 374 95 243 6172 144 14 GA 1.9 221 5613 144 3658 147.5 1 GA 3.4 17 2718 7 1778 149.75 3/16 4.7 67 172 44 1118 149 1. 1/4 6.4 47 1194 31 787 Aluminum Arc Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Current Voltage Delay Inches mm IPM mm/min IPM mm/min 25 15 1/32.8 61 15494 397 184 152 1/16 1.5 268 687 174 442 146.25 3/32 2.4 293 7442 19 4826 4 149.5 1/8 3.2 24 5182 133 3378 151 1. 1/4 6.4 76 193 49 1245 " " 4-16 powermax165
1 12979 2248 2264 2237 2251 T1M " " powermax165 4-17
4 1.5 12979 12928 226 12926 12925 T1M Mild Steel Arc Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Current Voltage Delay Inches mm IPM mm/min IPM mm/min 125 26 GA.5 55 1397 353 8966 25 128 22 GA.8 484 12294 315 81 13 18 GA 1.3 238 645 155 3937 131 16 GA 1.5 167 4242 19 2769 4 129.25 14 GA 1.9 326 828 212 5385 Stainless Arc Current 25 4 Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Voltage Delay Inches mm IPM mm/min IPM mm/min 127 26 GA.5 561 14249 365 9271 127 22 GA.8 453 1156 295 7493 123 18 GA 1.3 5 127 325 8255 127.25 16 GA 1.5 367 9322 239 671 128 14 GA 1.9 22 5588 143 3632 Aluminum Arc Arc Pierce Material Thickness Maximum Travel Speeds Optimum Travel Speeds Current Voltage Delay Inches mm IPM mm/min IPM mm/min 25 125 1/32.8 564 14326 366 9296 127 1/16 1.5 236 5994 153 3886 4 127.25 3/32 2.4 261 6629 17 4318 " " 4-18 powermax165
...5-2...5-3...5-4...5-5...5-6...5-9...5-1...5-11...5-11...5-13...5-13...5-14 powermax165 5-1
5 6 7 8 PSI 4. 5. 6. BAR LED LED 3 6 5-2 powermax165
.8.8 O 2755 powermax165 5-3
A. B. C. A O B C A. B. C. B C A 5-4 powermax165
3 4 AMPS 6 1 AC 5 6 8 4. 5. _ + V 7 8 PSI 6. BAR ON (I) / OFF () / LED LED AC LED ON ( I ) LED 4.5 2.8 LED LED LED LED LED V LED 17 68 powermax165 5-5
/ 1. ON/OFF / I POWER ON 1.1 1.2 ON AC 2. POWER ON LOW GAS PRESSURE RANGE FAULT 2.1 2.2 6.2-8.3 2.3 4-7 3 3. POWER ON LINE VOLTAGE RANGE FAULT 3.1 V 5-6 powermax165
/ 4. POWER ON TEMPERATURE FAULT 4.1 5. POWER ON TORCH PARTS LOOSE OR REMOVED FAULT 5.1 4 6. 6.1 6.2 6.3 4 powermax165 5-7
/ 7. 7.1 4 7.2 6.1 4 26 / 7.3 8. 8.1 8.2 3 8.3 9. 9.1 4 5-8 powermax165
/ 1. POWER ON FAULTG 1.1 11. POWER ON FAULT 11.1 ON/OFF / ON OFF ON OFF 12. POWER ON FAULT 1 12.1 OFF 1. 2. 3. Powermax165 Service Manual powermax165 5-9
AC Input PE S1 PCB1 EMI Filter Board (CE Only) Air/Gas Source D1 Input Diode Bridge + ~ ~ - Filter PCB3 Control Board UP CPA MID NORMAL CURRENT DOWN GOUGE AC V GAS STATUS 45 5 55 6 65 7 75 8 85 L1 Q1 Boost IGBT PCB2 Power Board TS1 TS2 TS3 M1 PS1 Pressure Sensor (gas) Regulator Q2 Invertor IGBT V1 Solenoid Valve (gas) D1... D2... L1... L2... r M1... PCB1... PCB2... PCB3... PS1... Q1... IGBT Q2... IGB Q3... IGBT S1... / J1... TS1,TS2... TS3... T2... V1... D2 Output Diode Bridge L2 T2 Power xfmr ~ - ~ + Q3 PA IGBT J1 Electrode Nozzle Work IFB Start Switch Cap Switch Transfer Sensor Air/Gas to Torch Torch Workpiece 5-1 powermax165
4A 12929 12928 12932 6A 12929 12928 12931 12926 12925 O 58519 8A 12929 12928 12927 1A 2265 2248 2211 2237 2251 6A 12977 12928 2259 O 58519 8A 12926 12925 12977 12928 12978 1A 12977 2248 2263 2237 2251 powermax165 5-11
4A 1293 12928* 12932 6A 1293 12928* 12931 12926 12925 O 58519 8A 1293 12928* 12927 1A 2247 2248* 2211 2237 2251 4A-8A 1A 2261* 2226* * 4A ** CE 12979 12928 226 ** 6A 12979 12928 227 12926 12925 O 58519 8A 12979 12928 1298 1A 12979 2248 2264 2237 2251 5-12 powermax165
59264 T1 Hand Torch Assembly, 25' 5927 T1 Hand Torch Assembly, 5' 59265 T1M Machine Torch Assembly, 25' 59268 T1M Machine Torch Assembly, 35' 59272 T1M Machine Torch Assembly, 5' 2755 Silicone grease, 1/4 Oz. Tube 15337 Quick Disconnect Nipple: 1/4 NPT Steel (Non-CE) 15145 Adapter: 1/4 NPT x G1/4 BSPP Brass (CE) 58519 Torch O-Ring 128644 T1 Hand Torch Handle Replacement Kit (5 Screws included) 75586 T1 Hand Torch Handle Screw (5 Required) 2261 Shield Cap: T6M/T8M Ohmic Contact 2226 Shield Cap: T1M Ohmic Contact 59275 Powermax 9296 Hand System, 2-6V, 3PH, 5/6Hz, CSA, Auto- Voltage/Phase (Not CE Compliant), 25 Ft. Torch & Lead Assembly 59276 Powermax 9296 Hand System, 2-6V, 3PH, 5/6Hz, CSA, Auto- Voltage/Phase (Not CE Compliant), 5 Ft. Torch & Lead Assembly 59279 Powermax 9296 Machine System, 2-6V, 3PH, 5/6Hz, CSA, Auto- Voltage/Phase (Not CE Compliant), 25 Ft. Torch & Lead Assembly 5928 Powermax 9296 Machine System, 2-6V, 3PH, 5/6Hz, CSA, Auto- Voltage/Phase (Not CE Compliant), 5 Ft. Torch & Lead Assembly 59288 Powermax 9296 Hand System, 23-4V, 3PH, 5/6Hz, CE, Auto-Voltage, 25 Ft. Torch & Lead Assembly 59289 Powermax 9296 Hand System, 23-4V, 3PH, 5/6Hz, CE, Auto-Voltage, 5 Ft. Torch & Lead Assembly 5929 Powermax 9296 Machine System, 23-4V, 3PH, 5/6Hz, CE, Auto- Voltage, 25 Ft. Torch & Lead Assembly 59291 Powermax 9296 Machine System, 23-4V, 3PH, 5/6Hz, CE, Auto- Voltage, 5 Ft. Torch & Lead Assembly 12874 Cover Assembly, Non-CE (14 Screws Included) 128762 Cover Assembly, CE (14 Screws included) 75533 Cover Screws (Individual Cover Screw) 128627 Air Filter Bowl with Fittings 1192 Replacement Filter Element 129654 ETR Door Assembly 12945 Consumable Box 123654 2 Ft Ground Clamp with Cable & Strain-relief powermax165 5-13
128788 Stationary Mounting Kit 128647 Optional Air Filtration Kit 1193 Replacement Filter For Optional Air Filtration Kit 27668 Circle Cutting Guide Assembly 27684 Replacement Bushing for Circle Cutting Guide Assembly 123655 5 Ft (15M) Ground Clamp with Cable & Strain-relief 12877 Power Cord Stain Relief Inserts 2326 CNC Interface Cable 2249 Gouging Heat Shield for Hand Torch 12865 On/Off Pendant for Machine Torch, 25 Ft (7.5M) 128651 On/Off Pendant for Machine Torch, 5 Ft (15M) 128652 On/Off Pendant for Machine Torch, 75 Ft (22.5M) 8447 PMX9296 Service Manual 5-14 powermax165