MAXPRO200™

Instruction Manual
807700 | Revision 7 | English
 Register your new Hypertherm system

Benefits of registration

5 Safety: Registration allows us to contact you in the unlikely event a safety or quality notification
is required.

5 Education: Registration gives you free access to online product training content via the
Hypertherm Cutting Institute.

5 Confirmation of ownership: Registration can serve as proof of purchase in case of an

insurance loss.

Go to www.hypertherm.com/registration for easy and fast registration.

If you experience any problems with the product registration process, please contact
[email protected].

For your records

Serial number: __________________________________________________________________________

Purchase date: __________________________________________________________________________
Distributor: _____________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Maintenance notes: ______________________________________________________________________

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

MAXPRO200, Sensor THC, Sensor PHC, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the
United States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment

© 2020 Hypertherm, Inc.

 MAXPRO200

Instruction Manual

807700
Revision 7

English
Original instructions

September 2020

Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9, 4704 SE
Hanover, NH 03755 USA Roosendaal, Nederland
603-643-3441 Tel (Main Office) 31 165 596907 Tel
603-643-5352 Fax (All Departments) 31 165 596901 Fax
[email protected] (Main Office Email) 31 165 596908 Tel (Marketing)
800-643-9878 Tel (Technical Service) 31 (0) 165 596900 Tel (Technical Service)
[email protected] (Technical Service Email)
00 800 4973 7843 Tel (Technical Service)
800-737-2978 Tel (Customer Service) [email protected]
[email protected] (Customer Service Email)
(Technical Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization) Hypertherm (Shanghai) Trading Co., Ltd.
[email protected] (RMA email) B301, 495 ShangZhong Road
Shanghai, 200231
Hypertherm México, S.A. de C.V. PR China
Avenida Toluca No. 444, Anexo 1, 86-21-80231122 Tel
Colonia Olivar de los Padres 86-21-80231120 Fax
Delegación Álvaro Obregón 86-21-80231128 Tel (Technical Service)
México, D.F. C.P. 01780 [email protected]
52 55 5681 8109 Tel (Technical Service Email)
52 55 5683 2127 Fax
[email protected] (Technical Service Email) South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Hypertherm Plasmatechnik GmbH Guarulhos, SP – Brasil
Sophie-Scholl-Platz 5 CEP 07115-030
63452 Hanau 55 11 2409 2636 Tel
Germany [email protected] (Technical Service Email)
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax Hypertherm Korea Branch
31 (0) 165 596900 Tel (Technical Service) #3904. APEC-ro 17. Heaundae-gu. Busan.
00 800 4973 7843 Tel (Technical Service) Korea 48060
[email protected] (Technical Service Email) 82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Hypertherm (Singapore) Pte Ltd. [email protected] (Marketing Email)
82 Genting Lane [email protected]
Media Centre (Technical Service Email)
Annexe Block #A01-01
Singapore 349567, Republic of Singapore Hypertherm Pty Limited
65 6841 2489 Tel GPO Box 4836
65 6841 2490 Fax Sydney NSW 2001, Australia
[email protected] (Marketing Email)
61 (0) 437 606 995 Tel
[email protected] (Technical Service Email) 61 7 3219 9010 Fax
[email protected] (Main Office Email)
Hypertherm Japan Ltd. [email protected]
Level 9, Edobori Center Building (Technical Service Email)
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan Hypertherm (India) Thermal Cutting Pvt. Ltd
81 6 6225 1183 Tel A-18 / B-1 Extension,
81 6 6225 1184 Fax Mohan Co-Operative Industrial Estate,
[email protected] (Main Office Email)
Mathura Road, New Delhi 110044, India
[email protected] (Technical Service Email) 91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[email protected] (Main Office Email)
[email protected]
(Technical Service Email)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at
www.hypertherm.com/hci.
 Contents

Safety ........................................................................................................................................SC-13
Recognize safety information ...............................................................................................................................................SC-13
Inspect equipment before using ..........................................................................................................................................SC-13
Follow safety instructions ......................................................................................................................................................SC-13
Responsibility for safety ........................................................................................................................................................SC-13
A plasma arc can damage frozen pipes ............................................................................................................................SC-13
Static electricity can damage printed circuit boards ......................................................................................................SC-14
Grounding safety ....................................................................................................................................................................SC-14
Electrical hazards ....................................................................................................................................................................SC-14
Electric shock can kill ............................................................................................................................................................SC-15
Cutting can cause fire or explosion ....................................................................................................................................SC-16
Fire prevention .................................................................................................................................................................SC-16
Explosion prevention ......................................................................................................................................................SC-16
Machine motion can cause injury ........................................................................................................................................SC-16
Compressed gas equipment safety ....................................................................................................................................SC-17
Gas cylinders can explode if damaged .............................................................................................................................SC-17
Toxic fumes can cause injury or death ...............................................................................................................................SC-17
A plasma arc can cause injury and burns .........................................................................................................................SC-18
Arc rays can burn eyes and skin .........................................................................................................................................SC-18
Medical implant, pacemaker, and hearing aid operation ...............................................................................................SC-18
Noise can damage hearing ...................................................................................................................................................SC-19
Dry dust collection information ............................................................................................................................................SC-19
Laser radiation .........................................................................................................................................................................SC-20
Additional safety information ................................................................................................................................................SC-20

Electromagnetic Compatibility (EMC) .............................................................................SC-21

Introduction ..............................................................................................................................................................................SC-21
Installation and use .................................................................................................................................................................SC-21
Assessment of area ................................................................................................................................................................SC-21

MAXPRO200 Instruction Manual 807700 5

Contents

Methods of reducing emissions ..........................................................................................................................................SC-21

Mains supply ....................................................................................................................................................................SC-21
Maintenance of cutting equipment .....................................................................................................................................SC-21
Cutting cables .........................................................................................................................................................................SC-21
Equipotential bonding ....................................................................................................................................................SC-21
Earthing of the workpiece .............................................................................................................................................SC-22
Screening and shielding .......................................................................................................................................................SC-22

Warranty .................................................................................................................................. SC-23

Attention ...................................................................................................................................................................................SC-23
General .....................................................................................................................................................................................SC-23
Patent indemnity .....................................................................................................................................................................SC-23
Limitation of liability ................................................................................................................................................................SC-23
National and local codes ......................................................................................................................................................SC-23
Liability cap ..............................................................................................................................................................................SC-24
Insurance ..................................................................................................................................................................................SC-24
Transfer of rights .....................................................................................................................................................................SC-24
Waterjet product warranty coverage .................................................................................................................................SC-24
Product ..............................................................................................................................................................................SC-24
Parts coverage ................................................................................................................................................................SC-24

Product Stewardship ........................................................................................................... SC-25

Introduction ..............................................................................................................................................................................SC-25
National and local safety regulations .................................................................................................................................SC-25
Certification test marks .........................................................................................................................................................SC-25
Differences in national standards .......................................................................................................................................SC-25
Safe installation and use of shape cutting equipment ...................................................................................................SC-25
Procedures for periodic inspection and testing ..............................................................................................................SC-25
Qualification of test personnel .............................................................................................................................................SC-26
Residual current devices (RCDs) .......................................................................................................................................SC-26
Higher-level systems ..............................................................................................................................................................SC-26

Environmental Stewardship .............................................................................................. SC-27

Introduction ..............................................................................................................................................................................SC-27
National and local environmental regulations ...................................................................................................................SC-27
The RoHS directive ................................................................................................................................................................SC-27
Proper disposal of Hypertherm products ..........................................................................................................................SC-27
The WEEE Directive ..............................................................................................................................................................SC-27
The REACH regulation ..........................................................................................................................................................SC-27
Proper handling and safe use of chemicals .....................................................................................................................SC-28

6 MAXPRO200 Instruction Manual 807700

 Contents

Fumes emission and air quality ............................................................................................................................................SC-28

California’s Proposition 65 regulation ................................................................................................................................SC-28

1 Specifications .............................................................................................................................. 29
System description ....................................................................................................................................................................... 29
General .................................................................................................................................................................................... 29
Power supply ......................................................................................................................................................................... 29
Ignition console ..................................................................................................................................................................... 29
Torch ........................................................................................................................................................................................ 30
Gas system ............................................................................................................................................................................ 30
Cooling system ...................................................................................................................................................................... 32
System gas requirements ........................................................................................................................................................... 32
Power supply ................................................................................................................................................................................. 33
Mechanized torches ..................................................................................................................................................................... 35
Straight torch – 428024 or 228937 ............................................................................................................................... 35
Quick-disconnect torch – 428027 or 428028 ............................................................................................................. 36
Hand torches ................................................................................................................................................................................. 37
90 degree hand torch – 420108 ...................................................................................................................................... 37
65 degree hand torch – 420107 ...................................................................................................................................... 38
Critical raw materials ................................................................................................................................................................... 39
Symbols and marks ...................................................................................................................................................................... 40

2 Installation .................................................................................................................................... 43
Upon receipt .................................................................................................................................................................................. 43
Claims .............................................................................................................................................................................................. 43
Installation requirements ............................................................................................................................................................. 43
Noise levels .................................................................................................................................................................................... 44
Placement of system components ............................................................................................................................................ 44
Recommended grounding and shielding ................................................................................................................................. 46
Introduction.............................................................................................................................................................................. 46
Types of grounding................................................................................................................................................................ 46
Grounding practices ............................................................................................................................................................. 47
Example grounding diagram with an HPR or MAXPRO200 cutting system ........................................................... 50
Placement of the power supply ................................................................................................................................................. 51
Torch lead connections ............................................................................................................................................................... 52
Machine torch leads ............................................................................................................................................................. 52
Hand torch leads ................................................................................................................................................................... 52
Work lead connections ............................................................................................................................................................... 55
Torch connections ........................................................................................................................................................................ 56
Connect the torch to the quick-disconnect receptacle ....................................................................................................... 57
Torch mounting and alignment .................................................................................................................................................. 58

MAXPRO200 Instruction Manual 807700 7

Contents

Mounting the torch ............................................................................................................................................................... 58

Torch alignment ..................................................................................................................................................................... 58
CNC interface cable .................................................................................................................................................................... 59
Notes to CNC interface cable run list ............................................................................................................................. 59
Remote ON/OFF switch (provided by customer) ................................................................................................................. 61
Power requirements ..................................................................................................................................................................... 63
General ................................................................................................................................................................................... 63
Line disconnect switch ........................................................................................................................................................ 64
Main power cable ................................................................................................................................................................. 64
Connect the power ...................................................................................................................................................................... 65
Torch coolant requirements ....................................................................................................................................................... 66
Premixed coolant for standard operating temperatures .............................................................................................. 66
Custom Coolant mix for cold operating temperatures (below -12° C / 10° F) ...................................................... 67
Custom Coolant mix for hot operating temperatures (above 38° C / 100° F) ....................................................... 68
Water purity requirements .................................................................................................................................................. 68
Fill the power supply with coolant ............................................................................................................................................ 69
Connect the supply gases .......................................................................................................................................................... 70
Air/air cutting ......................................................................................................................................................................... 70
N2/N2 supply gas connection ............................................................................................................................................ 70
O2/Air Supply gas hook up ................................................................................................................................................ 70
Gas requirements ......................................................................................................................................................................... 74
Setting the supply gas regulators ..................................................................................................................................... 74
Gas regulators ............................................................................................................................................................................... 75
Supply gas plumbing ................................................................................................................................................................... 77
Supply gas hoses ......................................................................................................................................................................... 78
Air ............................................................................................................................................................................................. 78
Oxygen .................................................................................................................................................................................... 78
Nitrogen .................................................................................................................................................................................. 78

3 Operation ...................................................................................................................................... 79
Daily start-up ................................................................................................................................................................................. 79
Controls and indicators ............................................................................................................................................................... 80
Power supply operation .............................................................................................................................................................. 81
General ................................................................................................................................................................................... 81
3-digit display functions ...................................................................................................................................................... 82
Choosing a cutting process ............................................................................................................................................... 83
Handheld cutting .......................................................................................................................................................................... 84
Safety ....................................................................................................................................................................................... 84
Specifications ........................................................................................................................................................................ 84
Consumable selection and gas settings ......................................................................................................................... 84
Starting a cut ......................................................................................................................................................................... 85

8 MAXPRO200 Instruction Manual 807700

 Contents

Piercing ................................................................................................................................................................................... 86
Gouging .......................................................................................................................................................................................... 87
Safety ....................................................................................................................................................................................... 87
Specifications ........................................................................................................................................................................ 87
Parameters of operation for frequently-used gouge processes ................................................................................ 87
How to change the gouge contour and metal-removal rate ....................................................................................... 89
Output current (A) ........................................................................................................................................................ 90
Angle of the torch ......................................................................................................................................................... 90
Turn of the torch ............................................................................................................................................................ 90
Torch-to-work standoff / arc stretch ..................................................................................................................... 91
Speed of the torch ....................................................................................................................................................... 91
Mechanized gouging ............................................................................................................................................................ 92
Handheld gouging ................................................................................................................................................................ 93
Handheld gouging techniques ................................................................................................................................... 94
Cutting parameters ...................................................................................................................................................................... 96
Mechanized consumables .......................................................................................................................................................... 97
Handheld consumables ............................................................................................................................................................... 97
How to select cutting and gouging consumables ........................................................................................................ 97
Mild steel cutting ........................................................................................................................................................... 97
Mild steel gouging ........................................................................................................................................................ 98
Stainless steel cutting .................................................................................................................................................. 99
Stainless steel gouging ............................................................................................................................................... 99
Aluminum cutting ........................................................................................................................................................ 100
Aluminum gouging ...................................................................................................................................................... 100
Install and inspect consumables ............................................................................................................................................. 101
Install consumables ............................................................................................................................................................ 101
Inspect consumables ......................................................................................................................................................... 102
Torch maintenance ..................................................................................................................................................................... 103
Routine maintenance ......................................................................................................................................................... 103
Quick-disconnect maintenance ....................................................................................................................................... 103
Maintenance kit ................................................................................................................................................................... 103
Torch connections .............................................................................................................................................................. 104
Quick-disconnect torch ............................................................................................................................................. 104
Straight torch ............................................................................................................................................................... 104
Replace the torch water tube .......................................................................................................................................... 105
Common cutting faults .............................................................................................................................................................. 106
Machine torch ...................................................................................................................................................................... 106
Hand torch ............................................................................................................................................................................ 106
Optimizing cut quality ................................................................................................................................................................ 107
Tips for table and torch ..................................................................................................................................................... 107

MAXPRO200 Instruction Manual 807700 9

Contents

Plasma setup tips ............................................................................................................................................................... 107

Maximize the life of consumable parts ........................................................................................................................... 107
Additional factors of cut quality ....................................................................................................................................... 108
Cut angle ...................................................................................................................................................................... 108
Dross ............................................................................................................................................................................. 109
Straightness of the cut surface ............................................................................................................................... 109
How to increase cutting speed ............................................................................................................................... 109
Estimated kerf-width compensation ............................................................................................................................... 110
Metric ............................................................................................................................................................................. 110
English ........................................................................................................................................................................... 111
Cut charts ..................................................................................................................................................................................... 112
Standard consumables ..................................................................................................................................................... 113
Extreme bevel consumables ............................................................................................................................................. 129
Recommended torch-pivot lengths ........................................................................................................................ 129
Clearance ..................................................................................................................................................................... 130
Maximum torch angle ................................................................................................................................................. 130
Effective thickness ...................................................................................................................................................... 130
Gouging ................................................................................................................................................................................ 136

4 Maintenance .............................................................................................................................. 139

Introduction .................................................................................................................................................................................. 139
Preventive maintenance ............................................................................................................................................................ 139
Power supply state ..................................................................................................................................................................... 140
Sequence of operation and power supply state ................................................................................................................. 141
Block diagram .............................................................................................................................................................................. 146
Error codes .................................................................................................................................................................................. 147
Diagnostic functions .................................................................................................................................................................. 148
Troubleshooting table ................................................................................................................................................................ 149
Initial checks ................................................................................................................................................................................ 157
Power measurement .................................................................................................................................................................. 158
Power supply coolant system servicing ................................................................................................................................ 159
Draining the coolant system ............................................................................................................................................. 159
Coolant flow test ................................................................................................................................................................. 160
Coolant system filter replacement .................................................................................................................................. 162
Air filter element replacement .................................................................................................................................................. 163
Control board .............................................................................................................................................................................. 164
Control board LED list ....................................................................................................................................................... 164
Control board test points .................................................................................................................................................. 164
Gas leak tests .............................................................................................................................................................................. 167

10 MAXPRO200 Instruction Manual 807700

 Contents

Start circuit ................................................................................................................................................................................... 168

Operation .............................................................................................................................................................................. 168
Start circuit functional schematic .................................................................................................................................... 168
Start circuit troubleshooting ............................................................................................................................................. 169
Pilot arc current levels ............................................................................................................................................................... 171
Transfer current ................................................................................................................................................................... 171
Chopper tests .............................................................................................................................................................................. 172
Automatic chopper and current sensor tests during power-up ............................................................................... 172
Using a meter to measure open circuit voltage (OCV) ...................................................................................... 173
Phase loss detection .......................................................................................................................................................... 174
Torch lead test ..................................................................................................................................................................... 175
Preventive maintenance ............................................................................................................................................................ 176

5 Parts List ..................................................................................................................................... 177

Control panel ............................................................................................................................................................................... 177
Power supply ............................................................................................................................................................................... 178
Ignition enclosure ........................................................................................................................................................................ 184
Height control connection kits ................................................................................................................................................. 185
Sensor THC connection kit – 428023 .......................................................................................................................... 185
Sensor PHC connection kit – 428022 ......................................................................................................................... 185
Wire groups and harnesses ..................................................................................................................................................... 185
USB cables for software updates ........................................................................................................................................... 185
Cable for USB update – 223291 ................................................................................................................................... 185
Cable for USB update – 223273 ................................................................................................................................... 185
Power supply gas hose kit – 228862 ................................................................................................................................. 186
Machine torches ......................................................................................................................................................................... 186
Straight torch ....................................................................................................................................................................... 186
Quick-disconnect torch ..................................................................................................................................................... 187
Leads and cables ........................................................................................................................................................................ 188
Machine torch leads ........................................................................................................................................................... 188
CNC cables ......................................................................................................................................................................... 188
Work leads ........................................................................................................................................................................... 188
Work clamp .......................................................................................................................................................................... 188
Hand torch leads ................................................................................................................................................................. 188
Inline valve kit ............................................................................................................................................................................... 188
Hand torch heat shield – 127389 ........................................................................................................................................ 188
90 degree hand torch ................................................................................................................................................................ 189
65-degree hand torch ............................................................................................................................................................... 190
Consumable parts kits ............................................................................................................................................................... 191
Mechanized torch consumable kit – 428013 .............................................................................................................. 191
Hand torch consumable kit – 428014 .......................................................................................................................... 192

MAXPRO200 Instruction Manual 807700 11

Contents

Supply gas hoses ....................................................................................................................................................................... 193

Oxygen .................................................................................................................................................................................. 193
Nitrogen ................................................................................................................................................................................ 193
Air ........................................................................................................................................................................................... 193
Recommended spare parts ...................................................................................................................................................... 194

6 Wiring Diagrams ....................................................................................................................... 195

Wiring diagram symbols ........................................................................................................................................................... 196

Material Safety Data Sheet (MSDS) — Torch Coolant Safety Data ........................... 209
1 – Identification of the substance/mixture and of the company undertaking .............................................. 209
2 – Hazards identification ......................................................................................................................................... 209
3 – Composition / Information on ingredients ..................................................................................................... 210
4 – First Aid measures .............................................................................................................................................. 210
5 – Fire-Fighting measures ...................................................................................................................................... 210
6 – Accidental release measures ............................................................................................................................ 210
7 – Handling and storage ......................................................................................................................................... 211
8 – Exposure controls / personal protection ........................................................................................................ 211
9 – Physical and chemical properties .................................................................................................................... 211
10 – Stability and reactivity ...................................................................................................................................... 212
11 – Toxicological information ................................................................................................................................. 212
12 – Ecological information ..................................................................................................................................... 212
13 – Disposal considerations .................................................................................................................................. 212
14 – Transport information ....................................................................................................................................... 213
15 – Regulatory information ..................................................................................................................................... 213
16 – Other information .............................................................................................................................................. 214

12 MAXPRO200 Instruction Manual 807700

 Safety

DANGER WARNING CAUTION

RECOGNIZE SAFETY
INFORMATION American National Standards Institute (ANSI) guidelines are used for
safety signal words and symbols. The signal word DANGER or
WARNING is used with a safety symbol. DANGER identifies the most
The symbols shown in this section are used to identify potential serious hazards.
hazards. When you see a safety symbol in this manual or on your
• DANGER and WARNING safety labels are located on your machine
machine, understand the potential for personal injury, and follow the
near specific hazards.
related instructions to avoid the hazard.
• DANGER safety messages precede related instructions in the
manual that will result in serious injury or death if not followed
FOLLOW SAFETY correctly.
INSTRUCTIONS • WARNING safety messages precede related instructions in this
manual that may result in injury or death if not followed correctly.
Carefully read all safety messages in this manual and safety labels • CAUTION safety messages precede related instructions in this
on your machine. manual that may result in minor injury or damage to equipment if not
• Keep the safety labels on your machine in good condition. followed correctly.
Replace missing or damaged labels immediately.
• Learn how to operate the machine and how to use the controls INSPECT EQUIPMENT BEFORE USING
properly. Do not let anyone operate it without instruction.
• Keep your machine in proper working condition. Unauthorized All cutting equipment must be inspected as required to make sure it is in
modifications to the machine may affect safety and machine safe operating condition. When found to be incapable of reliable and
service life. safe operation, the equipment must be repaired by qualified personnel
prior to its next use or withdrawn from service.

RESPONSIBILITY FOR SAFETY

The person or entity responsible for the safety of the workplace must: • Select contractors who provide trained and qualified personnel, and
• Make sure that operators and their supervisors are trained in the safe who have awareness of the risks involved, to do cutting.
use of their equipment, the safe use of the process, and emergency • Tell contractors about flammable materials or hazardous conditions
procedures. that are specific to the site, or hazardous conditions that they may not
• Make sure that all hazards and safety precautions identified herein be aware of.
are communicated to and understood by workers before the start of • Make sure that the quality and quantity of air for ventilation is such
work. that personnel exposures to hazardous contaminants are below the
• Designate approved cutting areas and establish procedures for safe allowable limits.
cutting. • Make sure that ventilation in confined spaces is sufficient to allow
• Be responsible for authorizing cutting operations in areas not adequate oxygen for life support, to prevent accumulation of
specifically designed or approved for such processes. asphixiants or flammable explosive mixtures, to prevent
oxygen-enriched atmospheres, and to keep airborne contaminants in
• Make sure that only approved equipment, such as torches and
breathing atmospheres below allowable limits.
personal protective equipment, are used.

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.

Safety and Compliance 13

Safety

STATIC ELECTRICITY CAN DAMAGE PRINTED CIRCUIT BOARDS

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

GROUNDING SAFETY
Work lead Attach the work lead securely to the workpiece or the Input power
cutting table with good metal-to-metal contact. Do not connect it to • Make sure to connect the power cord ground wire to the ground in
the piece that will fall away when the cut is complete. the disconnect box.
Cutting table Connect the cutting table to an earth ground, in • If installation of the plasma system involves connecting the power
accordance with appropriate national and local electrical regulations. cord to the power supply, make sure to connect the power cord
ground wire properly.
• Place the power cord’s ground wire on the stud first, then place any
other ground wires on top of the power cord ground. Tighten the
retaining nut.
• Tighten all electrical connections to avoid excessive heating.

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

14 Safety and Compliance

 Safety

ELECTRIC SHOCK CAN KILL

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

Safety and Compliance 15

Safety

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire prevention WARNING

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

WARNING
Explosion Hazard
Hydrogen Detonation with Aluminum Cutting

When you use a plasma torch to cut aluminum alloys under water or Also, make sure that the water table, fume extraction (ventilation), and
on a water table, a chemical reaction between the water and the other parts of the cutting system have been designed with aluminum
workpiece, parts, fine particles, or molten aluminum droplets cutting in mind.
generates significantly more hydrogen gas than occurs with other
metals. This hydrogen gas may get trapped under the workpiece. If Do not cut aluminum alloys underwater or on a water table
exposed to oxygen or air, the plasma arc or a spark from any source unless you can prevent the accumulation of hydrogen gas.
can ignite this trapped hydrogen gas, causing an explosion that may Note: With proper mitigation, most aluminum alloys can be plasma
result in death, personal injury, loss of property, or equipment damage.
cut on a water table. An exception is aluminum-lithium alloys. Never
Consult with the table manufacturer and other experts prior to cutting cut aluminum-lithium alloys in the presence of water. Contact
aluminum to implement a risk assessment and mitigation plan that your aluminum supplier for additional safety information regarding
eliminates the risk of detonation by preventing hydrogen hazards associated with aluminum-lithium alloys.
accumulation.

MACHINE MOTION CAN CAUSE INJURY

When an original equipment manufacturer (OEM) makes a cutting system by combining Hypertherm equipment with other equipment, the end-use
customer and the OEM are responsible for providing protection against the hazardous moving parts of this cutting system. However, we advise the
following to prevent operator injury and equipment damage:
• Read and follow the instruction manual provided by the OEM. • Do not service or clean the machinery during operation.
• Maintain a restricted-access area larger than the maximum • If servicing is required, enable the safety interlock or disconnect
movement range of the cutting system’s moving parts. and lock out/tag out power to disable the motors and prevent
• Where there is a risk of collision, do not allow personnel or motion.
equipment near the cutting system’s moving parts. • Allow only qualified personnel to operate, maintain, and service the
• Avoid accidental contact with the CNC touchscreen or joystick. machinery.
Accidental contact can activate commands and result in
unintended motion.

16 Safety and Compliance

 Safety

COMPRESSED GAS EQUIPMENT GAS CYLINDERS CAN

SAFETY EXPLODE IF DAMAGED

• Never lubricate cylinder valves or regulators with oil or grease. Gas cylinders contain gas under high pressure. If damaged, a
• Use only correct gas cylinders, regulators, hoses, and fittings cylinder can explode.
designed for the specific application. • Handle and use compressed gas cylinders in accordance with
• Maintain all compressed gas equipment and associated parts in applicable national and local regulations.
good condition. • Never use a cylinder that is not upright and secured in place.
• Label and color-code all gas hoses to identify the type of gas in • Keep the protective cap in place over the valve except when the
each hose. Consult applicable national and local regulations. 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.

TOXIC FUMES CAN CAUSE INJURY OR DEATH

The plasma arc by itself is the heat source used for cutting. The air quality level in any relevant workplace depends on site-specific
Accordingly, although the plasma arc has not been identified as a variables such as:
source of toxic fumes, the material being cut can be a source of toxic • Table design (wet, dry, underwater).
fumes or gases that deplete oxygen.
• Material composition, surface finish, and composition of coatings.
The fumes produced vary depending on the metal that is cut. Metals • Volume of material removed.
that may release toxic fumes include, but are not limited to, stainless
• Duration of cutting or gouging.
steel, carbon steel, zinc (galvanized), and copper.
• Size, air volume, ventilation, and filtration of the workplace.
In some cases, the metal may be coated with a substance that could
• Personal protective equipment.
release toxic fumes. Toxic coatings include, but are not limited to,
lead (in some paints), cadmium (in some paints and fillers), and • Number of welding and cutting systems in operation.
beryllium. • Other workplace processes that may produce fumes.

The gases produced by plasma cutting vary based on the material to If the workplace must conform to national or local regulations, only
be cut and the method of cutting, but may include ozone, oxides of monitoring or testing done at the site can determine whether the
nitrogen, hexavalent chromium, hydrogen, and other substances if workplace is above or below allowable levels.
such are contained in or released by the material being cut.
To reduce the risk of exposure to fumes:
Caution should be taken to minimize exposure to fumes produced by • Remove all coatings and solvents from the metal before cutting.
any industrial process. Depending on the chemical composition and
concentration of the fumes (as well as other factors, such as • Use local exhaust ventilation to remove fumes from the air.
ventilation), there may be a risk of physical illness, such as birth • Do not inhale fumes. Wear an air-supplied respirator when cutting
defects or cancer. any metal coated with, containing, or suspected to contain toxic
elements.
It is the responsibility of the equipment and site owner to test the air
• Make sure that those using welding or cutting equipment, as well as
quality in the cutting area and to make sure that the air quality in the
air-supplied respiration devices, are qualified and trained in the
workplace meets all local and national standards and regulations.
proper use of such equipment.
• 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 make sure air
quality is safe.

Safety and Compliance 17

Safety

A PLASMA ARC CAN CAUSE INJURY AND BURNS

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

ARC RAYS CAN BURN EYES AND SKIN

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

Minimum protective Suggested shade

OSHA 29CFR Europe
Arc current shade number number for comfort
1910.133(a)(5) EN168:2002
(ANSI Z49.1:2012) (ANSI Z49.1:2012)
Less than 40 A 5 5 8 9
41 A to 60 A 6 6 8 9
61 A to 80 A 8 8 8 9
81 A to 125 A 8 9 8 9
126 A to 150 A 8 9 8 10
151 A to 175 A 8 9 8 11
176 A to 250 A 8 9 8 12
251 A to 300 A 8 9 8 13
301 A to 400 A 9 12 9 13
401 A to 800 A 10 14 10 N/A

MEDICAL IMPLANT, PACEMAKER, AND HEARING AID OPERATION

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

18 Safety and Compliance

 Safety

NOISE CAN DAMAGE HEARING

Cutting with a plasma arc can exceed acceptable noise levels as Use ear protectors if the noise is disruptive or if there is a risk of
defined by local regulations in many applications. Prolonged exposure hearing damage after all other engineering and administrative
to excessive noise can damage hearing. Always wear proper ear controls have been implemented. If hearing protection is required,
protection when cutting or gouging, unless sound pressure level wear only approved personal protective equipment such as ear muffs
measurements taken at the site have verified personal hearing or ear plugs with a noise reduction rating appropriate for the
protection is not necessary per relevant international, regional, and situation. Warn others near the cutting area of possible noise
local regulations. 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 and limit
operator exposure time, and screen off noisy areas and/or take
measures to reduce reverberation in cutting areas by putting up noise
absorbers.

DRY DUST COLLECTION INFORMATION

In some workplaces, dry dust can represent a potential explosion Note 1 – Unless a site-specific evaluation has been completed that
hazard. determines that none of the dust generated is combustible, then
NFPA standard 68 requires the use of explosion vents. Design the
The U.S. National Fire Protection Association’s NFPA standard 68, explosion vent size and type to conform to the worst-case Kst value
“Explosion Protection by Deflagration Venting,” provides requirements as described in Annex F of NFPA standard 68. NFPA standard 68
for the design, location, installation, maintenance, and use of devices does not specifically identify plasma cutting or other thermal cutting
and systems to vent combustion gases and pressures after any processes as requiring deflagration venting systems, but it does
deflagration event. Consult with the manufacturer or installer of any apply these new requirements to all dry dust collection systems.
dry dust collection system for applicable requirements before you
install a new dry dust collection system or make significant changes Note 2 – Users should consult and comply with all applicable
in the process or materials used with an existing dry dust collection national, state, and local regulations. Publications do not intend to
system. urge action that is not in compliance with all applicable regulations
and standards, and this manual may never be construed as doing so.
Consult your local “Authority Having Jurisdiction” (AHJ) to determine
whether any edition of NFPA standard 68 has been “adopted by
reference” in your local building codes.

Refer to NFPA standard 68 for definitions and explanations of

regulatory terms such as deflagration, AHJ, adopted by reference, the
Kst value, deflagration index, and other terms.

Safety and Compliance 19

Safety

LASER RADIATION
Exposure to the laser beam from a laser pointer can result in serious eye injury. Avoid direct eye exposure.

On products that use a laser pointer for alignment, 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, pulse duration are also provided.

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

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American 6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in
Welding Society, 8669 NW 36 Street, # 130, Miami, Florida Cylinders, Compressed Gas Association, 14501 George
33166-6672 Carter Way, Suite 103, Chantilly, VA 20151
2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and 7. CSA Standard W117.2, Code for Safety in Welding and
Welding Processes, American National Standards Institute, Cutting, Canadian Standards Association Standard Sales,
25 West 43rd Street, 4th floor, New York, NY 10036 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, National
Educational Eye and Face Protection, American National Fire Protection Association, 1 Batterymarch Park, Quincy, MA
Standards Institute, 25 West 43rd Street, 4th floor, New York, 02169-7471
NY 10036 9. NFPA Standard 70, National Electrical Code, National Fire
4. AWS F4.1, Recommended Safe Practices for the Preparation Protection Association, 1 Batterymarch Park, Quincy, MA
for Welding and Cutting of Containers and Piping That Have 02169-7471
Held Hazardous Substances, American Welding Society, 8669 10. U.S. Department of Labor Occupational Safety & Health
NW 36 Street, # 130, Miami, Florida 33166-6672 Administration, 200 Constitution Avenue NW, Room Number
5. AWS F5.2, Recommended Safe Practices for Plasma Arc N3626, Washington, D.C. 20210
Cutting, American Welding Society, 8669 NW 36 Street, 11. AWS Safety and Health Fact Sheets, American Welding
# 130, Miami, Florida 33166-6672 Society, 8669 NW 36 Street, # 130, Miami, Florida
33166-6672, www.aws.org/technical/facts/

20 Safety and Compliance

 Electromagnetic Compatibility (EMC)

Introduction Methods of reducing emissions

Hypertherm’s CE-marked equipment is built in compliance with standard Mains supply
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to
compatibility. the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
The limits required by EN60974-10 may not be adequate to completely supply.
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to Consideration should be given to shielding the supply cable of
use other measures to further reduce interference. permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
This cutting equipment is designed for use only in an industrial length. The shielding should be connected to the cutting mains supply so
environment. that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Installation and use
Maintenance of cutting equipment
The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions. The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
If electromagnetic disturbances are detected then it shall be the
covers should be closed and properly fastened when the cutting
responsibility of the user to resolve the situation with the technical
equipment is in operation. The cutting equipment should not be modified
assistance of the manufacturer. In some cases this remedial action may in any way, except as set forth in and in accordance with the
be as simple as earthing the cutting circuit, see Earthing of the
manufacturer’s written instructions. For example, the spark gaps of arc
workpiece. In other cases, it could involve constructing an
striking and stabilizing devices should be adjusted and maintained
electromagnetic screen enclosing the power source and the work according to the manufacturer’s recommendations.
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome. Cutting cables
The cutting cables should be kept as short as possible and should be
Assessment of area positioned close together, running at or close to the floor level.

Before installing the equipment, the user shall make an assessment of Equipotential bonding
potential electromagnetic problems in the surrounding area. The
following shall be taken into account: Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment. However, metallic components bonded to the workpiece will increase
b. Radio and television transmitters and receivers. the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
c. Computer and other control equipment. same time.
d. Safety critical equipment, for example guarding of industrial
equipment. The operator should be insulated from all such bonded metallic
components.
e. Health of the people around, for example the use of
pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall
ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be carried
out.

The size of the surrounding area to be considered will depend on the

structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.

Safety and compliance 21

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s
hull or building steel work, a connection bonding the workpiece to earth
may reduce 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 equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will increase
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment.
Further guidance is provided in IEC 60974-9, Arc Welding Equipment,
Part 9: Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire plasma cutting installation may be considered for special
applications.

22 Safety and compliance

 Warranty

Attention The warranty set forth above is exclusive and is in lieu of all other
warranties, express, implied, statutory, or otherwise with respect to the
Genuine Hypertherm parts are the factory-recommended replacement Products or as to the results which may be obtained therefrom, and all
parts for your Hypertherm system. Any damage or injury caused by the implied warranties or conditions of quality or of merchantability or fitness
use of other than genuine Hypertherm parts may not be covered by the for a particular purpose or against infringement. The foregoing shall
Hypertherm warranty, and will constitute misuse of the Hypertherm constitute the sole and exclusive remedy for any breach by Hypertherm
Product. of its warranty.

You are solely responsible for the safe use of the Product. Hypertherm Distributors/OEMs may offer different or additional warranties, but
does not and cannot make any guarantee or warranty regarding the safe Distributors/OEMs are not authorized to give any additional warranty
use of the product in your environment. protection to you or make any representation to you purporting to be
binding upon Hypertherm.

General
Patent indemnity
Hypertherm, Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth Except only in cases of products not manufactured by Hypertherm or
herein and as follows: if Hypertherm is notified of a defect (i) with respect manufactured by a person other than Hypertherm not in strict conformity
to the plasma power supply within a period of two (2) years from the date with Hypertherm’s specifications and in cases of designs, processes,
of its delivery to you, with the exception of Powermax brand power formulae, or combinations not developed or purported to be developed
supplies, which shall be within a period of three (3) years from the date of by Hypertherm, Hypertherm will have the right to defend or settle, at its
delivery to you, and (ii) with respect to the torch and leads within a period own expense, any suit or proceeding brought against you alleging that
of one (1) year from its date of delivery to you, with the exception of the the use of the Hypertherm product, alone and not in combination with
HPRXD short torch with integrated lead, which shall be within a period of any other product not supplied by Hypertherm, infringes any patent of
six (6) months from the date of delivery to you, and with respect to torch any third party. You shall notify Hypertherm promptly upon learning of any
lifter assemblies within a period of one (1) year from its date of delivery to action or threatened action in connection with any such alleged
you, and with respect to Automation products one (1) year from its date infringement (and in any event no longer than fourteen (14) days after
of delivery to you, with the exception of the EDGE Connect CNC, learning of any action or threat of action), and Hypertherm’s obligation to
EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, defend shall be conditioned upon Hypertherm’s sole control of, and the
EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which indemnified party’s cooperation and assistance in, the defense of the
shall be within a period of two (2) years from the date of delivery to you, claim.
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
Limitation of liability
a period of one (1) year from its date of delivery to you. In no event shall Hypertherm be liable to any person or entity for
All third-party engines, engine accessories, alternators, and alternator any incidental, consequential direct, indirect, punitive or
accessories are covered by the respective manufacturers’ warranties and exemplary damages (including but not limited to lost profits)
not covered by this warranty. regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranty, failure of
This warranty shall not apply to any Powermax brand power supplies that essential purpose, or otherwise, and even if advised of the
have been used with phase converters. In addition, Hypertherm does not possibility of such damages. Hypertherm shall not be liable for
warranty systems that have been damaged as a result of poor power any losses to Distributor based on down time, lost production or
quality, whether from phase converters or incoming line power. This lost profits. It is the intention of the Distributor and Hypertherm
warranty shall not apply to any product which has been incorrectly that this provision be construed by a court as being the
installed, modified, or otherwise damaged. broadest limitation of liability consistent with applicable law.

Hypertherm provides repair, replacement or adjustment of the Product as

the sole and exclusive remedy, if and only if the warranty set forth herein National and local codes
properly is invoked and applies. Hypertherm, at its sole option, shall
repair, replace, or adjust, free of charge, any defective Products covered National and local codes governing plumbing and electrical installation
by this warranty which shall be returned with Hypertherm’s prior shall take precedence over any instructions contained in this manual.
authorization (which shall not be unreasonably withheld), properly In no event shall Hypertherm be liable for injury to persons or property
packed, to Hypertherm’s place of business in Hanover, New Hampshire, damage by reason of any code violation or poor work practices.
or to an authorized Hypertherm repair facility, all costs, insurance and
freight pre paid by the customer. Hypertherm shall not be liable for any
repairs, replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph and with
Hypertherm’s prior written consent.

Safety and compliance 23

Warranty

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.

Insurance
At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.

Transfer of rights
You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

Waterjet product warranty coverage

Product Parts coverage
HyPrecision pumps 27 months from the ship date, or 24 months
from the date of proven installation, or
4,000 hours, whichever occurs first

PowerDredge 15 months from the ship date or 12 months

abrasive removal from the date of proven installation,
system whichever occurs first

EcoSift abrasive 15 months from the ship date or 12 months

recycling system from the date of proven installation,
whichever occurs first

Abrasive metering 15 months from the ship date or 12 months

devices from the date of proven installation,
whichever occurs first

On/off valve air 15 months from the ship date or 12 months

actuators from the date of proven installation,
whichever occurs first

Diamond orifices 600 hours of use with the use of a thimble

filter and compliance with Hypertherm’s
water quality requirements

Consumable parts are not covered by this warranty. Consumable parts

include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.

24 Safety and compliance

 Product Stewardship

Introduction Differences in national standards

Hypertherm maintains a global Regulatory Management System to Nations may apply different performance, safety or other standards.
ensure that products comply with regulatory and environmental National differences in standards include, but are not limited to:
requirements. • Voltages
• Plug and cord ratings
National and local safety regulations • Language requirements

National and Local safety regulations shall take precedence over any • Electromagnetic compatibility requirements
instructions provided with the product. The product shall be imported, These differences in national or other standards may make it impossible
installed, operated and disposed of in accordance with national and local
or impractical for all certification test marks to be placed on the same
regulations applicable to the installed site.
version of a product. For example, the CSA versions of Hypertherm’s
products do not comply with European EMC requirements, and therefore
Certification test marks do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations

Certified products are identified by one or more certification test marks
must use CE versions of Hypertherm products with the CE marking on
from accredited testing laboratories. The certification test marks are
located on or near the data plate. the data plate. These include, but are not limited to:
• Australia
Each certification test mark means that the product and its safety-critical
• New Zealand
components conform to the relevant national safety standards as
reviewed and determined by that testing laboratory. Hypertherm places • Countries in the European Union
a certification test mark on its products only after that product is • Russia
manufactured with safety-critical components that have been authorized
by the accredited testing laboratory. It is important that the product and its certification test mark be suitable
for the end-use installation site. When Hypertherm products are shipped
Once the product has left the Hypertherm factory, the certification test to one country for export to another country; the product must be
marks are invalidated if any of the following occurs: configured and certified properly for the end-use site.
• The product is modified in a manner that creates a hazard or
non-conformance with the applicable standards.
Safe installation and use of shape cutting
• Safety-critical components are replaced with unauthorized spare
parts.
equipment
• Any unauthorized assembly, or accessory that uses or generates a IEC 60974-9, titled Arc Welding Equipment – Installation and use,
hazardous voltage is added. provides guidance in the safe installation and use of shape cutting
• There is any tampering with a safety circuit or other feature that is equipment and the safe performance of cutting operations. The
designed into the product as part of the certification, or otherwise. requirements of national and local regulations shall be taken into
consideration during installation, including, but not limited to, grounding
CE marking constitutes a manufacturer’s declaration of conformity to or protective earth connections, fuses, supply disconnecting device, and
applicable European directives and standards. Only those versions of type of supply circuit. Read these instructions before installing the
Hypertherm products with a CE Marking located on or near the data equipment. The first and most important step is the safety assessment of
plate have been tested for compliance with the European Low Voltage the installation.
Directive and the European EMC Directive. EMC filters needed to
comply with the European EMC Directive are incorporated within The safety assessment must be performed by an expert, and determines
versions of the power supply with a CE Marking. what steps are necessary to create a safe environment, and what
precautions should be adopted during the actual installation and
Certificates of compliance for Hypertherm products are available from operation.
the Documents Library on the Hypertherm web site at
www.hypertherm.com/docs.
Procedures for periodic inspection and
testing
Where required by local national regulations, IEC 60974-4 specifies test
procedures for periodic inspection and after repair or maintenance, to
ensure electrical safety for plasma cutting power sources built in
conformity with IEC 60974-1. Hypertherm performs the continuity of the
protective circuit and insulation resistance tests in the factory as
non-operating tests. The tests are performed with the power and ground
connections removed.

Safety and Compliance 25

Product Stewardship

Hypertherm also removes some protective devices that would cause Higher-level systems
false test results. Where required by local national regulations, a label
shall be attached to the equipment to indicate that it has passed the When a system integrator adds additional equipment; such as cutting
tests prescribed by IEC 60974-4. The repair report shall indicate the tables, motor drives, motion controllers or robots; to a Hypertherm
results of all tests unless an indication is made that a particular test has plasma cutting system, the combined system may be considered a
not been performed. 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
Qualification of test personnel and standards than those relevant to the plasma cutting system as
manufactured by Hypertherm.
Electrical safety tests for shape cutting equipment can be hazardous and
shall be carried out by an expert in the field of electrical repair, preferably It is the responsibility of the end-use customer and the OEM to perform a
someone also familiar with welding, cutting, and allied processes. The risk assessment for the higher-level system, and to provide protection
safety risks to personnel and equipment, when unqualified personnel are against hazardous moving parts. Unless the higher-level system is
performing these tests, may be much greater than the benefit of periodic certified when the OEM incorporates Hypertherm products into it, the
inspection and testing. installation also may be subject to approval by local authorities. Seek
advice from legal counsel and local regulatory experts if you are uncertain
Hypertherm recommends that only visual inspection be performed unless
the electrical safety tests are specifically required by local national about compliance.
regulations in the country where the equipment is installed. External interconnecting cables between component parts of the higher
level system must be suitable for contaminants and movement as
Residual current devices (RCDs) required by the final end use installation site. When the external
interconnecting cables are subject to oil, dust, water, or other
In Australia and some other countries, local codes may require the use of contaminants, hard usage ratings may be required.
a Residual Current Devices (RCD) when portable electrical equipment is
When external interconnecting cables are subject to continuous
used in the workplace or at construction sites to protect operators from
movement, constant flexing ratings may be required. It is the
electrical faults in the equipment. RCDs are designed to safely
responsibility of the end-use customer or the OEM to ensure the cables
disconnect the mains electrical supply when an imbalance is detected
are suitable for the application. Since there are differences in the ratings
between the supply and return current (there is a leakage current to
and costs that can be required by local regulations for higher level
earth). RCDs are available with both fixed and adjustable trip currents
systems, it is necessary to verify that any external interconnecting cables
between 6 to 40 milliamperes and a range of trip times up to
are suitable for the end-use installation site.
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 selected or adjusted high enough to avoid nuisance
tripping during normal operation of the plasma cutting equipment and
low enough in the extremely unlikely event of an electrical fault in the
equipment to disconnect the supply before the leakage current under a
fault condition can pose a life threatening electrical hazard to operators.

To verify that the RCDs continue to function properly over time, both the
trip current and the trip time should be tested periodically. Portable
electrical equipment and RCDs used in commercial and industrial areas
in Australia and New Zealand are tested to the Australian standard
AS/NZS 3760. When you test the insulation of plasma cutting
equipment to AS/NZS 3760, measure the insulation resistance
according to Appendix B of the standard, at 250 VDC with the power
switch in the ON position to verify proper testing and to avoid the false
failure of the leakage current test. False failures are possible because the
metal oxide varistors (MOVs) and electromagnetic compatibility (EMC)
filters, used to reduce emissions and protect the equipment from power
surges, may conduct up to 10 milliamperes leakage current to earth
under normal conditions.

If you have any questions regarding the application or interpretation of

any IEC standards described here, you are required to consult with an
appropriate legal or other advisor familiar with the International
Electrotechnical standards, and shall not rely on Hypertherm in any
respect regarding the interpretation or application of such standards.

26 Safety and Compliance

 Environmental Stewardship

Introduction • In the United States, check all federal, state, and local laws.
• In the European Union, check the EU directives, national, and local
The Hypertherm Environmental Specification requires RoHS, WEEE laws.
and REACH substance information to be provided by Hypertherm’s • In other countries, check national and local laws.
suppliers.
• Consult with legal or other compliance experts when appropriate.
Product environmental compliance does not address the indoor air
A variety of options for sustainable disposal of Hypertherm products are
quality or environmental release of fumes by the end user. Any materials
available on our website at www.hypertherm.com/recycle.
that are cut by the end user are not provided by Hypertherm with the
product. The end user is responsible for the materials being cut as well
as for safety and air quality in the workplace. The end user must be aware The WEEE Directive
of the potential health risks of the fumes released from the materials
being cut and comply with all local regulations. The European Parliament and the Council of the European Union
authorized Directive 2012/19/EU or WEEE (Waste Electrical and
Electronic Equipment) Recast.
National and local environmental
regulations As required by the legislation, any Hypertherm product covered by the
directive and sold in the EU after August 13, 2005 is marked with the
National and local environmental regulations shall take precedence over WEEE symbol. This directive encourages and sets specific criteria for
any instructions contained in this manual. the collection, handling, and recycling of EEE waste. Consumer and
business-to-business wastes are treated differently (all Hypertherm
The product shall be imported, installed, operated and disposed of in products are considered business-to-business). Disposal options for
accordance with all national and local environmental regulations Hypertherm systems can be found at www.hypertherm.com/recycle.
applicable to the installed site.
The URL is printed on the symbol-only warning label for each CE version
The European Environmental regulations are discussed later in Hypertherm plasma system since 2006. The CSA versions of products
The WEEE Directive. manufactured by Hypertherm are either out of scope or exempt from
WEEE.
The RoHS directive
The REACH regulation
Hypertherm is committed to complying with all applicable laws and
regulations, including the European Union Restriction of Hazardous The REACH regulation, in force since June 1, 2007, has an impact on
Substances (RoHS) Directive that restricts the use of hazardous chemicals available to the European market. The REACH regulation
materials in electronics products. Hypertherm exceeds RoHS Directive requirements for component manufacturers states that the component
compliance obligations on a global basis. shall not contain more than 0.1% by weight of the Substances of Very
High Concern (SVHC).
Hypertherm continues to work toward the reduction of RoHS materials in
our products, which are subject to the RoHS Directive, except where it is Component manufacturers and other downstream users, such as
widely recognized that there is no feasible alternative. Hypertherm, are obligated to obtain assurances from its suppliers that
all chemicals used in or on Hypertherm products will have a European
Declarations of RoHS Conformity have been prepared for the current CE
Chemical Agency (ECHA) registration number. To provide chemical
versions of Hypertherm products that fall within the scope of the RoHS information as required by the REACH regulation, Hypertherm requires
Directive. These RoHS-compliant products also have a “RoHS mark”
suppliers to provide REACH declarations and identify any known use of
near the “CE Marking” on the data plate. Parts and other products
REACH SVHC. Any use of SVHC in amounts exceeding 0.1% w/w of
manufactured by Hypertherm that are either out of scope or exempt from the parts has been eliminated.
RoHS are continuously being converted to RoHS compliance in
anticipation of future requirements, and there is no “RoHS mark” on their The lubricants, sealants, coolants, adhesives, solvents, coatings and
data plates. other preparations or mixtures used by Hypertherm in, on, for, or with its
shape cutting equipment are used in very small quantities (except the
coolant) and are commercially available with multiple sources that can
Proper disposal of Hypertherm products and will be replaced in the event of a supplier problem associated with
REACH Registration or REACH Authorization (SVHCs).
Hypertherm plasma cutting systems, like all electronic products, may
contain materials or components, such as printed circuit boards, that
cannot be discarded with ordinary waste. It is your responsibility to
dispose of any Hypertherm product or component part in an
environmentally acceptable manner according to national and local
codes.

Safety and Compliance 27

Environmental Stewardship

Proper handling and safe use of chemicals

Chemical Regulations in the USA, Europe, and other locations require
that Material Safety Data Sheets (MSDS) or Safety Data Sheets (SDS)
be made available for all chemicals. The list of chemicals is provided by
Hypertherm. The MSDS are for chemicals provided with the product and
other chemicals used in or on the product. MSDS can be downloaded
from the Documents Library on the Hypertherm web site at
www.hypertherm.com/docs. In the Documents Library, select “Material
Safety Data Sheets” in the Category drop-down menu.

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.

Hypertherm does not manufacture or provide the materials that are cut
and has no knowledge whether the fumes released from materials that
are cut will pose a physical hazard or health risk. Please consult with your
supplier or other technical advisor if you need guidance concerning the
properties of the material you will cut using a Hypertherm product.

Fumes emission and air quality

Note: The following information on air quality is intended for general
information only and should not be used as a substitute for reviewing and
implementing applicable government regulations or legal standards in
the country where the cutting equipment will be installed and operated.

In the USA, the National Institute for Occupational Safety and Health
(NIOSH) Manual of Analytical Methods (NMAM) is a collection of
methods for sampling and analyzing contaminants in workplace air.
Methods published by others, such as OSHA, MSHA, EPA, ASTM, ISO
or commercial suppliers of sampling and analytical equipment, may have
advantages over NIOSH methods.

For example, ASTM Practice D 4185 is a standard practice for the

collection, dissolution, and determination of trace metals in workplace
atmospheres. The sensitivity, detection limit, and optimum working
concentrations for 23 metals are listed in ASTM D 4185. An industrial
hygienist should be used to determine the optimum sampling protocol,
considering analytical accuracy, cost, and optimum sample number.
Hypertherm uses a third party industrial hygienist to perform and interpret
air quality testing results taken by air sampling equipment positioned at
operator stations in Hypertherm buildings where plasma cutting tables
are installed and operated.

Where applicable, Hypertherm also uses a third party industrial hygienist

to obtain air and water permits.

If you are not fully aware and up to date on all applicable government
regulations and legal standards for the installation site, you should
consult a local expert prior to purchasing, installing, and operating the
equipment.

California’s Proposition 65 regulation

California’s Proposition 65 regulation requires all businesses and
industries that sell products in California to include warning labels if
exposure to one or more of the chemicals on the Proposition 65 chemical
list is possible. The regulation requires clear and reasonable warnings on
products and facilities that contain these chemicals that are “known to
cause cancer, birth defects, or other reproductive harm.” As always, we
encourage our customers to use our equipment correctly, including the
use of ventilation and personal protective equipment (PPE) during
cutting, and to make and keep a safe working environment. For more
information go to www.p65warnings.ca.gov.

28 Safety and Compliance

 Section 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.

MAXPRO200 Instruction Manual 807700 29

Specifications

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.

30 MAXPRO200 Instruction Manual 807700

 Specifications

MAXPRO200 Instruction Manual 807700 31

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

32 MAXPRO200 Instruction Manual 807700

 Specifications

Power supply
Maximum Open Circuit Voltage (OCV) (U0) 360 VDC
Maximum output current (I2) 200 A
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 and +40° C
(+14° F and 104° F)
Idle state power consumption (CE systems) 55.45 W
Power source efficiency at rated maximum output power 90.05%
(CE systems)
Power factor 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 50-60 108/104 CSA 37.4
078611 220 3 50-60 98 CSA 37.4
078612 240 3 60 90 CSA 37.4
078613 380 3 50-60 57 CCC 37.4
078614 400 3 50-60 54 CE/EAC/AAA/ 37.4
RCM/UKr
078615 415 3 50 52 CE/EAC/AAA/ 37.4
RCM/UKr
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

MAXPRO200 Instruction Manual 807700 33

Specifications

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)

34 MAXPRO200 Instruction Manual 807700

 Specifications

Mechanized torches
Straight torch – 428024 or 228937
• The torch mounting sleeve for the straight torch is available with an outside diameter of 50.80 mm
(2.00 inches) or 44.45 mm (1.75 inches).
• The minimum bend radius for the torch lead is 152.40 mm (6.00 inches).

2 3 4

6 5

7
8

9 10 11

13 12

14

Standard and extreme bevel

consumables shown for
1.02 kg comparison
(2.25 lb)

Standard MAXPRO200 consumables Extreme bevel MAXPRO200 consumables

1 397.15 mm (15.64 in.) 8 424.15 mm (16.71 in.)

2 279.40 mm (11.00 in.) 9 279.40 mm (11.00 in.)

3 117.75 mm (4.64 in.) 10 144.88 mm (144.88 in.)

4 12.70 mm (0.50 in.) 11 7.62 mm (.30 in.)

5 44.20 mm (1.74 in. 12 44.20 mm (1.74 in.)

6 50.80 mm (2.00 in.) or 44.45 mm (1.75 in.) 13 50.80 mm (2.00 in.) or 44.45 mm (1.75 in.)

7 46 degrees 14 23.5 degrees

MAXPRO200 Instruction Manual 807700 35

Specifications

Quick-disconnect torch – 428027 or 428028

• The torch mounting sleeve for the quick-disconnect torch is available with an outside diameter of
50.80 mm (2.00 inches) or 44.45 mm (1.75 inches).
• The minimum bend radius for the torch lead is 152.40 mm (6.00 inches).

2 3 4 5

9 6
8
7

10

11 12 13 14

18 16 15
17

1.45 kg Standard and extreme bevel

(3.20 lb) consumables shown for
comparison

Standard MAXPRO200 consumables Extreme bevel MAXPRO200 consumables

1 435.33 mm (17.14 in.) 10 462.28 mm (18.20 in.)

2 279.40 mm (11.00 in.) 11 279.40 mm (11.00 in.)

3 76.98 mm (3.03 in.) 12 76.98 mm (3.03 in.)

4 78.95 mm (3.11 in.) 13 64.52 mm (2.54 in.)

5 12.70 mm (.50 in.) 14 7.62 mm (.30 in.)

6 44.20 mm (1.74 in.) 15 44.20 mm (1.74 in.)

7 46 degrees 16 23.5 degrees

8 57.15 mm (2.25 in.) 17 57.15 mm (2.25 in.)

9 50.80 mm (2.00 in.) or 44.45 mm (1.75 in.) 18 50.80 mm (2.00 in.) or 44.45 mm (1.75 in.)

36 MAXPRO200 Instruction Manual 807700

 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 37

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)

38 MAXPRO200 Instruction Manual 807700

 Specifications

Critical raw materials

Critical raw material Components that contain more than 1 gram
Borate All printed circuit boards, torch, torch mounting sleeve
Magnesium Heatsinks, cold plates
Natural graphite Pump motor, resistors
Phosphorus Sheet metal panels
Rare earth elements (heavy and light) Torch breakaway, pump motor
Silicon metal Heatsinks, cold plates, transformers, inductors, IGBT modules
Tantalum Capacitors
Tungsten Power resistors

MAXPRO200 Instruction Manual 807700 39

Specifications

Symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of 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 60974-1.
CSA mark
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 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 products with a CE marking located on or near
the data plate comply with European Directives. Applicable directives may include the European
Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio
Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive.
See the European CE Declaration of Conformity for details.
Eurasian Customs Union (CU) mark
CE versions of products that include an EAC mark of conformity meet the product safety and
EMC requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and
EMC requirements for export to the Russian Federation.
RCM mark
CE versions of products with a RCM mark comply with the EMC and safety regulations required
for sale in Australia and New Zealand.
CCC mark
s
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 products that include a UkrSEPRO mark of conformity meet the product safety
and EMC requirements for export to the Ukraine.
Serbian AAA mark
CE versions of products that include a AAA Serbian mark meet the product safety and
EMC requirements for export to Serbia.
RoHS mark
The RoHS mark indicates that the product meets the requirements of the European Restriction of
Hazardous Substances (RoHS) Directive.

40 MAXPRO200 Instruction Manual 807700

 Specifications

IEC symbols
The following symbols can appear on the data plate, control labels, and switches.

Direct current (DC) AC input power connection

The terminal for the external

Alternating current (AC)
protective (earth) conductor

I Power is ON

Plasma torch cutting

O Power is OFF

1~ f 1
f2 An inverter-based power
source, either 1-phase or 3-
phase
Gouging

Volt/amperage curve,
“drooping” characteristic

MAXPRO200 Instruction Manual 807700 41

Specifications

42 MAXPRO200 Instruction Manual 807700

 Section 2
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.

MAXPRO200 Instruction Manual 807700 43

Installation

Noise levels
This plasma system can make more than the permitted acoustical noise levels as defined by national and local codes.
Always put on correct ear protection when cutting or gouging. Any acoustical noise measurements taken are related to
the specific environment in which the system is used. Refer to Noise can damage hearing in the Safety and Compliance
Manual (80669C).

In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com/docs. In the search
box, enter data sheet.

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 on page 46 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

44 MAXPRO200 Instruction Manual 807700

 Installation

System components
1 Power supply
2 Torch
1 Cable and lead
3 Torch lead
4 Work lead
5 CNC interface cable
Supply gas hoses
6 Air
7 N2
8 O2
Customer supplied power cable
9 Main power cable

7 2

MAXPRO200 Instruction Manual 807700 45

Installation

Recommended grounding and shielding

Introduction
This section describes practices for grounding and shielding a plasma cutting system to minimize its susceptibility to
electromagnetic interference (EMI) (also known as noise). It also describes the service ground, protective earth (PE)
ground, and DC power 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 EMI problems. Hypertherm recommends that you consult your local and national electrical codes
to make sure that the grounding and shielding practices that you use satisfy the requirements for your location.

Types of grounding
Service ground (also known as safety 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.

Protective earth (PE) ground is the grounding system inside the electrical equipment. The PE ground, which connects
to the service ground, provides electrical continuity between the equipment and the AC service.

DC power ground (also known as cutting current ground or work) 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 cable. It also requires that the slats, on which the
workpiece rests, make firm contact with the table and the workpiece.

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

46 MAXPRO200 Instruction Manual 807700

 Installation

Grounding practices
1. Unless noted, for HPR or MAXPRO200 cutting systems, use cables with a minimum gauge of 13.3 mm2
(6 AWG) (047040) for the EMI ground cables shown in the Example grounding diagram with an HPR or
MAXPRO200 cutting system on page 50.

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 or combined ignition/gas connect console must each run separately to the table
ground bus.

3. Inadequate grounding not only exposes operators to dangerous voltages, but inadequate grounding also
increases the risk of equipment failure and unnecessary downtime. Ideally a ground should be zero ohms
resistance, but field experience indicates under 1 ohm resistance is satisfactory for most applications.
Hypertherm recommends that you consult your local and national electrical codes to make sure that the
grounding and shielding practices that you use satisfy the requirements for your location.

4. A ground rod (a PE ground) that meets all applicable local and national electric codes must be installed
within 6 m (20 ft) of the cutting table. For HPR or MAXPRO200 cutting systems, the PE ground must be
connected to the cutting table ground bus bar using a minimum 13.3 mm2 (6 AWG) green and yellow
grounding cable (047121).

5. 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.

6. 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.

7. AC power, PE, and service grounds must be connected to all equipment according to local and national
codes.

8. For a system with a remote high frequency (RHF) console or combined ignition/gas connect console, 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.

9. For a system with a RHF console or combined ignition/gas connect console, Hypertherm recommends
that you mount this console as close as possible to the torch. This console also must have a separate
ground cable that connects directly to the cutting table ground bus bar.

10. 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/gas connect
console, whether it is bolted to the plasma system or to the cutting table.

MAXPRO200 Instruction Manual 807700 47

Installation

11. For HPR or MAXPRO200 cutting systems, the metal braided shield on the torch lead must be connected
firmly to the ignition/gas connect console and to the torch. It is recommended to 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.

12. 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.

13. 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.

14. 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.

15. 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.

48 MAXPRO200 Instruction Manual 807700

 Installation

The following picture shows an example of a cutting table ground bus with an HPR or MAXPRO200 cutting system. 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 RHF console (if applicable, not on all
systems)
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 connect to the bus. A single heavy cable then
connects 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

MAXPRO200 Instruction Manual 807700 49

Installation

Example grounding diagram with an HPR or MAXPRO200 cutting system

6 7 8 9 10

5
12

11

Chassis and RFI ground

3 13
AC earth ground (PE)

1 Cutting table 8, 9 System-specific component such as metering

2 Gantry console, gas console, or selection console

3 Plasma system 10 CNC chassis

4 Table ground bus bar 11 Torch height control module

(ArcGlide, Command THC)
5 Gantry ground bus bar
12 System-specific component such as a cooler or
6 Torch height control lifter (ArcGlide, Sensor THC, chiller
Sensor PHC, or other)
13 DC power ground
7 RHF console (not on all systems). Connect to
table ground bus bar.

Note: This example is based on practices in North America. Other regions can have different local or national
electrical codes. Hypertherm recommends that you consult your local and national electrical codes to make sure
that the grounding and shielding practices that you use satisfy the requirements for your location.

50 MAXPRO200 Instruction Manual 807700

 Installation

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.

MAXPRO200 Instruction Manual 807700 51

Installation

Torch lead connections

Machine torch leads
Part number Length
229477 7.5 m (25 ft)
229478 15 m (50 ft)
229479 23 m (75 feet)
229480 30 m (100 feet)

Hand torch leads

Part number Length
229498 7.5 m (25 ft)
229499 15 m (50 ft)
229500 23 m (75 feet)
229501 30 m (100 feet)

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.

52 MAXPRO200 Instruction Manual 807700

 Installation

2. Connect the CPC connector to the CPC receptacle

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).

MAXPRO200 Instruction Manual 807700 53

Installation

4. Connect the plasma gas hose (black).

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).

54 MAXPRO200 Instruction Manual 807700

 Installation

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)

MAXPRO200 Instruction Manual 807700 55

Installation

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

56 MAXPRO200 Instruction Manual 807700

 Installation

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.

MAXPRO200 Instruction Manual 807700 57

Installation

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.

58 MAXPRO200 Instruction Manual 807700

 Installation

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.

MAXPRO200 Instruction Manual 807700 59

Installation

CNC cable routing and connection to control board

from the
CNC

To J6 on the control board

60 MAXPRO200 Instruction Manual 807700

 Installation

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 13 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

MAXPRO200 Instruction Manual 807700 61

Installation

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.

62 MAXPRO200 Instruction Manual 807700

 Installation

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 A 175 A N/A 67.5 mm2 (2/0)
220 VAC 3 98 A 150 A 85.2 mm2 (3/0) 42.4 mm2 (1 AWG)
240 VAC 3 90 A 150 A 85.2 mm2 (3/0) 42.4 mm2 (1 AWG)
380 VAC 3 57 A 90 A 33.6 mm2 (2 AWG) 21.2 mm2 (4 AWG)
400 VAC 3 54 A 80 A 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG)
415 VAC 3 52 A 80 A 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG)
440 VAC 3 49 A 80 A 26.7 mm2 (3 AWG) 21.2 mm2 (4 AWG)
480 VAC 3 45 A 70 A 21.2 mm2 (4 AWG) 13.3 mm2 (6 AWG)
600 VAC 3 36 A 50 A 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).

MAXPRO200 Instruction Manual 807700 63

Installation

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).

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.

64 MAXPRO200 Instruction Manual 807700

 Installation

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

MAXPRO200 Instruction Manual 807700 65

Installation

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.

66 MAXPRO200 Instruction Manual 807700

 Installation

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. 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

MAXPRO200 Instruction Manual 807700 67

Installation

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)

68 MAXPRO200 Instruction Manual 807700

 Installation

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 amperage 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 4. Add coolant to the power supply until the tank is
the system and add coolant to the tank until it is full full and replace the filler cap.
again. Repeat steps 2 and 3 until no error is displayed.

MAXPRO200 Instruction Manual 807700 69

Installation

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 74.

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.

70 MAXPRO200 Instruction Manual 807700

 Installation

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 75 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

MAXPRO200 Instruction Manual 807700 71

Installation

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

72 MAXPRO200 Instruction Manual 807700

 Installation

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 74.

MAXPRO200 Instruction Manual 807700 73

Installation

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 70.

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 amperage (A) icon is illuminated.

74 MAXPRO200 Instruction Manual 807700

 Installation

Gas regulators
The installer or user must supply the gas regulator (regulators) for the cutting system.

It is important to choose the correct gas regulator (regulators) for the conditions at the installation site. A gas regulator
must be compatible with the gases used and appropriate for the environmental conditions. For example, certain
regulators are recommended for specific temperature ranges. The type of gas (cylinder gas, line gas, or liquefied gas),
and the gas-delivery pressure and flow, can also influence regulator selection.

Single-stage gas • Reduces source gas pressure to the necessary delivery pressure in
regulation 1 step.
• Delivery pressure is not tightly controlled with this type of gas regulation.
• Good choice for generic applications and where fluctuations in source
gas pressure are small.
Dual-stage gas regulations • Reduces source gas pressure to the necessary delivery pressure in
2 steps. Dual-stage regulation uses 2 single-stage regulators. The first
regulator reduces the pressure to approximately 3 times the maximum
delivery pressure. The second regulator reduces pressure to the
necessary delivery pressure.
• Good choice for applications that require consistent delivery pressure
and where fluctuations in source gas pressure are large.
• Dual-stage gas regulation can restrict gas flow and give bad results if the
choice of regulator is bad or if the regulator settings are not correct.

Your gas supplier can recommend the best gas regulator (regulators) for the conditions at your site.

MAXPRO200 Instruction Manual 807700 75

Installation

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.

Note: A separate gas regulator is needed only when cutting with oxygen.

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

76 MAXPRO200 Instruction Manual 807700

 Installation

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 78
for part numbers.

Caution: Never use PTFE 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.

MAXPRO200 Instruction Manual 807700 77

Installation

Supply gas hoses

Caution: Never use PTFE tape

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)

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)

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)

78 MAXPRO200 Instruction Manual 807700

 Section 3
Operation

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 13.

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 101 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 101 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)

MAXPRO200 Instruction Manual 807700 79

Operation

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

80 MAXPRO200 Instruction Manual 807700

 Operation

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 172.
• 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 see 1 through 5). If the system is powered up with the start signal on,
the 3-digit display will continue to count up to 98.
• 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 amperage 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.

MAXPRO200 Instruction Manual 807700 81

Operation

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 amperage (A)
5 icon and turning the knob. The current increases or decreases in 1 A
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 more 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.
The plasma start LED illuminates white when the plasma start signal
6 Plasma start
is given and stays illuminated until the start signal is removed.
The arc transfer LED illuminates green when the arc transfers to the
7 Arc transfer
workpiece.

82 MAXPRO200 Instruction Manual 807700

 Operation

Choosing a cutting process

1. Use the current selection knob to set the amperage (A). Turning the knob slowly increases or decreases the current
1 A at a time. Turning the knob fast lets you jump quickly to the next process current (50 A, 130 A, and 200 A).
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 A, mild steel, air/air process. See the cut chart for details.

1 2

MAXPRO200 Instruction Manual 807700 83

Operation

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 13 for more information.

Handheld cutting
Safety
During handheld cutting, always use full protection:

• A welding helmet with at least a #12 glass

• Welding gloves and a welding jacket
• A heat shield for additional protection – available from Hypertherm (127389)

Specifications
Materials Mild steel, stainless steel, and aluminum
Current 50 A, 130 A, and 200 A
Plasma gas types Air, O2, N2
Shield gas types Air, N2

Consumable selection and gas settings

Refer to Cutting parameters on page 96 for consumable and process information.

84 MAXPRO200 Instruction Manual 807700

 Operation

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 (.25 inch) of the workpiece.

MAXPRO200 Instruction Manual 807700 85

Operation

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 45-degree 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.

86 MAXPRO200 Instruction Manual 807700

 Operation

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 13 for more information.

Gouging
Safety
During gouging, always use full protection:

• A welding helmet with at least a #12 glass

• Welding gloves and a welding jacket
• A heat shield for additional protection – available from Hypertherm (127389)

Specifications
Materials Mild steel, stainless steel, and aluminum
Current 200 A
Plasma gas types Air, O2
Shield gas types Air

Parameters of operation for frequently-used gouge processes

2
General parameters for gouging
1 Speed 508 to 1,270 mm/min (20 to 50 in/min)
2 Angle 45 to 57.5 degrees
1 3 Standoff 3.1 to 19.0 mm (.125 to 0.75 inch)
3 Maximum arc stretch 76 mm (3 inches)*
*For infrequent use, not 100% duty cycle

Parameters for gouging with 200 A – Air Plasma / Air Shield on mild steel
Metal-removal rate 19.9 kg/hr (44 lb/hr)
Speed 889 mm/min (35 in/min)
Angle 57.5 degrees
Stand off 4.7 mm (0.187 inch)

MAXPRO200 Instruction Manual 807700 87

Operation

4 5

4 9.9 mm (0.39 inch)

5 7.6 mm (0.30 inch)

Parameters for gouging with 200 A – O2 Plasma / Air Shield on mild steel
Metal-removal rate 19.5 kg/hr (43 lb/hr)
Speed 889 mm/min (.35in/min)
Angle 57.5 degrees
Stand off 7.8 mm (.31 inch)

6 7

6 11.6 mm (0.46 inch)

7 6.3 mm (0.25 inch)

Refer to Cut charts for details about gouging parameters and settings.

88 MAXPRO200 Instruction Manual 807700

 Operation

How to change the gouge contour and metal-removal rate

You can change the gouge contour and the metal-removal rate by changing the speed of the torch as it moves along the
workpiece, changing the distance between the torch and the workpiece, changing the angle of the torch to the
workpiece, and changing the output current (A) of the plasma power supply. For example:

• 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 plasma power supply will increase width and increase depth.
• Decreasing the current of the plasma power supply will decrease width and decrease depth.

Angle of the torch

Torch center line

Turn of the torch

Speed
Standoff / arc stretch Output current (A)

Adjust the following conditions of operation in combination to get the gouge you want:

• Output current (A) of the plasma power supply

• Angle of the torch to the workpiece
• Turn of the torch

MAXPRO200 Instruction Manual 807700 89

Operation

• Distance between the torch and workpiece

• Torch speed

Output current (A)

1
Use the knob on the front panel of the plasma power 1 2
supply to change the output current (A). Decrease the
amperage (-) to make the gouge narrower and
shallower 1 . Increase the amperage (+) to make it wider 2
and deeper 2 .

• Arc stretch is related to the amperage of the plasma power supply. The higher the amperage, the
longer you can stretch the arc. Hypertherm recommends that you keep amperage and arc stretch
consistent.
• The lowest and highest possible amperage settings are related to the plasma power supply and the
Hypertherm consumables.

Angle of the torch

1
Put the torch in a more vertical position to make the gouge
narrower and deeper 1 . Tilt down the torch so that it is
more horizontal and near the workpiece to make the gouge
wider and more shallow 2 . 2

Turn of the torch

Turn the torch in the direction of the torch center line to
make the gouge flatter and steeper on one side 1 .
1

90 MAXPRO200 Instruction Manual 807700

 Operation

Torch-to-work standoff / arc stretch

1
Move the torch away from the workpiece to make the
gouge wider, shallower, and smoother on the bottom 1 .
Move the torch near the workpiece to make the gouge
2
narrower and deeper 2 .

• Arc stretch is related to the amperage of the plasma

power supply. The higher the amperage, the longer
that you can stretch the arc. Hypertherm recommends
that you keep amperage and arc stretch consistent.
• Keep at least a small distance between the torch tip
and the molten metal. Contact with molten metal can 1
damage the torch and reduce the life of consumables. 1
2

Speed of the torch

Increase the speed of the torch to make the gouge more
narrow and more shallow 1 . Decrease the speed of the
torch to make the gouge wider and deeper 2 .

1 1

MAXPRO200 Instruction Manual 807700 91

Operation

Mechanized gouging

Gouging can be mechanized for repeatable results if the torch is installed on a track-mounted carriage, stationary
manipulator, or other fixture. The quality of the torch installation and software integration can have an effect on the quality
of mechanized gouging. Experienced installers and integrators who understand gouging can contribute to good results.

For the best results, Hypertherm recommends a Sensor™ PHC (plasma height control) or OEM THC (torch height
control) to keep the correct torch-to-work distance during mechanized gouging.

The figure below shows how different settings and conditions of operation can change the gouge width, depth, and
angle.

Included angle

1/3 depth Depth

Width

Bottom radius

For guidance about how to produce single-pass automated gouges using air / air or O2 / air on mild steel, refer to
Automated Gouging with Sensor PHC (810730) available at www.hypertherm.com/docs.

92 MAXPRO200 Instruction Manual 807700

 Operation

Handheld gouging
To select the correct consumables, see How to select cutting and
gouging consumables on page 97.

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. Move the torch into the angle necessary to get the gouge angle
and shape you want. Make sure to keep a gap between the torch
tip and the workpiece.
3. Press the trigger to obtain a pilot arc. Transfer the arc to the
work piece.
4. Maintain the angle to the workpiece during the gouge. Push the
plasma arc in the direction of the gouge you want to create. 32.5º – 60º
Keep at least a small distance between the torch tip and the
molten metal. Contact with molten metal can damage the torch
and reduce the life of consumables
Note: Changing the torch angle changes the dimensions of the
Feeding into the gouge
gouge. Refer to How to change the gouge contour and
metal-removal rate on page 89.

MAXPRO200 Instruction Manual 807700 93

Operation

Handheld gouging techniques

Straight and straight-weaving

Straight gouge

Straight-weaving gouge

94 MAXPRO200 Instruction Manual 807700

 Operation

Side and side-weaving

60°

Side gouge

60°

Side-weaving gouge

MAXPRO200 Instruction Manual 807700 95

Operation

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 Handheld consumables below for the consumables to use with handheld torches.

The cut chart values in this document are recommended for high-quality cuts with minimal dross. Because of differences
between installations and material composition, some adjustments can be necessary.

96 MAXPRO200 Instruction Manual 807700

 Operation

Mechanized consumables
The consumable part numbers included with each cut chart are specific to mechanized torches. Each cut chart has a
drawing and part number for every consumable, as shown in the example below.

420063 220935 220890 220529 220528

Note: Drawings are for reference only.

Handheld consumables
Handheld consumables are intended for use with handheld torches to cut mild steel, stainless steel, and aluminum. Use
the cutting parameters in the Cut charts for cutting with the MAXPRO200 handheld torches.

How to select cutting and gouging consumables

The following sets of consumables are intended for use with handheld torches to cut and gouge mild steel, stainless
steel, and aluminum. You can use the cutting parameters detailed under Cut charts on page 112 with the MAXPRO200
handheld torches as long as you use the following consumables for each process.

Gouging consumables can be used with both handheld or mechanized torches.

Mild steel cutting

50 A
Air Plasma
Air Shield

420063 220935 220890 220529 220528 220521

50 A
O2 Plasma
Air Shield

420063 220935 220891 220529 220528 220521

MAXPRO200 Instruction Manual 807700 97

Operation

130 A
Air Plasma
Air Shield

420061 220935 220892 220488 220487 220487

130 A
O2 Plasma
Air Shield

420062 220935 220893 220892 220488 220487

200 A
Air Plasma
Air Shield

420058 220935 420044 220488 220937 220487

200 A
O2 Plasma
Air Shield

420059 220935 220831 220834 220937 220487

Mild steel gouging

200 A
O2 Plasma
Air Shield
420928 (Air) /
420885 420794* / 420793** 420886 420883 (O2) 420887 420881

*with Initial Height Sensing (IHS) tab / **without IHS tab

98 MAXPRO200 Instruction Manual 807700

 Operation

Stainless steel cutting

50 A
Air Plasma
Air Shield
420063 220935 220890 220529 220528 220521

130 A
Air Plasma
Air Shield

420061 220935 220892 220488 220487 220487

130 A
N2 Plasma
N2 Shield
420061 220935 220892 220529 020415 220487

200 A
Air Plasma
Air Shield

420058 220935 420044 220488 220937 220487

200 A
N2 Plasma
N2 Shield
420058 220935 420044 220529 020415 220487

Stainless steel gouging

200 A
Air Plasma
Air Shield

420885 420794* / 420793** 420886 420928 420887 420881

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 99

Operation

Aluminum cutting

50 A
Air Plasma
Air Shield

420063 220935 220890 220529 220528 220521

130 A
Air Plasma
Air Shield

420061 220935 220892 220488 220487 220487

130 A
N2 Plasma
N2 Shield
420061 220935 220892 220529 020415 220487

200 A
Air Plasma
Air Shield

420058 220935 420044 220488 220937 220487

200 A
N2 Plasma
N2 Shield

420058 220935 420044 220529 020415 220487

Aluminum gouging

200 A
Air Plasma
Air Shield

420885 420794* / 420793** 420886 420928 420887 420881

*with IHS tab / **without IHS tab

100 MAXPRO200 Instruction Manual 807700

 Operation

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 102. 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 over tighten 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

MAXPRO200 Instruction Manual 807700 101

Operation

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

102 MAXPRO200 Instruction Manual 807700

 Operation

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 the 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 External
shiny, but there should not be any excess or built-up threads Rear view of torch
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.

MAXPRO200 Instruction Manual 807700 103

Operation

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

104 MAXPRO200 Instruction Manual 807700

 Operation

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.

CAUTION!

Different cutting and gouging processes can require different water tubes.
Make sure to select the correct water tube. Failure to select the correct water tube can prevent
installation of consumables or decrease cutting system performance.

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 101.
3. Remove the old water tube.
4. Select the replacement water tube. Make sure to select the correct water tube for the process you plan to use:

Standard (220521)

Gouging (420881)

Extreme bevel (420823)

MAXPRO200 Instruction Manual 807700 105

Operation

5. 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.
6. Replace consumables. See Install and inspect consumables on page 101.

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 Troubleshooting table on page 149.
• 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 101).
• 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 101).
• 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 101).
• 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 that has a high nickel content, will shorten consumable life. Long
consumable life is difficult to achieve when cutting a workpiece that is magnetized or becomes magnetized
easily.
• Beginning or ending the cut beyond the workpiece 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 workpiece 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.

106 MAXPRO200 Instruction Manual 807700

 Operation

• Cut quality is poor. The causes can be:

• The workpiece 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.

MAXPRO200 Instruction Manual 807700 107

Operation

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.

108 MAXPRO200 Instruction Manual 807700

 Operation

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.

MAXPRO200 Instruction Manual 807700 109

 Estimated kerf-width compensation

110

Optimizing cut quality

Operation
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
50 A Air / Air 1.72 1.51 1.46 1.52 1.62 1.58 1.53 1.47 1.44 1.57
50 A O2 / Air 1.36 1.35 1.36 1.37 1.39 1.41 1.42 1.44 1.51 1.52
130 A Air / Air 2.08 2.21 2.38 2.45 2.48 2.68 3.08 3.46 3.98
130 A O2 / Air 2.29 2.35 2.40 2.56 2.63 2.92 3.45 3.82 4.33 4.78
200 A Air / Air 2.68 2.90 2.98 2.95 3.12 3.53 3.98 4.20 4.37 5.02 5.69
200 A 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
50 A Air / Air 1.45 1.71 1.77 1.68 1.56 1.52 1.50 1.55 1.66 1.71
130 A Air / Air 2.57 2.70 2.74 2.90 3.19
130 A N2 / N2 2.56 2.40 2.43 2.40 2.59 2.97
200 A Air / Air 3.03 2.76 2.76 2.76 2.98 3.35 3.42 3.64 3.85 4.67
200 A 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
50 A Air / Air 1.40 1.40 1.40 1.40 1.40 1.47 1.50 1.52 1.55 1.58
MAXPRO200 Instruction Manual 807700

130 A Air / Air 2.84 2.80 2.78 2.76 2.77 2.88

130 A N2 / N2 2.73 2.57 2.62 2.46 2.61 3.00
200 A Air / Air 3.73 3.94 3.44 3.42 3.51 3.73 4.03 4.29 5.38
200 A N2 / N2 3.55 3.35 3.04 3.02 3.16 3.52 4.00 4.57 5.04
MAXPRO200 Instruction Manual 807700
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
50 A Air / Air 0.069 0.065 0.061 0.056 0.060 0.064 0.063 0.059 0.056 0.058 0.063
50 A O2 / Air 0.054 0.053 0.053 0.053 0.054 0.055 0.055 0.056 0.057 0.063 0.059
130 A Air / Air 0.085 0.090 0.095 0.096 0.098 0.108 0.119 0.137 0.156
130 A O2 / Air 0.092 0.093 0.095 0.100 0.105 0.119 0.133 0.151 0.170 0.188
200 A 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
200 A 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
50 A 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
130 A Air / Air 0.104 0.106 0.108 0.116 0.124
130 A N2 / N2 0.101 0.093 0.096 0.094 0.105 0.116
200 A Air / Air 0.119 0.105 0.109 0.109 0.120 0.131 0.135 0.134 0.143 0.152 0.184
200 A 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
50 A 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
130 A Air / Air 0.112 0.110 0.109 0.109 0.108 0.114
130 A N2 / N2 0.107 0.099 0.105 0.095 0.106 0.117
200 A Air / Air 0.151 0.157 0.136 0.134 0.140 0.145 0.152 0.159 0.167 0.213
200 A N2 / N2 0.140 0.130 0.120 0.119 0.127 0.135 0.147 0.159 0.179 0.199

Optimizing cut quality

Operation
111
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 How to select cutting and gouging consumables on page 97 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.

112 MAXPRO200 Instruction Manual 807700

 Operation

Standard consumables
Mild steel Flow rates – lpm/scfh
Air Plasma / Air Shield Air (Plasma) Air (Shield)
50 A Cutting 12/25 103/218

220532 220936* / 220935** 220890 220529 220528 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.

Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.5 112 1.5 9400 3.0 200 0.0
0.8 111 1.5 8510 3.0 200 0.0
1.0 111 1.5 8050 3.0 200 0.1
1.2 110 1.8 7625 3.6 200 0.1
1.5 110 1.8 7370 3.6 200 0.1
62 63 63 63 39 42 45 47
2.0 110 1.8 6735 3.6 200 0.1
2.5 111 2.0 5080 4.0 200 0.2
3.0 111 2.0 3760 4.0 200 0.3
4.0 113 2.3 2415 4.6 200 0.4
6.0 118 2.5 1600 4.6 180 0.5

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.018 112 0.06 375 0.12 200 0.0
0.024 112 0.06 350 0.12 200 0.0
0.030 111 0.06 340 0.12 200 0.0
0.036 111 0.06 325 0.12 200 0.1
0.048 110 0.07 300 0.14 200 0.1
62 63 63 63 39 42 45 47 0.060 110 0.07 290 0.14 200 0.1
0.075 110 0.07 275 0.14 200 0.1
0.105 111 0.08 180 0.16 200 0.2
0.135 111 0.08 110 0.16 200 0.3
3/16 116 0.09 75 0.18 200 0.4
1/4 118 0.10 60 0.18 180 0.5

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 113

Operation

Mild steel Flow rates – lpm/scfh

O2 Plasma / Air Shield O2 (Plasma) Air (Shield)
50 A Cutting 12/25 73/155

220532 220936* / 220935** 220891 220529 220528 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.5 98 1.5 7550 3.0 200 0.0
0.8 96 1.5 7050 3.0 200 0.0
1.0 90 1.5 6775 3.0 200 0.1
1.2 94 1.5 6600 3.0 200 0.1
1.5 99 1.5 6150 3.0 200 0.1
68 68 69 69 25 27 29 31
2.0 99 1.5 5400 3.0 200 0.1
2.5 99 1.8 4300 3.6 200 0.2
3.0 99 1.8 3650 3.6 200 0.3
4.0 101 2.0 2800 3.8 190 0.4
6.0 103 2.5 1750 3.8 150 0.5

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.018 98 0.06 300 0.12 200 0.0
0.024 98 0.06 290 0.12 200 0.0
0.030 98 0.06 280 0.12 200 0.0
0.036 89 0.06 270 0.12 200 0.1
0.048 94 0.06 260 0.12 200 0.1
68 68 69 69 25 27 29 31 0.060 99 0.06 240 0.12 200 0.1
0.075 99 0.06 220 0.12 200 0.1
0.105 99 0.07 160 0.14 200 0.2
0.135 99 0.07 130 0.14 200 0.3
3/16 103 0.09 85 0.15 160 0.4
1/4 103 0.10 65 0.15 150 0.5

*with IHS tab / **without IHS tab

114 MAXPRO200 Instruction Manual 807700

 Operation

Mild steel Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
130 A Cutting 33/70 68/145

220536 220936* / 220935** 220892 220488 220487 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3.0 149 3.0 5350 6.0 200 0.1
4.0 147 3.0 4630 6.0 200 0.2
6.0 142 2.4 3865 7.2 300 0.3
10.0 152 4.1 2445 8.2 200 0.5
68 69 70 71 22 24 26 28 12.0 154 4.1 2045 8.2 200 0.5
15.0 155 4.4 1445 8.8 200 0.8
20.0 158 4.6 815 9.6 210 1.2
25.0 166 4.6 415
Edge start
32.0 178 5.1 250

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.135 149 0.12 220 0.24 200 0.1
3/16 145 0.12 160 0.24 200 0.2
1/4 141 0.10 150 0.28 300 0.3
3/8 151 0.16 100 0.32 200 0.5
68 69 70 71 22 24 26 28 1/2 154 0.16 75 0.32 200 0.5
5/8 155 0.18 50 0.36 200 0.8
3/4 156 0.18 35 0.38 210 1.2
1 167 0.18 15
Edge start
1-1/4 178 0.20 10

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 115

Operation

Mild steel Flow rates – lpm/scfh

O2 Plasma / Air Shield O2 (Plasma) Air (Shield)
130 A Cutting 20/42 86/183

220491 220936* / 220935** 220833 220488 220987 220521

220534* / 220533** MIRROR-IMAGE 420795

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3.0 130 2.6 5900 5.2 200 0.1
4.0 131 2.7 5325 5.4 200 0.2
6.0 134 2.8 3925 5.6 200 0.3
10.0 136 3.0 2680 6.0 200 0.4
12.0 138 3.0 2200 6.0 200 0.5
62 62 64 64 30 32 35 37
15.0 140 3.6 1665 7.2 200 0.7
20.0 145 3.9 1195 7.8 200 1.0
25.0 151 4.1 685
32.0 158 4.6 515 Edge start
38.0 163 4.6 310

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.135 130 0.10 240 0.20 200 0.1
3/16 132 0.11 190 0.22 200 0.2
1/4 134 0.11 150 0.22 200 0.3
3/8 136 0.12 110 0.24 200 0.3
1/2 138 0.12 80 0.24 200 0.5
62 62 64 64 30 32 35 37
5/8 141 0.15 60 0.30 200 0.7
3/4 144 0.15 50 0.30 200 1.0
1 151 0.16 25
1-1/4 158 0.18 20 Edge start
1-1/2 163 0.18 12

*with IHS tab / **without IHS tab

116 MAXPRO200 Instruction Manual 807700

 Operation

Mild steel Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
200 A Cutting 32/68 123/260

420045 220936* / 220935** 420044 220488 220937 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
6.0 147 1.0 4885 3.0 300 0.3
8.0 148 1.3 4515 3.9 300 0.5
10.0 151 3.0 3556 5.2 200 0.8
12.0 153 3.0 2794 6.0 200 0.9
15.0 158 4.3 2265 8.6 200 1.0
52 54 55 56 48 50 54 58 20.0 165 4.8 1415 9.6 200 1.4
25.0 172 6.4 940 11.4 180 1.7
32.0 176 6.4 630 11.4 180 2.3
38.0 179 6.4 510
44.0 189 6.4 320 Edge start
50.0 199 6.4 215

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
1/4 145 0.04 190 0.12 300 0.3
5/16 148 0.05 180 0.15 300 0.5
3/8 151 0.10 140 0.20 200 0.8
1/2 154 0.13 110 0.25 200 0.9
5/8 159 0.19 85 0.38 200 1.0
3/4 164 0.19 60 0.38 200 1.2
52 54 55 56 48 50 54 58
7/8 169 0.19 50 0.38 200 1.4
1 173 0.25 35 0.45 180 1.7
1-1/4 176 0.25 25 0.45 180 2.3
1-1/2 179 0.25 20
1-3/4 190 0.25 12 Edge start
2 200 0.25 8

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 117

Operation

Mild steel Flow rates – lpm/scfh

O2 Plasma / Air Shield O2 (Plasma) Air (Shield)
200 A Cutting 32/67 123/260

220832 220936* / 220935** 220831 226834 220937 220521

220534* / 220533** MIRROR-IMAGE 420795 MIRROR-IMAGE
Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
6.0 146 1.5 6210 3.0 200 0.3
8.0 150 3.4 4850 5.1 150 0.4
10.0 156 4.6 3735 6.9 150 0.4
12.0 154 3.8 3415 9.5 250 0.6
15.0 153 3.1 2845 7.8 250 0.7
68 69 70 71 48 50 54 58 20.0 154 3.0 1920 7.5 250 0.8
25.0 154 3.2 1430 8.0 250 1.0
32.0 161 3.1 805 8.9 280 1.3
38.0 168 4.4 570
44.0 175 4.4 395 Edge start
50.0 180 4.4 270

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
1/4 143 0.08 235 0.15 200 0.3
3/8 157 0.19 150 0.28 150 0.3
1/2 153 0.14 130 0.28 200 0.3
5/8 153 0.12 105 0.28 250 0.5
3/4 154 0.12 80 0.28 250 0.6
68 69 70 71 48 50 54 58 7/8 154 0.13 65 0.31 250 0.7
1 154 0.13 55 0.31 250 0.8
1-1/4 161 0.13 32 0.35 280 1.5
1-1/2 168 0.18 22
1-3/4 175 0.18 15 Edge start
2 181 0.18 10

*with IHS tab / **without IHS tab

118 MAXPRO200 Instruction Manual 807700

 Operation

Stainless steel Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
50 A Cutting 12/25 103/218

220532 220936* / 220935** 220890 220529 220528 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.5 101 1.5 8000 3.0 200 0.0
0.8 102 1.6 7750 3.2 200 0.0
1.0 102 1.8 7115 3.6 200 0.1
1.2 103 1.8 6350 3.6 200 0.1
1.5 106 1.8 5335 3.6 200 0.1
62 63 63 63 39 42 45 47
2.0 108 2.0 4200 4.0 200 0.1
2.5 111 2.0 3300 4.0 200 0.2
3.0 112 2.0 2800 4.0 200 0.3
4.0 116 2.2 2300 4.4 200 0.4
6.0 123 2.5 1400 4.6 180 0.5

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.018 101 0.06 300 0.12 200 0.0
0.024 101 0.06 275 0.12 200 0.0
0.030 102 0.06 265 0.12 200 0.0
0.036 102 0.06 250 0.12 200 0.1
0.048 103 0.07 225 0.14 200 0.1
62 63 63 63 39 42 45 47 0.060 106 0.07 190 0.14 200 0.1
0.075 107 0.07 165 0.14 200 0.1
0.105 112 0.08 125 0.16 200 0.2
0.135 113 0.08 85 0.16 200 0.3
3/16 119 0.09 55 0.18 200 0.4
1/4 124 0.10 45 0.18 180 0.5

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 119

Operation

Stainless steel Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
130 A Cutting 33/70 69/145

220536 220936* / 220935** 220892 220488 220487 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
6.0 147 3.5 2625 7.0 200 0.3
10.0 153 4.1 1700 8.2 200 0.5
68 69 70 71 22 24 26 28 12.0 155 4.1 1380 8.2 200 0.8
15.0 160 4.4 900
Edge start
20.0 170 4.6 430

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
1/4 148 0.14 100 0.28 200 0.3
3/8 152 0.16 70 0.32 200 0.5
68 69 70 71 22 24 26 28 1/2 156 0.16 50 0.32 200 0.8
5/8 162 0.18 30
Edge start
3/4 168 0.18 20

*with IHS tab / **without IHS tab

120 MAXPRO200 Instruction Manual 807700

 Operation

Stainless steel Flow rates – lpm/scfh

N2 Plasma / N2 Shield N2 (Plasma) N2 (Shield)
130 A Cutting 32/68 104/218

220536 220936* / 220935** 220892 220529 020415 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
5.0 148 3.0 3140 6.1 200 0.3
6.0 151 3.0 2980 6.1 200 0.3
10.0 152 3.3 1830 6.6 200 0.5
68 69 70 71 36 39 42 44
12.0 154 3.3 1510 6.6 200 0.8
15.0 158 3.6 1120
Edge start
20.0 166 3.8 470

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3/16 149 0.12 125 0.24 200 0.3
1/4 151 0.12 115 0.24 200 0.3
3/8 152 0.13 75 0.26 200 0.5
68 69 70 71 36 39 42 44
1/2 154 0.13 55 0.26 200 0.8
5/8 159 0.14 40
Edge start
3/4 165 0.15 25

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 121

Operation

Stainless steel Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
200 A Cutting 32/68 123/260

420045 220936* / 220935** 420044 220488 220937 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
4.0 148 2.7 6200 5.4 200 0.4
6.0 150 3.0 5500 6.0 200 0.4
10.0 150 3.2 4120 6.4 200 0.5
12.0 152 3.2 3320 6.4 200 0.8
15.0 157 3.8 2400 7.6 200 0.8
52 54 55 56 48 50 54 58
20.0 164 4.9 1440 9.8 200 1.0
25.0 168 5.6 1040 11.8 210 1.6
32.0 174 5.6 500
38.0 180 5.6 305 Edge start
50.0 188 5.6 210

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3/16 149 0.11 240 0.22 200 0.4
1/4 150 0.12 210 0.24 200 0.4
3/8 150 0.13 170 0.25 200 0.5
1/2 153 0.13 120 0.25 200 0.8
5/8 159 0.16 85 0.32 200 0.8
52 54 55 56 48 50 54 58 3/4 163 0.19 60 0.38 200 1.0
7/8 166 0.21 50 0.42 200 1.4
1 168 0.22 40 0.45 210 1.6
1-1/4 174 0.22 20
1-1/2 180 0.22 12 Edge start
2 188 0.22 8

*with IHS tab / **without IHS tab

122 MAXPRO200 Instruction Manual 807700

 Operation

Stainless steel Flow rates – lpm/scfh

N2 Plasma / N2 Shield N2 (Plasma) N2 (Shield)
200 A Cutting 37/79 107/225

420045 220936* / 220935** 420044 220529 220937 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
5.0 156 3.2 4460 6.4 200 0.4
6.0 159 3.2 3980 6.4 200 0.4
10.0 160 3.2 2900 6.4 200 0.5
12.0 162 3.2 2260 6.4 200 0.8
69 70 71 72 42 45 48 51 15.0 165 3.4 1760 7.9 230 0.9
20.0 172 4.2 1190 10.1 240 1.1
25.0 185 6.4 790 11.4 180 2.0
32.0 191 6.4 520
Edge start
38.0 197 6.4 310

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3/16 159 0.13 180 0.25 200 0.4
1/4 159 0.13 150 0.25 200 0.4
3/8 160 0.13 120 0.25 200 0.5
1/2 163 0.13 80 0.25 200 0.8
5/8 166 0.14 65 0.32 230 0.9
69 70 71 72 42 45 48 51
3/4 170 0.16 50 0.38 240 1.0
7/8 178 0.19 40 0.38 200 1.5
1 186 0.25 30 0.45 180 2.0
1-1/4 191 0.25 21
Edge start
1-1/2 197 0.25 12

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 123

Operation

Aluminum Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
50 A Cutting 12/25 104/218

420063 220935 220890 220529 220528 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.5 112 1.5 8000 3.0 200 0.0
0.8 113 1.6 7750 3.2 200 0.0
1.0 114 1.8 7115 3.6 200 0.1
1.2 114 1.8 6350 3.6 200 0.1
1.5 115 1.8 5335 3.6 200 0.1
62 63 63 63 39 42 45 47
2.0 120 2.0 4200 4.0 200 0.1
2.5 123 2.0 3300 4.0 200 0.2
3.0 124 2.0 2800 4.0 200 0.3
4.0 125 2.2 2300 4.4 200 0.4
6.0 130 2.5 1400 4.6 180 0.5

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
0.018 112 0.06 325 0.12 200 0.0
0.020 112 0.06 315 0.12 200 0.0
0.024 112 0.06 305 0.12 200 0.0
0.030 113 0.06 295 0.12 200 0.1
0.036 114 0.07 280 0.14 200 0.1
0.048 114 0.07 230 0.14 200 0.2
62 63 63 63 39 42 45 47
0.060 115 0.07 195 0.14 200 0.2
0.075 120 0.08 160 0.16 200 0.2
0.105 123 0.08 120 0.16 200 0.3
0.125 124 0.08 100 0.16 200 0.3
3/16 126 0.09 75 0.18 200 0.4
1/4 131 0.10 50 0.18 180 0.5

*with IHS tab / **without IHS tab

124 MAXPRO200 Instruction Manual 807700

 Operation

Aluminum Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
130 A Cutting 33/70 69/145

220536 220936* / 220935** 220892 220488 220487 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
6.0 156 2.8 2370 5.6 200 0.2
10.0 161 3.0 1470 6.0 200 0.3
12.0 163 3.0 1230 6.0 200 0.5
68 69 70 71 22 24 26 28
15.0 165 3.2 1050 6.4 200 0.8
20.0 169 3.6 725 7.9 220 1.3
25.0 175 4.0 525 Edge start

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
1/4 156 0.11 90 0.22 200 0.2
3/8 160 0.12 60 0.24 200 0.3
1/2 164 0.12 45 0.24 200 0.5
68 69 70 71 22 24 26 28
5/8 166 0.13 40 0.26 200 0.8
3/4 168 0.14 30 0.31 220 1.3
1 176 0.16 20 Edge start

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 125

Operation

Aluminum Flow rates – lpm/scfh

N2 Plasma / N2 Shield N2 (Plasma) N2 (Shield)
130 A Cutting 32/68 104/218

220536 220936* / 220935** 220892 220529 020415 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
5.0 153 3.0 3140 6.1 200 0.2
6.0 154 3.0 2980 6.1 200 0.2
10.0 158 3.3 1830 6.6 200 0.3
68 69 70 71 36 39 42 44
12.0 160 3.3 1510 6.6 200 0.5
15.0 162 3.6 1120 7.1 200 0.8
20.0 166 3.9 470 8.7 220 1.4

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3/16 153 0.12 125 0.24 200 0.2
1/4 154 0.12 115 0.24 200 0.2
3/8 158 0.13 75 0.26 200 0.3
68 69 70 71 36 39 42 44
1/2 160 0.13 55 0.26 200 0.5
5/8 163 0.14 40 0.28 200 0.8
3/4 165 0.15 25 0.33 220 1.3

*with IHS tab / **without IHS tab

126 MAXPRO200 Instruction Manual 807700

 Operation

Aluminum Flow rates – lpm/scfh

Air Plasma / Air Shield Air (Plasma) Air (Shield)
200 A Cutting 32/68 123/260

420045 220936* / 220935** 420044 220488 220937 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
4.0 150 2.2 6215 4.4 200 0.5
6.0 156 3.0 5195 6.0 200 0.5
10.0 156 3.3 3930 6.6 200 0.5
12.0 159 3.7 3370 7.4 200 0.5
52 54 55 56 48 50 54 58 15.0 163 4.0 2625 8.0 200 0.8
20.0 169 4.9 1625 9.8 200 1.0
25.0 177 5.6 1050 11.4 210 1.4
32.0 187 5.6 515 11.4 210 1.7
38.0 195 5.6 310 Edge start

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3/16 150 0.10 230 0.20 200 0.5
1/4 158 0.13 200 0.25 200 0.5
3/8 155 0.13 160 0.25 200 0.5
1/2 160 0.15 125 0.30 200 0.5
5/8 164 0.16 95 0.32 200 0.8
52 54 55 56 48 50 54 58
3/4 168 0.19 70 0.38 200 1.0
7/8 173 0.21 50 0.42 200 1.2
1 178 0.22 40 0.45 210 1.4
1-1/4 187 0.22 20 0.45 210 1.7
1-1/2 195 0.22 12 Edge start

*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 127

Operation

Aluminum Flow rates – lpm/scfh

N2 Plasma / N2 Shield N2 (Plasma) N2 (Shield)
200 A Cutting 37/79 107/225

420045 220936* / 220935** 420044 220529 220937 220521

Note: Gas pressure values are set automatically by the system when the process is chosen. The arc voltage
settings in these cut charts were measured with a lead length of 30.5 meters (100 feet). Adjustments to arc voltage
settings can be necessary for shorter leads.
Metric
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22 9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
mm Volts mm mm/min mm Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
5.0 164 3.2 4770 6.4 200 0.5
6.0 165 3.2 4530 6.4 200 0.5
10.0 165 3.2 3930 6.4 200 0.5
12.0 164 3.2 3370 6.4 200 0.5
69 70 71 72 42 45 48 51 15.0 169 4.1 2620 8.1 200 0.8
20.0 179 5.1 1630 10.2 200 1.2
25.0 189 6.4 1050
32.0 198 6.4 500 Edge start
38.0 206 6.4 310

English
Material Arc Cut Cutting Pierce
Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead Lead
3/16 165 0.13 190 0.25 200 0.5
1/4 165 0.13 175 0.25 200 0.5
3/8 165 0.13 160 0.25 200 0.5
1/2 164 0.13 125 0.25 200 0.5
5/8 171 0.16 95 0.32 200 0.8
69 70 71 72 42 45 48 51
3/4 177 0.19 70 0.38 200 1.0
7/8 183 0.25 50 0.45 180 1.5
1 190 0.25 40
1-1/4 198 0.25 20 Edge start
1-1/2 206 0.25 12

*with IHS tab / **without IHS tab

128 MAXPRO200 Instruction Manual 807700

 Operation

Extreme bevel consumables

The MAXPRO200 extreme bevel consumables include the following components:

Part number Description Current Gas

420737 Shield 200 A Air and O2
420735 Shield 130 A Air and O2
420732 Electrode 200 A Air and O2
420824 Electrode 130 A Air and O2
420734 Nozzle 200 A Air
420829 Nozzle 130 A Air
420733 Nozzle 200 A O2
420828 Nozzle 130 A O2

Standard MAXPRO200 retaining caps and swirl rings are compatible with extreme bevel consumables. Refer to the
extreme bevel cut charts that start on page132.

The standard MAXPRO200 water tube is not compatible with extreme bevel consumables. You must exchange it with the
longer water tube (420823) before cutting with extreme bevel consumables. Refer to Replace the torch water tube on
page 105.

Recommended torch-pivot lengths

The bevel-pivot point has an effect on the recommended torch-pivot length. The bevel-pivot point is the intersection of
the torch axis and the top of the workpiece when the torch is at its maximum angle and minimum clearance.

Using bevel consumables increases the recommended torch-pivot length by more than 100%, as shown in the following
drawing and table.

4 In this example, the torch-pivot length shows the

extreme-bevel consumables at 66.5 degrees and
3 5 at a clearance of 2 mm (0.080 in.).

1 Torch pivot length 4 Clearance

2 Maximum tilt angle 5 Bevel pivot point
3 Effective thickness

MAXPRO200 Instruction Manual 807700 129

Operation

Recommended torch-pivot lengths by product type

MAXPRO200 standard mechanized MAXPRO200 extreme bevel
consumables consumables
Torch-pivot length 30 mm (1.18 in.) 31 mm (1.24 in.) 62 mm (2.44 in.) 65 mm (2.55 in.)
Maximum torch angle 45 degrees 45 degrees 66.5 degrees 66.5 degrees
Clearance 2 mm (0.08 in.) 3 mm (0.125 in.) 2 mm (0.08 in.) 3 mm (0.125 in.)

Clearance
Clearance is the minimum distance between the torch and the top of the workpiece. A higher clearance can decrease the
chance of torch collisions with the workpiece. But, it can also cause the following conditions:

• Increased cut heights that give bad edge quality and make higher-angle compensations necessary
• Increased voltages that can have a bad effect on the duty cycle of the plasma power supply

Maximum torch angle

The maximum torch angle with extreme bevel consumables is 66.5 degrees at a clearance of 2 mm (0.080 in). Using a
maximum torch angle during bevel cutting increase the effective thickness of the workpiece being cut. For example, bevel
cutting a 12 mm (.50 inch) workpiece at a 60-degree angle is like cutting a 25 mm (1 inch) workpiece at a 90-degree
angle Refer to Effective thickness.

Hypertherm recommends using the default torch-clearance settings to start cutting. Adjust clearance settings only when
necessary.

Effective thickness
Effective thickness is directly related to the thickness of the workpiece and the angle of the torch. When cutting at an
angle, the thickness that the torch has to cut is increased.

Effective thickness 1 = Workpiece thickness 3

sin(a) 2

3
1
2
a

1 Effective thickness
2 Angle of the torch – sin(a)
3 Workpiece thickness

130 MAXPRO200 Instruction Manual 807700

 Operation

Effective thickness 1 = Wall thickness 3

sin(a) 2

1 a 2

* For pipe cutting, substitute “workpiece thickness” with “wall thickness” to calculate the effective thickness.

1 Effective thickness
2 Angle of the torch – sin(a)
3 Wall thickness

The table below shows how effective thickness change with different torch angles.

Effective thickness Torch angle

12 mm (.50 inch) 90 degrees
17 mm (.71 inch) 45 degrees
25.4 mm (1.00 inch) 60 degrees

You can calculate the effective thickness for any thickness and torch-angle combination with the following formula:

Effective thickness = Workpiece thickness / sin(a)

Hypertherm recommends that you use the thickness settings in the cut chart that are most similar to the effective
thickness that you want to cut. After cutting starts, adjust thickness settings only as necessary.

MAXPRO200 Instruction Manual 807700 131

Operation

Mild steel
Air Plasma / Air Shield
130 A Extreme Bevel Cutting

420735 220936* / 220935** 420829 220488 420824 420823

Metric

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22.9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm/min mm Factor % Seconds

3 142 3.0 5350 6.0 200 0.1

4 143 3.0 4630 6.0 200 0.2
6 146 2.4 3865 7.5 300 0.3
10 151 4.1 2445 8.2 200 0.5
68 69 70 71 22 24 26 28 12 153 4.1 2045 8.2 200 0.5
15 157 4.4 1445 8.8 200 0.8
20 163 4.6 815 9.6 210 1.2
25 170 4.6 415
Edge start
32 179 4.6 250

English

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
Lead in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead
0.135 145 0.120 220 0.240 200 0.1
0.1875 144 0.120 160 0.240 200 0.2
0.25 143 0.120 150 0.300 300 0.3
0.375 152 0.160 100 0.320 200 0.5
68 69 70 71 22 24 26 28 0.50 153 0.160 75 0.320 200 0.5
0.625 158 0.180 50 0.360 200 0.8
0.75 160 0.180 35 0.375 210 1.2
1.00 172 0.180 15
Edge start
1.25 178 0.180 10
*with IHS tab / **without IHS tab

132 MAXPRO200 Instruction Manual 807700

 Operation

Mild steel
O2 Plasma / Air Shield
130 A Extreme Bevel Cutting

420735 220936* / 220935** 420828 220529 420824 420823

Metric

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22.9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm/min mm Factor % Seconds

3 130 2.6 5900 5.2 200 0.1

4 131 2.7 5325 5.4 200 0.2
6 134 2.8 3925 5.6 200 0.3
10 136 3.0 2680 6.0 200 0.4
62 62 64 64 30 32 35 37 12 138 3.0 2200 6.0 200 0.5
15 140 3.6 1310 7.2 200 0.7
20 145 3.9 880 7.8 200 1.0
25 151 3.9 845
Edge start
32 158 3.9 365

English

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
Lead in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead
0.135 130 0.100 240 0.200 200 0.1
0.1875 132 0.110 190 0.220 200 0.2
0.25 134 0.110 150 0.220 200 0.3
0.375 136 0.120 110 0.240 200 0.3
62 62 64 64 30 32 35 37 0.50 138 0.120 80 0.240 200 0.5
0.625 141 0.150 50 0.300 200 0.7
0.75 144 0.150 35 0.300 200 1.0
1.00 151 0.150 18
Edge start
1.25 158 0.150 14
*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 133

Operation

Mild steel
Air Plasma / Air Shield
200 A Extreme Bevel Cutting

420737 220936* / 220935** 420734 220488 420732 420823

Metric

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22.9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm/min mm Factor % Seconds

6 137 1.0 4885 3.0 300 0.3

8 140 1.3 4515 3.9 300 0.5
10 142 3.0 3556 5.5 200 0.8
12 144 3.0 2794 6.0 200 0.9
15 147 4.3 2265 8.6 200 1.0
52 54 55 56 48 50 54 58 20 153 4.8 1415 9.6 200 1.4
25 159 6.4 940 11.4 180 1.7
32 167 6.4 630 11.4 180 2.3
38 174 6.4 510
44 180 6.4 320 Edge start
50 187 6.4 215

English

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
Lead in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead
.25 140 0.100 190 0.120 300 0.3
0.3125 139 0.100 180 0.150 300 0.5
0.375 138 0.100 140 0.200 200 0.8
0.50 142 0.130 110 0.250 200 0.9
0.625 149 0.190 85 0.380 200 1.0
0.75 152 0.190 60 0.380 200 1.2
52 54 55 56 48 50 54 58
0.875 156 0.190 50 0.380 200 1.4
1.00 165 0.250 35 0.450 180 1.7
1.25 166 0.250 25 0.450 180 2.3
1.50 171 0.250 20
1.75 181 0.250 12 Edge start
2.00 188 0.250 8
*with IHS tab / **without IHS tab

134 MAXPRO200 Instruction Manual 807700

 Operation

Mild steel
O2 Plasma / Air Shield
200 A Extreme Bevel Cutting

420737 220936* / 220935** 420733 220488 420732 420823

Metric

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
7.6 m 15.3 m 22.9 m 30.5 m 7.6 m 15.3 m 22.9 m 30.5 m
Lead Lead Lead Lead Lead Lead Lead Lead mm Volts mm mm/min mm Factor % Seconds

6 139 1.5 6210 3.0 200 0.3

8 143 3.4 4850 5.1 150 0.4
10 148 4.6 3735 6.9 150 0.5
12 146 3.8 3415 9.5 250 0.7
15 145 3.1 2845 7.8 250 0.9
68 69 70 71 48 50 54 58 20 146 3.0 1920 7.5 250 1.3
25 146 3.2 1430 8.0 250 1.6
32 153 3.1 805 8.9 280 2.5
38 160 4.4 570
44 166 4.4 395 Edge start
50 171 4.4 270

English

Effective Arc Cut Cut Pierce

Plasma Cutflow Shield Cutflow Pierce Height
Thickness Voltage Height Speed Delay
25 ft 50 ft 75 ft 100 ft 25 ft 50 ft 75 ft 100 ft
Lead in Volts in ipm in Factor % Seconds
Lead Lead Lead Lead Lead Lead Lead
.25 137 0.100 235 0.200 200 0.3
.375 151 0.190 150 0.280 150 0.5
0.50 147 0.140 130 0.280 200 0.5
0.625 147 0.120 105 0.280 250 0.9
.75 148 0.120 80 0.280 250 1.2
68 69 70 71 48 50 54 58 .875 148 0.130 65 0.280 250 1.4
1.00 148 0.130 55 0.310 250 1.6
1.25 155 0.130 32 0.350 280 2.5
1.50 161 0.180 22
1.75 168 0.180 15 Edge start
2.00 174 0.180 10
*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 135

Operation

Gouging

Mild steel
Air Plasma / Air Shield
200 A Gouging

420885 420794* / 420793** 420886 420883 420887 420881

Metric
Metal-
Torch Plasma Shield Arc Motion Included Bottom
Speed Standoff Width Depth Removal
Angle Pressure Pressure Voltage Delay Angle Radius
Rate
degree psi psi V mm/min mm seconds mm mm degree mm kg/hr
508 3.18 1.2 9.91 10.92 33 1.02 18.1
635 3.71 1.1 8.89 10.66 44 1.27 18.1
762 4.24 1.0 8.12 9.90 44 1.27 18.5
57.5 68 48 165 889 4.75 0.9 9.90 7.62 48 1.27 19.9
1016 5.28 0.8 9.39 6.85 54 1.52 19.5
1143 5.82 0.7 9.39 6.35 57 1.52 19.5
1270 6.10 0.6 9.14 5.33 72 1.77 16.7

English
Metal-
Torch Plasma Shield Arc Motion Included Bottom
Speed Standoff Width Depth Removal
Angle Pressure Pressure Voltage Delay Angle Radius
Rate
degree psi psi V in/min in seconds in in degree in lb/hr
20 0.125 1.2 0.39 0.43 33 0.04 40
25 0.146 1.1 0.35 0.42 44 0.05 40
30 0.167 1.0 0.32 0.39 44 0.05 41
57.5 68 48 165 35 0.187 0.9 0.39 0.30 48 0.05 44
40 0.208 0.8 0.37 0.27 54 0.06 43
45 0.229 0.7 0.37 0.25 57 0.06 43
50 0.250 0.6 0.36 0.21 72 0.07 37
*with IHS tab / **without IHS tab

136 MAXPRO200 Instruction Manual 807700

 Operation

Mild steel
O2 Plasma / Air Shield
200 A Gouging

420885 420794* / 420793** 420886 420883 420887 420881

Metric
Metal-
Torch Plasma Shield Arc Motion Included Bottom
Speed Standoff Width Depth Removal
Angle Pressure Pressure Voltage Delay Angle Radius
Rate
degree psi psi V mm/min mm seconds mm mm degree mm kg/hr
508 5.59 1.2 14.48 9.65 55 2.79 21.3
635 7.37 1.1 13.21 7.87 64 2.54 19.5
762 7.87 1.0 12.19 7.11 64 2.28 19.5
57.5 68 48 165 889 7.87 0.9 11.68 6.35 68 2.28 19.5
1016 7.87 0.8 10.41 5.58 68 2.28 18.1
1143 8.89 0.7 9.91 5.33 68 2.03 18.1
1270 8.89 0.6 9.39 5.08 68 2.03 18.1

English
Metal-
Torch Plasma Shield Arc Motion Included Bottom
Speed Standoff Width Depth Removal
Angle Pressure Pressure Voltage Delay Angle Radius
Rate
degree psi psi V in/min in seconds in in degree in lb/hr
20 0.22 1.2 0.57 0.38 55 0.11 47
25 0.29 1.1 0.52 0.31 64 0.10 43
30 0.31 1.0 0.48 0.28 64 0.09 43
57.5 68 48 165 35 0.31 0.9 0.46 0.25 68 0.09 43
40 0.31 0.8 0.41 0.27 68 0.09 40
45 0.35 0.7 0.39 0.21 68 0.08 40
50 0.35 0.6 0.37 0.20 68 0.08 40
*with IHS tab / **without IHS tab

MAXPRO200 Instruction Manual 807700 137

Operation

138 MAXPRO200 Instruction Manual 807700

 Section 4
Maintenance

Introduction
Hypertherm assumes that the service personnel performing the troubleshooting testing are high-level
electronic service technicians who have worked with high-voltage electro-mechanical systems. Knowledge
of final isolation troubleshooting techniques is also assumed.

In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.

CAUTION!

Use extreme care when working near the chopper modules. Each large electrolytic capacitor
(blue-cased cylinder) stores large amounts of electrical energy. Even if the power is off, dangerous
voltages may remain at the capacitor terminals, on the chopper, and the diode heatsinks. Never
discharge any capacitor with a screwdriver or other implement… explosion, property damage
and/or personal injury will result.

Preventive maintenance
For a complete list of preventive maintenance recommendations, see the MAXPRO200 Preventive Maintenance Program
Instruction Manual (808800). Contact the Technical Services department listed at the front of this manual with any
questions regarding the maintenance schedule or procedures.

MAXPRO200 Instruction Manual 807700 139

Maintenance

Power supply state

The state of the power supply is shown in the three digit display. To view the power supply state, navigate to the fault icon
and press and hold the current selection knob until the state appears.

State number Name

00 Power up

01 Initial checks

02 Gas purge

03 Ready for start

04 Preflow

05 Preflow hold

06 Ignite

07 Pilot arc

08 Rampup

09 Main arc

10 Rampdown

11 Rampdown complete

12 End of cycle

14 Shutdown

17 Standby

140 MAXPRO200 Instruction Manual 807700

 Maintenance

Sequence of operation and power supply state

Power up (state 00)
1. Initialization of microprocessor hardware.
2. Initialization of power supply, gas system, and display.
3. System will display dots on the current display.
4. System will look for shield gas button press to indicate USB host firmware update.
5. System will stay in this state until the rocker switch is turned on.

Initial checks (state 01)

1. System will turn on the plasma gas channel at 100% flow and will measure the pressure. The system will use this
value as the inlet pressure. If the inlet is above or below the minimum, the system will generate error code 63.
2. System will read the torch ID jumpers, and verify it’s a valid ID. If no torch ID is detected the system will generate
error code 99.
3. System will perform a chopper test, verifying there is no output.
a. Main contactor off (open), IGBTs off
• If there is current on channel A the system will generate error code 401
• If there is current on channel B the system will generate error code 402
• If there is current on both channels the system will generate error code 400
b. Main contactor on (closed), IGBTs off
• If there is current on channel A the system will generate error code 406
• If there is current on channel B the system will generate error code 407
• If there is current on both channels the system will generate error code 408
4. System will verify that there is
a. No transfer signal or the system will generate error code 108
b. No start signal or the system will generate error code 50
c. No coolant flow or the system will generate error code 109
5. System will verify that
a. Temperatures are above the minimum
• Chopper temperature is above minimum or the system will generate error code 300
• Transformer temperature is above minimum or the system will generate error code 301
• Inductor 1 temperature is above minimum or the system will generate error code 302
• Inductor 2 temperature is above minimum or the system will generate error code 303
• Coolant temperature is above minimum or the system will generate error code 304
b. Temperatures are below the maximum values.
• Chopper temperature is below maximum or the system will generate error code 65
• Transformer temperature is below maximum or the system will generate error code 67
• Inductor 1 temperature is below maximum or the system will generate error code 68
• Inductor 2 temperature is below maximum or the system will generate error code 69
• Coolant temperature is below maximum or the system will generate error code 71
6. After about 1 second the system will advance to state 2 (Gas purge) if there are no high priority errors (See Error
codes on page 147). If a high priority error is generated the system will go to state number 14 (Shutdown).

MAXPRO200 Instruction Manual 807700 141

Maintenance

Gas purge (state 02)

1. System turns on the plasma and shield gases.
2. System counts the time in seconds and this is displayed on the 3-digit current display.
3. System turns on the coolant pump.
4. After six seconds the system will verify the coolant flow is greater than the minimum value.
5. If the coolant flow is above the minimum the system will do a high power test on the chopper.
Note: the system is “live” at this time. The system is applying power to the torch even though no arc will
be present at the torch.
6. Chopper LEM Test
a. Main contactor closed, IGBTs on
• If there is no current on channel A the system will generate error code 409
• If there is no current on channel B the system will generate error code 410
• If there is no current on both channels the system will generate error code 408
b. Main contactor closed, IGBTs on
• If channel A current does not go to 0 the system will generate error code 411
• If channel B current does not go to 0 the system will generate error code 412
• If the current on both channels does not go to 0 the system will generate error code 413
c. Main contactor closed, IGBTs on
• Channel A current detected on channel B input the system will generate error code 415
• Channel B current detected on channel A input the system will generate error code 416
• Channel A current detected on channel B input and Channel B current detected on channel A input the
system will generate error code 414
d. Main contactor closed, IGBTs on
• Channel A current higher than expected: the system will generate error code 417
• Channel B current higher than expected: the system will generate error code 418
• Both channels current higher than expected: the system will generate error code 419
7. If the chopper test is successful and there are no other severe errors the system will advance to state 3 (Ready for
start), otherwise the system will go to state 14 (Shutdown).

Ready for start (state 03)

1. System is waiting for a plasma start signal.
2. System is monitoring the over-current signals, and over-temperature conditions.
• Chopper temperature in range or the system will generate error code 65
• Transformer temperature in range or the system will generate error code 67
• Inductor 1 temperature in range or the system will generate error code 68
• Inductor 2 temperature in range or the system will generate error code 69
• Coolant temperature in range or the system will generate error code 71
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
3. System is monitoring the pilot arc duty cycle to ensure it is less than 50%.
4. Diagnostic mode is active, the system will perform the function for the mode that is selected.
a. Test gas – the plasma and shield gases flow at a set value
b. Revision – the display will show the software revision

142 MAXPRO200 Instruction Manual 807700

 Maintenance

c. Plasma leak check – the plasma channel will be pressurized then the pressure trapped. The display on the power
supply control panel will show actual pressures. The system will remain in this state until commanded to another
test. The pressure in the plasma channel is expected to remain within 2 psi for a period of 5 minutes. The shield
gas channel is expected to drop to near 0 psi.
d. Test gas full pressure – plasma and shield gases flow at full pressure. Low pressure errors will be typical in this
mode as the system is attempting to achieve the maximum flow possible.
e. Torch ID – the display on the power supply control panel will show the torch ID
f. In-line valve test – the plasma channel will briefly pressurize, then the system will close the Burkert valve in the
power supply and open the in-line torch valve. The plasma pressure is expected to drop to near 0 psi (less than
5 psi), in less than 30 seconds.
5. If a plasma start signal is received and there are no temperature errors, the system will advance to state 4 – Preflow.

Preflow (state 04)

1. System will turn on plasma and shield gases.
2. System will verify gas pressures are above the minimum and below the maximum values.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will charge the surge injection circuit.
4. System will check for an over-current condition.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
5. After 1 second the system will advance to state 5 (Preflow hold).

Preflow hold (state 05)

1. System will continue running the plasma and shield gas until the hold signal is removed.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for an over-current condition.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. If the hold signal is active for more than 60 seconds, the system will generate error code 32.
5. When the hold signal is removed the system will advance to state 6 (Ignite).

MAXPRO200 Instruction Manual 807700 143

Maintenance

Ignite (state 06)

1. System will execute the ignition sequence by turning off the torch valve, then turning on the High Frequency. The
system will turn on the torch valve again, while continuing to activate the High Frequency.
2. The system will monitor for pilot arc current. If pilot arc current is not detected, the ignition sequence will be repeated
up to 5 times, after that the system will have error code 20 (Pilot arc fault) and advance to state 11 (Rampdown
Complete).
3. System will check for an over-current condition.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. If chopper current is detected during the sequence the system will advance to state 7 (Pilot Arc).

Pilot arc (state 07)

1. System will display actual gas pressures on the 2-digit pressure displays.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for over-current.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. System will check for minimum coolant flow. If it is below minimum the system will generate error code 93.
5. System will check for minimum chopper current. If it is below minimum the system will generate error code 24
(Lost Current Fault).
6. System will check for the arc transfer signal, once it is active the system will advance to state 8, (Rampup).
7. If the transfer signal in not present within 0.5 seconds (Mechanized) or 5.0 seconds (Hand torch) the system will
have error code 21 (Transfer fault) and advance to state 11 (Rampdown complete).

Rampup (state 08)

1. System will ramp up the current based on the process parameters.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure: the system will generate error code 44
• High plasma pressure: the system will generate error code 45
• Low shield pressure: the system will generate error code 53
• High shield pressure: the system will generate error code 54
3. System will check for over-current.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. Once the ramp up is finished the system will advance to state 9 (Main arc).

Main arc (state 09)

1. System will display actual current and pressures.
2. System will verify the gas pressures are within tolerance.
• Low plasma pressure and the system will generate error code 44
• High plasma pressure and the system will generate error code 45

144 MAXPRO200 Instruction Manual 807700

 Maintenance

• Low shield pressure: the system will generate error code 53

• High shield pressure: the system will generate error code 54
3. System will check for over-current.
• Chopper A over-current: the system will generate error code 134
• Chopper B over-current: the system will generate error code 138
4. System will check for minimum coolant flow, error code 93.
5. System will check the bus voltage (equivalent to Line voltage).
• Bus voltage high: the system will generate error code 5
• Bus voltage low: the system will generate error code 6
6. System will check for phase loss (error code 27).
7. System will check for over-temperature conditions.
• Chopper over temperature: the system will generate error code 65
• Transformer over temperature: the system will generate error code 67
• Inductor 1 over temperature: the system will generate error code 68
• Inductor 2 over temperature: the system will generate error code 69
• Coolant over temperature: the system will generate error code 71
8. System will check for lost chopper current – error code 24 (Lost Current Fault).
9. System will check for lost transfer – error code 26 (Lost Transfer Fault).
10. If the plasma start signal is removed the system will advance to state 10 (Rampdown).

Rampdown (state 10)

1. System will shut off the plasma and shield gases.
2. System will rampdown the current.
3. When the system reaches the final current, it will advance to state 11 (Rampdown Complete).

Rampdown complete (state 11)

1. Ensure all power supply outputs are off except the main contactor.
2. Advance to state 12 (End of Cycle).

End of cycle (state 12)

1. Turn on plasma and shield gases for postflow.
2. System will verify coolant flow is above the minimum (error code 93).
3. System will verify the plasma start signal is off.
4. Once the plasma start signal is off the system will advance to state 3 (Ready for start).

Shutdown (state 14)

1. System will turn off all power supply, coolant, and gas outputs.

Standby (state 17)

1. If the rocker switch is turned off the system will enter the standby state.
2. When the rocker switch is turned on the system will advance to state 0 (Power up).

MAXPRO200 Instruction Manual 807700 145

 Block diagram

146

Block diagram
Maintenance
Sensor THC
(Sensor PHC)
CNC

2 3 4
Control board PCB1
Plasma interface board
(optional)

7
11 12
5 8
6 9 10

Plasma valve

13 15
14 16
17
MAXPRO200 Instruction Manual 807700

Chopper board PCB2

18
I/O Board
19 PCB3
20

1 CNC interface cable 6 Chopper temperature 11 Machine interface cable 16 Chopper A output
2 Torch valve 7 PWM A and PWM B 12 Arc voltage 17 Chopper B output
3 Trigger switch (hand torch) 8 Pilot arc enable 13 Chopper A current 18 Work lead
4 Lead length ID 9 High frequency enable 14 Chopper B current 19 Pilot arc collector
5 Bus voltage 10 Transfer 15 Chopper power 20 Pilot arc emitter
 Maintenance

Error codes
When the fault indicator is illuminated the error code number can be seen in the three digit display.

There are three general types of error codes:

• Self clearing – An over temperature error, for example, will clear when the power supply cools off.
• Low priority – The user must select the fault icon and press the current selection knob to see the error
code. This type of error can be cleared with the start signal.
• High priority – The system will automatically select the fault icon and show the error code. This type of
error requires the power to the system to be turned off and then on again, after the cause of the error
has been corrected.

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 amperage (A)
5 icon and turning the knob. The current increases or decreases in 1 A
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 more 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.
The plasma start LED illuminates white when the plasma start signal
6 Plasma start
is given and stays illuminated until the start signal is removed.
The arc transfer LED illuminates green when the arc transfers to the
7 Arc transfer
workpiece.

MAXPRO200 Instruction Manual 807700 147

Maintenance

Diagnostic functions
Press and release the current selection knob until the Test icon in the 3-digit display is selected. Turn the current
selection knob to access the functions shown in the table below. The function activates when the function number
appears in the 3-digit display.

Function Description
000 No function. Gases will stop flowing if the system was in another test mode.
001 Flow gas at set pressure. Plasma and shield gases flow at the set value.
002 Display software revision. Shows the current software revision of the power supply.
Plasma gas leak check. The plasma channel is pressurized and the pressure trapped. The 3-digit display shows the
actual pressure. The system remains in this state until you select another function or return to cutting. The pressure
003
in the plasma channel should remain stable (+/- 2 psi) for 5 minutes. The shield gas channel should drop to near
zero psi (less than 5 psi).
Flow gas at full pressure. The plasma and shield gases flow at full pressure. It is typical to see low pressure errors
004 during this function because the system is attempting to achieve the maximum flow possible. Function 4 is used
when setting the supply gas regulators.
005 Display torch ID. The torch ID indicates the lead length that is connected to the system.
In-line valve check. The plasma channel is pressurize, the system closes the Burkert valve and opens the in-line
006
torch valve. The plasma pressure is expected to drop to near zero psi (less than 5 psi) in less than 30 seconds.

148 MAXPRO200 Instruction Manual 807700

 Maintenance

Troubleshooting table
Number Name Description Corrective action
000 No Error System is ready to run None
Verify the line voltage at the control transformer and
the fuses on the control board.
The chopper bus voltage should be 360 VDC
Line voltage is close to or less than nominal.
the lower limit of 102 VAC (120 VAC 1. If the voltage is good, use a multimeter to measure
005 Low line voltage -15%). The normal lower limit for across TP102 (gnd) and TP 111 (isolated bus
operation is 108 VAC (120 VAC voltage) on the chopper.
-10%). 2. If the voltage is 2.1 VDC nominal, replace the
control board.
3. If the voltage is 0 VDC or 5 VDC, replace the
chopper.
Line voltage is close to or greater than
the upper limit of 138 VAC (120 VAC
Verify the line voltage at the control transformer and
006 High line voltage +15%). The normal upper limit for
the fuses on the control board.
operation is 132 VAC (120 VAC
+10%).
1. Verify that the correct consumable parts are
installed and in good condition.
2. Perform the gas checks (See Control board on
page 164).
No current detected from chopper at 3. Verify that there is spark across spark gap.
020 No pilot arc
ignition and before 1-sec timeout 4. Inspect CON1 for excessive wear.
5. Perform the torch lead test (See Torch lead test on
page 175).
6. Perform the start circuit test (See Start circuit
troubleshooting on page 169).
For a machine torch, no current 1. Verify proper transfer/pierce height.
detected on work lead 500-msec after 2. Verify proper cutflow settings.
pilot arc current was established. 3. Inspect the work lead for damage or loose
021 No arc transfer
For a hand torch, no current detected connections.
on work lead 5-sec after pilot arc 4. Perform the torch lead test (See Torch lead test on
current was established. page 175).
1. Verify that the correct consumable parts are
installed and in good condition.
2. Verify proper cutflow gas settings.
Lost current from chopper after 3. Verify the pierce height setting.
024 Lost current on chopper
transfer 4. Verify the pierce delay time.
5. Verify that the arc did not lose contact with the
workpiece while cutting (hole cutting, scrap
cutting, etc.).
1. Verify that the correct consumable parts are
installed and in good condition.
2. Verify proper cutflow gas settings.
3. Verify the pierce height setting.
4. Verify pierce delay time.
Lost the transfer signal after transfer 5. Verify that the arc did not loose contact with the
026 Lost transfer
completed. workpiece while cutting (hole cutting, scrap
cutting, etc.).
6. Inspect the work lead for damage or loose
connections.
7. Try connecting the work lead directly to the
workpiece.

MAXPRO200 Instruction Manual 807700 149

Maintenance

Number Name Description Corrective action

1. Verify phase-to-phase voltage to power supply.
2. Disconnect power to power supply, remove cover
on contactor and inspect contacts for excessive
Phase imbalance to chopper after wear.
027 Lost phase
contactor engaged or while cutting 3. Inspect power cord, contactor, and input to
chopper for loose connections.
4. Perform phase loss test. See Phase loss detection
on page 174.
1. Check the interface cable for damage. The hold
wires may be short-circuiting inside.
2. The CNC is maintaining this input, it could be
Hold signal was active for longer than
032 Hold timeout waiting for an IHS complete input from another
60 seconds
torch.
3. If the CNC interface cable is good and it is a
1-torch system, change the control board.
1. Inspect gas supply pressure and volume of gas
remaining in supply tanks.
2. Verify the gas settings on the front panel with the
parameters in the cut charts.
Plasma gas pressure is less than 25%
044 Low plasma gas pressure 3. See Setting the supply gas regulators on page 74.
of the set (desired) value
4. Perform the Flow gas at set pressure test (001),
and verify the gas settings on the front panel with
the parameters in the cut charts. See Control
board on page 164.
1. Verify gas supply pressure settings.
2. Perform the Flow gas at set pressure test (001),
and verify the gas settings on the front panel with
the parameters in the cut charts. See Control
High plasma gas Plasma gas pressure is greater than
045 board on page 164.
pressure 25% of the set (desired) value
3. See Setting the supply gas regulators on page 74.
4. The In-line valve may not be opening. Perform the
Plasma leak check (003) and the in-line valve
check (006). See Control board on page 164.
1. If a mechanical relay is being used to provide the
system with a start signal, this relay is either
bouncing when activated or the contacts are
faulty. Replace the relay.
2. Inspect the interface cable for damage; faulty
crimps, or poor electrical connections.
Start signal was received and then 3. If the interface cable is good and a relay is not
Start lost/Start at lost before an arc was established/ driving the start input, the CNC is dropping the
050
Initialization Start signal was applied when power start signal before a steady state arc has been
was applied to the system established.
4. Remove the start signal from the CNC or THC
and turn the system on again.

NOTE: It is normal to see an 050 error when cutting

with the hand torch if the start signal is removed
before the pilot arc time (5 seconds) has expired.
1. Allow the power supply to idle with the fans
running for 10 seconds.
051 Pilot Arc Over-temp Maximum pilot arc duration exceeded
2. Verify that the pierce height is correct.
3. Minimize pilot arcing off the workpiece.

150 MAXPRO200 Instruction Manual 807700

 Maintenance

Number Name Description Corrective action

1. Verify gas supply pressure and that sufficient gas
remains in your supply.
2. Perform the Flow gas at set pressure test (001),
Shield gas pressure is less than 25%
053 Low shield gas pressure and verify the gas settings on the front panel with
of the set (desired) value
the parameters in the cut charts. See Control
board on page 164.
3. See Setting the supply gas regulators on page 74.
1. Check for a restriction or dross on the shield cap
2. Perform the Flow gas at set pressure test (001),
and verify the gas settings on the front panel with
Shield gas pressure is 25% greater
054 High shield gas pressure the parameters in the cut charts. See Control
than the set (desired) value
board on page 164.
3. Verify that the pressure transducers are providing
the system with the proper pressures.
1. Verify that the correct consumables are properly
Coolant flow is less than the required installed.
060 Low coolant flow
2.3 lpm (0.6 gpm) 2. Perform the coolant flow test procedure. See
Coolant flow test on page 160.
Inlet pressure measured was greater Verify that the input pressures at the regulators are in
063 Inlet Pressure Fault
than 135 or less than 40 psi range.
1. Verify that the heat exchanger fan is spinning.
2. Blow dust out the heat exchanger with
compressed air to clean off the fins.
3. Verify that the level of coolant is at the proper
height.
4. Verify that the coolant mixture is correct
Chopper over-temp at Chopper is indicating an over-temp at
065 (% propylene glycol). A mixture with a high
power-up power-up
percentage of propylene glycol will have a lower
cooling capacity.
5. Change the consumables. Older consumables
emit more heat into the cooling loop.
6. Verify the pump flow rate. If it is less than 2.3 lpm
(0.6 GPM) troubleshoot the low flow rate issue.
1. Verify that the magnetics fan is operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of the system especially from fans
and the main transformer.
3. If voltage is low or near 0 VDC, inspect wiring
between the transformer’s temperature sensor and
067 Magnetics over temp Main transformer has over heated
J1.12, pins 1 and 2 on the control board. Look for
shorts between wires or to ground.
4. If wiring is good, the transformer has overheated.
Allow the power supply to idle with the fans
running for a minimum of 30 minutes to cool the
main transformer.

MAXPRO200 Instruction Manual 807700 151

Maintenance

Number Name Description Corrective action

1. Verify that the magnetics fan is operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of the system especially from fans
and inductors.
3. If voltage is low or near 0 VDC, inspect wiring
between inductor A’s temperature sensor and
068 Inductor A over temp Inductor has over heated
J1.12, pins 4 and 5 on the control board. Look for
shorts between wires or to ground.
4. If wiring is good, the inductor has overheated.
Allow the power supply to idle with the fans
running for a minimum of 30 minutes to cool the
inductors.
1. Verify that the magnetics fan is operating properly.
Spinning fan blades should be difficult to see.
2. Blow dust out of the system especially from fans
and inductors.
3. If voltage is low or near 0 VDC, inspect wiring
between inductor B’s temperature sensor and
069 Inductor B over temp Inductor has over heated
J1.12, pins 7 and 8 on the control board. Look for
shorts between wires or to ground.
4. If wiring is good, the inductor has overheated.
Allow the power supply to idle with the fans
running for a minimum of 30 minutes to cool the
inductors.
1. Verify that the heat exchanger fan is spinning.
2. Blow dust out the heat exchanger with
compressed air to clean off the fins.
3. Verify that the level of coolant is at the proper
height.
4. Verify that the coolant mixture is correct
(% propylene glycol). A mixture with a high
percentage of propylene glycol will have a lower
071 Coolant over temp Torch coolant has overheated
cooling capacity.
5. Change the consumables. Older consumables
emit more heat into the cooling loop.
6. Verify the pump Flow rate. If it is less than 0.5 gpm
troubleshoot the low flow rate issue.
7. Replace the coolant temperature sensor if it is
open or shorted. Replacement part number is
229474.
1. Verify that the level of coolant is at the proper level.
2. Verify that the coolant filter is in good condition.
replace if necessary.
3. The pump motor may have reached its internal
Coolant flow was below 1.9 lpm
thermal trip point. Make sure the side panel is
(0.5 gpm) while the system was
093 No coolant flow installed, for proper airflow, and that the heat
running or the coolant flow was below
exchanger fan is working properly.
1.7 lpm (0.45 gpm) while cutting.
4. Perform the coolant flow test. See Coolant flow
test on page 160.
5. See the corrective actions for the low coolant flow
error (60).
1. Verify that the torch connection by the I/O panel
Torch or torch ID jumper missing or
097 No Torch Found (CPC plug) is good.
installed incorrectly
2. Verify the pin out on the torch lead connection.

152 MAXPRO200 Instruction Manual 807700

 Maintenance

Number Name Description Corrective action

1. Turn OFF the line power to the system. Check the
wiring between the control board and the chopper
for damaged wires and proper connections and
A fault was detected on channel A of
102 Current Sensor A Fault then turn ON the line power again so the
the chopper
automatic diagnostic checks will run.
2. If the error changes to a 409 error replace the
chopper assembly.
1. Verify that the chopper PCB is functioning
properly by checking the LEDs on the board
against the LED list in the Maintenance section.
The system has detected current on See Start circuit troubleshooting on page 169.
108 Transfer at power-up
the work lead during power-up 2. Replace the chopper PCB if connections are
correct and not damaged.
3. Verify that the main contactor (CON1) is not
welded closed, or closing at power-up.
1. Verify that the shield cap is properly installed. A
loose shield cap can allow shield gas to get into
the coolant, and cause a coolant flow error.
Coolant flow measured during 2. Verify that the torch lead connections are good.
Coolant Flow At
109 power-up and before pump motor has 3. Turn off the power to the system, wait 30 seconds,
power-up
been turned on. and turn the power back on. Sometimes if you turn
the power off and then on too quickly it may cause
a 109 error.
4.
1. Verify that the chopper PCB is functioning
properly by checking the LEDs on the board
against the LED list in the Maintenance section.
2. Turn off the power to the system and then turn it
Chopper A current exceeded on again to verify that the system passes the initial
134 Chopper A over current
maximum power up test.
3. Verify the current output on J2.1 white to black
(4 VDC=100 A).
4. If the wiring is good, the IGBT may have failed.
Replace the chopper assembly.
1. Verify that the chopper PCB is functioning
properly by checking the LEDs on the board
against the LED list in the Maintenance section.
See Start circuit troubleshooting on page 169.
2. Turn off the power to the system and then turn it
Chopper B current has exceeded
138 Chopper B over current on again to verify that the system passes the initial
maximum
power up test.
3. Verify the current output on J2.6 white to black
(4 VDC=100 A).
4. If the wiring is good, the IGBT may have failed.
Replace the chopper assembly.
1. Check to make sure the shield cap is properly
installed. A loose shield cap can allow shield gas
Coolant flow rate has exceeded
161 High coolant flow rate to get into the coolant, and cause this error.
maximum
2. Check to make sure the consumables are installed
properly and are not damaged.

MAXPRO200 Instruction Manual 807700 153

Maintenance

Number Name Description Corrective action

1. Turn OFF the power to the system. Check the
wiring between the control board and the chopper
for damaged wires and proper connections and
A fault was detected on channel B of
190 Current Sensor B Fault then turn ON the power again so the automatic
the chopper
diagnostic checks will run.
2. If the error changes to a 410 error replace the
chopper assembly.
1. Verify that the red and black wires on chopper J2.8
The temperature reading was are plugged into the control board at J1.22.
Temp sensor unplugged
300 unexpectedly low, possibly indicating 2. Verify the cold workpiece temperature sensor
Chopper
the sensor is unplugged wires are plugged into the chopper at J2.9 (10K
ohm nominal).
The temperature reading was
Temp sensor unplugged Verify the electrical connection back to the control
301 unexpectedly low, possibly indicating
Transformer board at J1.12 pins 1-2 (10K ohm nominal).
the sensor is unplugged
The temperature reading was
Temp sensor unplugged Verify the electrical connection back to the control
302 unexpectedly low, possibly indicating
Inductor 1 board at J1.12 pins 4-5 (10K ohm nominal).
the sensor is unplugged
The temperature reading was
Temp sensor unplugged Verify the electrical connection back to the control
303 unexpectedly low, possibly indicating
Inductor 2 board at J1.12 pins 7-8 (10K ohm nominal).
the sensor is unplugged
The temperature reading was
Temp sensor unplugged Verify the electrical connection back to the control
304 unexpectedly low, possibly indicating
Coolant board at J1.18 pins 6-7 (10K ohm nominal).
the sensor is unplugged
1. Verify that the contactor is not welded shut or
always ON.
Current sensor A and During the chopper test, current was
2. Verify that there is no DC output on the I/O board
400 Current sensor B current detected on channel A and on channel
from the Torch to Work connections. If DC output
with contactor off B when no current was expected
is found, replace the chopper.
3. Verify that the LED for PWM is not active.
1. Verify that the contactor is not welded shut or
always ON.
During the chopper test, current was
Current sensor A current 2. Verify that there is no DC output on the I/O board
401 detected on channel A when no
with contactor off from the Torch to Work connections. If DC output
current was expected
is found, replace the chopper.
3. Verify that the LED for PWM is not active.
1. Verify that the contactor is not welded shut or
always ON.
During the chopper test, current was
Current sensor B current 2. Verify that there is no DC output on the I/O board
402 detected on channel B when no
with contactor off from the Torch to Work connections. If DC output
current was expected
is found, replace the chopper.
3. Verify that the LED for PWM is not active.
Current sensor A and 1. Verify that the LED for PWM is not active.
During the chopper test, current was
Current sensor B current 2. Verify that there is no DC output on the I/O board
405 detected on channel A and on channel
with contactor on and from the Torch to Work connections. If DC output
B when no current was expected
PWM off is found, replace the chopper.
1. Verify that the LED for PWM is not active.
Current sensor A current During the chopper test, current was
2. Verify that there is no DC output on the I/O board
406 with contactor on and detected on channel A when no
from the Torch to Work connections. If DC output
PWM off current was expected
is found, replace the chopper.
1. Verify that the LED for PWM is not active.
Current sensor B current During the chopper test, current was
2. Verify that there is no DC output on the I/O board
407 with contactor on and detected on channel B when no
from the Torch to Work connections. If DC output
PWM off current was expected
is found, replace the chopper.

154 MAXPRO200 Instruction Manual 807700

 Maintenance

Number Name Description Corrective action

1. Verify the output voltage from the contactor.
2. Verify the DC voltage on both bridges of the
Chopper.
With choppers active, no
3. Verify the DC output on the I/O board for each
current on Current
No current detected on channel A and chopper test.
408 sensor A and Current
channel B when current was expected 4. Verify that the 10 Ohm resistor on the I/O board is
sensor B during chopper
not damaged.
test
5. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
6. Replace the chopper.
1. Verify the output voltage from the contactor.
2. Verify the DC voltage on Chopper.
3. Verify the DC output on the I/O board for each
With choppers active, no
chopper test.
current on Current No current was detected on channel A
409 4. Verify that the 10 Ohm resistor on the I/O board is
sensor A during chopper when current was expected
not damaged.
test
5. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
6. Replace the chopper.
1. Verify the output voltage from the contactor.
2. Verify the DC voltage on Chopper.
3. Verify the DC output on the I/O board for each
With choppers active, no
chopper test.
current on Current No current was detected on channel B
410 4. Verify that the 10 Ohm resistor on the I/O board is
sensor B during chopper when current was expected
not damaged.
test
5. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
6. Replace the chopper.
Current detected for
longer than expected on Current on channel A and channel B Verify that the surge circuit on the I/O board is
411
Current sensor A and did not return to 0 as expected functioning properly.
Current sensor B
Current detected for
Current on channel A did not return to Verify that the surge circuit on the I/O board is
412 longer than expected on
0 as expected functioning properly.
Current sensor A
Current detected for
Current on channel B did not return to Verify that the surge circuit on the I/O board is
413 longer than expected on
0 as expected functioning properly.
Current sensor B
Current sensor A and Current from output A was detected
414 Current sensor B signals on channel B and output from channel Verify that the current sensor wiring is not crossed.
crossed B was detected on channel A
Current detected on
Current sensor B when Current from output A was detected
415 Verify that the current sensor wiring is not crossed.
expected on Current on channel B
sensor A

MAXPRO200 Instruction Manual 807700 155

Maintenance

Number Name Description Corrective action

Current detected on
Current sensor A when Current from output B was detected
416 Verify that the current sensor wiring is not crossed.
expected on Current on channel A
sensor B
1. Verify that the 10 Ohm resistor on the I/O board is
Current too high on Current exceeded the maximum not damaged.
417
Current sensor A expected value on channel A 2. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
1. Verify that the 10 Ohm resistor on the I/O board is
Current too high on Current exceeded the maximum not damaged.
418
Current sensor B expected value on channel B 2. Disconnect any exterior equipment from the I/O
Board (Example: Arc Voltage connection).
1. Verify that the 10 Ohm resistor on the I/O board is
Current too high on Current exceeded the maximum
not damaged.
419 Current sensor A and expected value on channel A and
2. Disconnect any exterior equipment from the I/O
Current sensor B channel B
Board (Example: Arc Voltage connection).

156 MAXPRO200 Instruction Manual 807700

 Maintenance

Initial checks
Before trouble-shooting, do a visual check and verify that proper voltages are present at the power source, transformers
and power distribution board.

DANGER!
ELECTRIC SHOCK HAZARD

Always use caution when servicing a power supply when plugged in and the covers are removed.
Dangerous voltages exist within the power supply which could cause injury or death.

1. Disconnect line power by turning OFF the main disconnect switch.

2. Remove the power supply’s top panel and 2 side panels.
3. Inspect interior of power supply for discoloration on PC boards, or other apparent damage. If a component or module
is obviously defective, replace it before doing any testing. Refer to the Parts List section to identify parts and part
numbers.
4. If no damage is apparent, connect power to the power supply, and turn ON the main disconnect switch.
5. Measure the voltage between the L1, L2 and L3 terminals of TB1 located on the left side of the power supply. See
figure on next page. Also refer to the wiring diagram in Section 7, if required. The voltage between any 2 of the 3
terminals should be equal to the supply voltage. If there is a problem at this point, disconnect main power and check
all connections, the power cable, and fuses at the line disconnect switch. Repair or replace any defective component.

MAXPRO200 Instruction Manual 807700 157

Maintenance

Power measurement

DANGER!
ELECTRIC SHOCK HAZARD

There is line voltage at the contactor when the main disconnect switch is on. Use extreme care when
measuring primary power in these areas. Voltages present at the terminal block and contactors can
cause injury or death.

4 3
2

1
1 Ground
2 L1
3 L2
4 L3

Check the lines in the following order:

• L1 to L2
• L1 to L3
• L2 to L3
Check each line to ground. If one line is 10% or higher than the other two, put that leg on L1.

158 MAXPRO200 Instruction Manual 807700

 Maintenance

Power supply coolant system servicing

Draining the coolant system
1. Turn OFF the power and remove the right side panel from the power supply.

2. Locate the coolant drain valve and use a 20 liter (5 gallon) container to catch the coolant. Coolant will flow as
soon as the drain is opened. Close the drain valve when the coolant stops flowing. Always dispose of coolant
according to local and national codes.

MAXPRO200 Instruction Manual 807700 159

Maintenance

Coolant flow test

The control board receives an electrical signal in Hz from the flow sensor, that is converted and shown as flow in gallons
per minute (gpm). Normal flow is 4.5 lpm (1.2 gpm), but this will vary depending on lead lengths and whether the power
is 50 Hz or 60 Hz. PCB4 will allow the system to operate if the coolant flow is 1.9 lpm (0.5 gpm) or greater. If the system
shows a coolant flow error (093) the system will need to be turned OFF and then ON again and the following test needs
to be performed to determine if the problem is coolant flow or the flow switch.

1. Turn OFF the power, and remove the right-side panel from the power supply.

2. Remove the return hose at the top of the coolant tank. Push the connector-collar toward the fitting, and pull the hose
away from the fitting This will release the coolant hose. No tools required. Put the end of the return hose into a 4 liter
(1 gallon) container.

160 MAXPRO200 Instruction Manual 807700

 Maintenance

3. You will need to enable the flow function before the count reaches 5 in the 3-digit display. Turn ON the power and
press and release the current knob twice until the flow function is enabled. Turn OFF the power after the coolant
flows for 30 seconds.

4. Measure the amount of coolant in the container. There should be about 2 liters (0.5 gallon). If there is less than 1 liter
(0.25 gallon) there may be a restriction in the coolant system or a problem with the pump or flow sensor.
5. Verify the flow sensor output by measuring the flow output (in frequency) at the control board. Measure the
Frequency on J21 pin 3 (pulse) and pin 2 (ground). Once you have the frequency use the chart below to get the flow
sensors measured flow rate. If this number differs more than 0.8 lpm (0.2 gpm) from your bucket test, the flow sensor
may need to be replaced.
Note: The 3-digit display shows actual coolant flow. You can compare that measurement to the measurement
you get in step 5 to troubleshoot for a PCB problem.

1.4

1.2

1
Flow rate (gpm)

0.8

0.6

0.4

0.2

0
0 20 40 60 80 100 120 140
Measured frequency

MAXPRO200 Instruction Manual 807700 161

Maintenance

CAUTION!

Coolant will flow from the filter when the housing is removed.
Drain coolant before replacing the filter.

Coolant system filter replacement

1. Make sure the coolant has been drained from the system, then turn OFF all power to the system.
2. Remove the filter housing. Make sure the o-ring inside the filter housing remains in place.
3. Remove and discard the filter element.
4. Install the new filter element 027005.
5. Make sure the o-ring is properly installed before re-installing the housing.
6. Refill the power supply with coolant. See Fill the power supply with coolant on page 69.

162 MAXPRO200 Instruction Manual 807700

 Maintenance

Air filter element replacement

1. Disconnect the electrical power and the gas supply and

remove the filter bowl and the old filter element.
a. Pull down and hold the black release tab.
b. Rotate the filter bowl in either direction until it
releases.
c. Pull the filter bowl down to remove it. The bowl has
an o-ring around the top. Do not discard the o-ring.
A
If the o-ring needs to be replaced, use part number
011105. B

2. Turn the plastic disk under the filter element

counter-clockwise about 1/4 turn and remove the old
filter element. Install the new filter element 011093.

3. Re-install the filter bowl.

a. Hold down the black tab and slide the filter bowl
over the new filter element.
b. Rotate the filter bowl until it locks in place.

MAXPRO200 Instruction Manual 807700 163

Maintenance

Control board
Control board LED list
LED Description LED Description
D1 Torch ID 0 D46 High frequency ignition (ON = HF circuit active)
D2 Torch ID 1 D51 Contactor output (ON = contacts closed)
D3 Torch ID 2 D61 Torch valve driver error (ON = error)
D4 Torch ID 3 D62 Torch valve driver OK (ON = 24V power is OK)
D6 CNC start signal (ON = active) D64 Not used
Transfer detect (ON = 3.5A or more detected on the
D9 Hold input (ON = active) D65
work lead)
D12 Motion output D68 Coolant flow input (pulses from flow sensor)
D14 Error output D70 Pump enable (ON = pump motor active)
D15 Hold output D71 Serial communications TX
D16 CAN RX D96 USB BUS voltage error flag
D17 CAN TX D100 Over current on chopper B (ON = overcurrent)
D26 +15/-15V voltage indicator D101 Chopper A PWM
D31 Fused side of 240VAC input power D102 Chopper B PWM
D33 +3.3V voltage indicator D103 Pilot arc enable
D35 Overcurrent on chopper A (ON = overcurrent) D104 Plasma valve PWM
D37 +5V voltage indicator D105 Shield valve PWM
D40 +24V voltage indicator D106 Torch valve enable
D41 Fused side of 120VAC input power D107 Not used
D42 240V input detection (ON = 240VAC input detected) D111 Serial communications RX
D44 120V input detection (ON = 120VAC input detected)

Control board test points

Test Test
Description Description
point point
TP1 +15V TP18 +5V regulated
TP2 Analog 3.3V TP19 +5V unregulated (should be 7V or higher)
TP3 Signal ground TP20 +24V
TP4 +3.3V TP21 Not used
TP5 -15V TP22 Serial communications RX
TP6 PWM channel A (5V) TP23 CNC start +
TP7 PWM channel B (5V) TP24 CNC start -
TP8 Pilot arc enable (5V) TP25 Serial communications TX
TP9 Shield valve output (24V) TP26 15VAC power output to chopper
TP10 Plasma valve enable (5V) TP27 Inductor 2 temp input (analog 3.3V)
TP11 Shield valve enable (5V) TP28 Inductor 1 temp input (analog 3.3V)
TP12 Plasma valve output (24V) TP29 Main transformer temp input (analog 3.3V)
TP13 Plasma valve enable TP30 Multiplexed transformer and inductor temps input
TP14 Digital logic ground TP31 +24V (same connection as TP20)
TP15 Power ground TP32 Spare input not used (analog 3.3V)
TP16 Analog/signal ground TP33 Plasma pressure input (analog 5V)
TP17 Pump motor enable (5V) TP34 Shield pressure input (analog 5V)

164 MAXPRO200 Instruction Manual 807700

 J19 J3
J19 J3
BAT1 1 1
TP43
TP34 BAT1

J9 J9
D96
1
141171 REV H

+
D31
J13
SHIELD

240VAC IN
J13

SERIAL NUMBER
J11

CM LABEL D41
PLASMA

120VAC IN
J11

1
TP33
TP33

1
1
J18 J18

+24V
+24V

D40
1

1
J8
J15

J8
J15

TP17 PUMP D70

TP2 A3.3V
TP2 A3.3V PUMP TP17

J14
J14
240VAC OUT
240VAC OUT
J1
J12

1
J12

TP27
TP30 D33 D42
TP30 TP27 +3.3V
+3.3V
TP28 TP29
TP29 TP28

TP16 U56
TP16

CNTOR
CNTOR
1
TP32 1
TP19 D51
+5VUN
TP32

1
TP19 D46
FIRMWARE
TP14 LABEL
TP14

HF
HF
U3 TP4 +3.3V
+3.3V
J20 TP4 120VAC OUT
+5V 120VAC OUT
D37 +5V
D111
D44
J7

FIRMWARE
CANRX

LABEL
J7

TP20 +24V
CANTX

D35 D100 +24V

D17 D16 OCA OCB TP20
TX OCA OCB
TP25 TP18 +5V
TP25 TX TP18 +5V
+ TCHVLV - SH PL PA PWMB PWMA
- TCHVLV +
TP13 TP21 SH
TP11 PL
TP10 PA
TP8 PWMBTP7 PWMA TP6
TP13 TP21 TP11 TP10 TP8 TP7 TP6

TP22
J5

TP22
D71 RX
J5

J4

RX TP5 -15V

D103

D102

D101
-15V TP5

D104
D105
D107

D106
D12
D15

D14
HLDO
HLDO MOTN
MOTN ERR
ERR
5

PWRGND D26
9

PWRGND
TP15 +/-15V
D68
TP15 TP1
D65
+15V
D9 +15V TP1
+24V
+24V
6

TP31
HLDI

TP31
FLAG
FLAG
START
START TID0
TID0 TID1TID1 TID2
TID2 TID3
TID3
TP3

TP26
TP26
1 TP3
D6 D1 D2 D3 D4
D61 D64 15VAC
PGOKPGOK

OKFLG
OKFLG SHVLV PLVLV
TP23 TP24
TP24
SHVLV
TP23
PLVLV
D62
1
TP9
TP9 TP12
1 J16 1
1 J21
J6
J6
J2
J2 J16 J21 1 J22
J22
J17
J17

165
166
 Maintenance

Gas leak tests

Note: See Diagnostic functions on page 148 for details about getting to the gas test functions
Function Description
001 Flow gas at set pressure. Plasma and shield gases flow at the set value.
003 Plasma gas leak check. The plasma channel is pressurized and the pressure trapped. The 3-digit display shows the
actual pressure. The system remains in this state until you select another function or return to cutting. The pressure
in the plasma channel should remain stable (+/- 2 psi) for 5 minutes. The shield gas channel should drop to near
zero psi (less than 5 psi).
004 Flow gas at full pressure. The plasma and shield gases flow at full pressure. It is typical to see low pressure errors
during this function because the system is attempting to achieve the maximum flow possible. Function 4 is used
when setting the supply gas regulators.
006 In-line valve check. The plasma channel is pressurized, the system closes the Burkert valve and opens the in-line
torch valve. The plasma pressure is expected to drop to near zero psi (less than 5 psi) in less than 30 seconds.

MAXPRO200 Instruction Manual 807700 167

Maintenance

Start circuit
Operation
The start circuit is a high-speed switch that quickly transfers the pilot arc current from the pilot arc lead to the work lead.
the start circuit is built into the chopper in the MAXPRO200. The start circuit performs 2 functions:

1. It allows the initial pilot arc current to flow through the pilot arc lead quickly, with little impedance.
2. After initial pilot arc current is established, the start circuit introduces impedance to the pilot arc lead to aid in
transferring the arc to the workpiece. See schematic below.

Start circuit functional schematic

Plasma power supply

1 2

5
4 7
3 6

Number Description
1 Chopper
2 Choke
3 Power supply control board
4 IGBT
5 Power resistors
6 Diode
7 Cutting arc
8 Pilot arc

168 MAXPRO200 Instruction Manual 807700

 Maintenance

Start circuit troubleshooting

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.

D14 should always be illuminated.

Note: Reference the chopper PCB figure on the next page.

D3 illuminates as soon as the torch fires and will extinguish as soon as the arc transfers to the workpiece. If arc transfer is
immediate, the LED may not illuminate.

If there is no arc at the torch or if the arc will not transfer:

1. Turn OFF all power to the system.

2. Remove the 6 AWG wire labeled R36
from the R36 power resistor terminal 1 2
(PA WORK). Not the smaller 140 mm 1 R34 (J2 COLLECTOR)
(5.5 inch) 10 AWG wire that connects 2 R35
to R34. 3 R36 (PA WORK)
3. Verify a series resistance of 3 Ω
between J2 (COLLECTOR, wire
labeled J2.2) and R36 (PA WORK). If
the resistance value is not correct,
check the wiring connections between
J2 (COLLECTOR, wire labeled J2.2)
and R34, between R34 (no label on
wire) and R35, and between R35 (no
label on wire) and R36.
Note: Resistance value may slowly
increase to the correct value due to the 3
capacitance in the circuit.
4. Verify a resistance of 1 Ω across each of R34, R35, and R36.
• The work lead should not have any cuts or breaks. Verify a resistance of 1Ω or less. The work lead connection to
the cutting table should be clean and have good contact to the table.
• Verify that D14 is illuminated. If it is not illuminated the board may need to be replaced or the board may not be
receiving power.
• Fire the torch in the air and verify that D3 is illuminated. If it is not illuminated, but a pilot arc is established, the
pilot arc IGBT (Q7) may need to be replaced.
5. Place a 10 AWG (6 mm2) jumper in parallel across the work lead (WORK, H8, wire labeled J2.9) and J7 (Nozzle, H9,
wire labeled J2.7). Perform a test cut. The nozzle will wear out after just a few starts. If the arc transfers, check, R34,
R35, R36, Q7, the chopper, and the wiring between them. replace parts as necessary.

MAXPRO200 Instruction Manual 807700 169

Maintenance

R3

R2

R1
LED Description

MTG1
R36
D1 Chopper A PWM

R33
D2 Chopper B PWM

D7

J2
D3 Pilot arc enable
C60

C54

D12
D6 +18V/-5V chopper circuit power

D8
indicator
D10 Gate drive optocoupler +5V power
H9

indicator J7 (H9, NOZZLE)

J7

D14 Pilot arc circuit power indicator

D20 Bus voltage +5V circuit power indicator
TP93
D22 Chopper +15V power indicator
J6
-15VB

-
C61

U3
1

Test TP92
+
Description
J16

+15VB
point

C2
D14

TP104 TP107
TP88 Chopper ground
J3

PAGND P+18V TP98

TP94 PWR
TP89 +15V (chopper A)
PILOT
ARC

TP91
D3

D+5V GND
TP96 GB
CHA

PWR
TP90 -15V (chopper A)
1

D1

TP114 TP100 TP113

TP91 IGBT chopper B gate drive P+18V P-5V
D10

+
TP92 +15V (chopper B) TP95 C3

TP115
TP93 -15V (chopper B)
J8

TP88
T2

DCKB
D2
CHB

GA PWRGND
1
1

TP94 Gate drive optocoupler +5V TP105

J9

SIGNAL
TP95 Chopper B PWM
-
+15V
D22

T1

TP96 Pilot arc circuit ground

TP106
TP97 Chopper unregulated +18V (should be TEMPADC TP99
+
+15V
+18.5 or higher)
C4
A+5V

TP111
TP102
U4

BUS
J10

TP98 Chopper ground VOLTAGE SIGNAL

TP109
TP103
TP99 Chopper +15V
1

TP112 VB3 -5V TP110

+VBUS TP101 +18V
TP89
-

TP101 Chopper ground PWRGND TP97

+18VIN +15VA

TP102 Signal (Bus voltage) ground

1 J1
J11

+
TP103 Chopper -5V
C5

TP108 TP90
PWRGND -15VA
TP104 Pilot arc ground
C14
1

C1

TP105 Signal (chopper temp) ground

TP106 Chopper temp (0–5V analog) 2A 1A
HYPERTHERM
+
+
-

200A CHP

TP107 Pilot arc +18V

TP27

TP108 Non-isolated chopper ground

TP109 Non-isolated Bus voltage (0–5V analog)
2B 1B
TP110 Chopper +18V J2 (H8, WORK)
TP111 Isolated Bus voltage (0–5V analog) 2C 1C
-
-
+ TP46

TP112 Bus voltage +5V

D28

TP113 Chopper A PWM

D29

TESTED LABEL
PART NUMBER
SERIAL NUMBER
C24

TP114 Pilot arc unregulated +18V (should be

+18.5 or higher)
TP115 IGBT chopper A gate drive

Chopper PCB

170 MAXPRO200 Instruction Manual 807700

 Maintenance

Pilot arc current levels

Plasma gas 50 A 130 A 200 A
Air 20 A 35 A 40 A
N2 — 35 A 40 A
O2 20 A 35 A 40 A

Transfer current
Transfer is determined by CS1 on PCB3 (I/O board). Transfer occurs when the current on the work lead is > 7 A.

MAXPRO200 Instruction Manual 807700 171

Maintenance

Chopper tests

WARNING!
ELECTRIC SHOCK HAZARD

Use extreme care when working near the chopper modules. Each large electrolytic capacitor
(blue-cased cylinder) stores large amounts of energy in the form of electric voltage. Even if the power
is off, dangerous voltages exist at the capacitor terminals, on the chopper, and the diode heatsinks.
Never discharge any capacitor with a screwdriver or other implement… explosion, property damage
and/or personal injury will result.

Automatic chopper and current sensor tests during power-up

After you turn ON the power to the system and the preflow starts, the system will automatically run the following series of
tests:

The system performs a chopper test verifying there is no output current (A). Less than 5 A is considered “no current”.

1. The main contactor is open, IGBTs are off

a. If there is current on channel A, error code 401 is displayed
b. If there is current on channel B, error code 402 is displayed
c. If there is current on both channels, error code 400 is displayed
2. The main contactor is closed, IGBTs are off
a. If there is current on channel A, error code 406 is displayed
b. If there is current on channel B, error code 407 is displayed
c. If there is current on both channels, error code 405 is displayed
If the coolant flow is above the minimum level the system will do a high power test on the chopper.

Note: the system is “live” at this time. The system is applying power to the torch even though no arc will be present
at the torch.
The system performs a chopper LEM Test. The test checks for current between 10–60 A. Less than 5 A is considered
“no current”.

3. The main contactor is closed, IGBTs are on

a. If there is no current on channel A, error code 409 is displayed
b. If there is no current on channel B, error code 410 is displayed
c. If there is no current on both channels, error code 408 is displayed
4. The main contactor is closed, IGBTs are on
a. If channel A current does not go to 0, error code 412 is displayed
b. If channel B current does not go to 0, error code 413 is displayed
c. If the current on both channels does not go to 0, error code 411 is displayed
5. The main contactor is closed, IGBTs are on
a. Channel A current detected on channel B input, error code 415 is displayed
b. Channel B current detected on channel A input, error code 416 is displayed
c. Channel A current detected on channel B input and Channel B current detected on channel A input, error code
414 is displayed

172 MAXPRO200 Instruction Manual 807700

 Maintenance

6. The main contactor is closed, IGBTs are on

a. Channel A current higher than expected, error code 417 is displayed
b. Channel B current higher than expected, error code 418 is displayed
c. Current on both channels is higher than expected, error code 419 is displayed
If the chopper test is successful and there are no other severe errors the system will advance to state #3, “Ready for
start”, otherwise the system will go to state #14 “Shutdown”.

Using a meter to measure open circuit voltage (OCV)

The OCV is 360VDC with no load on the system and can only be measured when the contactor is closed. The VAC on
the chopper bridges are 127 VAC on 1A-1B-1C & 2A-2B-2C.

1. It is best to use clip-on test leads to keep your hands and the meter outside the power supply. Connect the meter to
J9 (WORK) and J7 (NEGATIVE) on the I/O board.
2. Turn ON the power to the system.
3. The automatic chopper test will begin when the purge cycle starts. You will hear the main contactor close and 0 to
5 seconds later the meter should show 360 VDC. This is the OCV for chopper channel A. The voltage will start to
decrease, then spike back up to 360 VDC again. The second reading represents the OCV for chopper channel B.

MAXPRO200 Instruction Manual 807700 173

Maintenance

Phase loss detection

1. Turn OFF all power to the system and remove the cover from the contactor (CON1).

2. Inspect the condition of the 3 contacts for excessive wear. If one or more of the contacts are worn excessively,
replace CON1 and restart the system.

OK Excessive wear

174 MAXPRO200 Instruction Manual 807700

 Maintenance

Torch lead test

1. Turn OFF all power to the system.

2. Locate the chopper board.

3. Install a temporary jumper wire between J7 (H9, NOZZLE) and the work lead connection, J9 (H8, WORK) on the
chopper board.

J11 J10 J9 J8
1
P+18V
TP114

1 1 1 1 J16
H9
J9 (H8, WORK)

TP104

C61
PAGND
+VBUS
TP112 VB3

C60
TEMPADC
TP106

T2
VOLTAGE
2C

2B

2A

TP111

C54
BUS

J7
SIGNAL
TP109

TP105

J7 (H8, NOZZLE)
PWRGND
TP101

TP107
P+18V

+15V
-5V TP110
TP103

D22
TP100

A+5V
P-5V
TP108
PWRGND

D29
SIGNAL
TP102
+18V

PWR
TP96
+15V
TP99

+15VB

D10 R33
TP92

D14 D12
D8
ARC 1
TP113

PILOT J6
+ -
+18VIN
TP97

DCKB

TP46 D7
-15VB
TP93

T1 1 D3 J3
TP95

U4
D2
CHB J2
-- +
TP27
C24 CHA
+ D1 R36
TP94
D+5V
+15VA

U3
TP89

GA
TP115
-15VA
TP90

1 J1
GB
TP91
PWRGND
TP88

C14

- - -
GND
PWR
TP98

D28

C5 C2
C4 C3
R3
1C

1B

1A

SERIAL NUMBER
C1
PART NUMBER
R2
TESTED LABEL

200A CHP R1
HYPERTHERM
+

+
+

MTG1

4. Measure the ohm value between the nozzle and the workpiece. The reading should be < 4 ohms. A measurement
> 4 ohms indicates a faulty connection between the torch and I/O board, or between the I/O board and the power
supply.
5. Verify that the pilot arc wire on the torch lead is not damaged. If it is damaged, replace the lead. If it is not damaged,
replace the torch head.

MAXPRO200 Instruction Manual 807700 175

Maintenance

Preventive maintenance
Hypertherm created a Preventive Maintenance Program (PMP) specifically for your plasma system. The PMP has two
parts: a cleaning and inspection plan and a component replacement plan.

See the MAXPRO200 Preventive Maintenance Program Instruction Manual (808800) for part numbers.

If you have questions about how to maintain your Hypertherm plasma system, contact your OEM or regional Hypertherm
Technical Service team. You can find contact information for each regional office at www.hypertherm.com on the
“Contact us” page.

176 MAXPRO200 Instruction Manual 807700

 Section 5
Parts List

Control panel

1
2

4 3

Item Part Number Description Quantity

1 428032 Control panel replacement kit 1
2 108797 Knob: soft black, no pointer 3
3 007050 Rocker switch bezel 1
4 005678 Rocker switch 1
5 075237 Screw (control panel and enclosure panels): 10-32, Torx T-25 18

MAXPRO200 Instruction Manual 807700 177

Parts List

Power supply

2 3
1 Power supplies
Part number Voltage (AC)
078610 200/208 volt
078611 220 volt
078612 240 volt
078613 380 volt
078614 400 volt
078615 415 volt
078616 440 volt
078609 480 volt
078617 600 volt

4
7

6 5

Item Part Number Description Quantity

1 See chart above Power supply
2 428033 Lift eye replacement kit 1
3 428031 Top panel replacement kit 1
4 027967 Handle: side panels 2
5 428029 Right side panel replacement kit 1
6 101188 Front panel 1
7 428030 Left side (not shown) panel replacement kit 1
8 428032 Control panel replacement kit 1
Not shown 428035 Optional caster (wheel) kit 1

178 MAXPRO200 Instruction Manual 807700

 Parts List

Power supply
1 2 3 4

Item Part Number Description Quantity

1 141171 Control Board 1
2 110261 Label: Warning instant start 1
3 010298 Label: Warnings 1
4 011114 Air filter/regulator: 7–125 psi, 1/4 inch, auto drain with valve 1
011093 Air filter element 1
5 228862 Gas hoses kit (not all hoses shown above) 1
6 428038 Coolant filter replacement kit 1
027005 Coolant filter element 1
7 228861 Coolant hose kit (not all hoses shown above) 1
8 109377 Resistor: 1 ohm, 500 watts 3

MAXPRO200 Instruction Manual 807700 179

Parts List

Power supply
1 2 3

13

12

11

10 9 8 7 6

Item Part Number Description Quantity

1 428036 Chopper replacement kit 1
2 127014 Coolant reservoir cap 1
3 002546 Coolant reservoir 1
4 006099 Coolant drain valve 1
5 228993 Coolant solenoid valve replacement kit 1
6 428039 Pump motor replacement kit 1
7 015665 Fitting: male elbow, 3/8 inch NPT x 1/2 inch push-in tube 2
8 428043 Pump replacement kit 1
9 015815 Fitting: elbow, 1/2 inch x 1/2 inch push-in tube, brass 2
10 074354 Cable holder: for 1/2 inch diameter cable 17
11 104407 Bushing: dust seal 6
12 074353 Cable holder: for 1/4 inch diameter cable 10
13 074355 Cable holder: for 3/4 inch diameter cable 10

180 MAXPRO200 Instruction Manual 807700

 Parts List

Power supply

1 2

4
4

11

5
10

7
6
Item Part Number Description Quantity
1 015669 Male connector 3/8 inch NPT x 1/2 inch 7
2 428034 Gas manifold replacement kit 1
3 006128 Solenoid valve 1
4 428042 Pressure transducer replacement kit 2
5 428037 Flow meter replacement kit 1
6 109636 EMI filter: 250 VAC, 1 amp, 1 phase 2
7 229474 Thermistor: 3/8 inch diameter, copper pipe clip with connector 1
8 015663 Male connector 1/4 inch NPT x 1/2 inch tube 1
9 006075 Check valve 1
10 015664 Male elbow 1/4 inch NPT x 1/2 inch push-in tube 1
11 229482 Heat exchanger (with fan) 1
127091 Heat exchanger fan only 1

MAXPRO200 Instruction Manual 807700 181

Parts List

Power supply

1 2

6 5 4
Item Part Number Description Quantity
1 209177 EMI filter, 400V and 415V power supplies
2 008301 Fuse holder 1
108571 Fuse holder cover 1
110513 Fuse label: F1–F2 1
008551 Fuse: 7.5 amp, 600 volt: 380V, 400V, 415V, 440V, 480V, and 600V power supplies 2
008709 Fuse: 20 amp, 500 volt: 200/208V, 220V, and 240V power supplies 2
3 027567 Fan guard 1
4 014373 Inductor 2
5 074212 Cable holder: self sticking, for 1/2 inch diameter cable 5
6 074356 Cable holder: for 1.0 inch diameter cable 5
7 108671 Terminal block: 14 AWG – 2/0 1
8 003249 Contactor: 380V, 400V, 415V, 440V, 480V, and 600V power supplies 1
003233 Contactor: 200/208V, 220V, and 240V power supplies 1
228309 Transformer thermistor (not shown) 1

182 MAXPRO200 Instruction Manual 807700

 Parts List

Power supply

1 Control transformers
Part number Description Part number Description
229535 200 volt, 50–60 Hz 229538 415 volt, 50–60 Hz
229536 220 volt, 50–60 Hz 229539 440 volt, 50–60 Hz
229537 240 volt, 60 Hz 229488 480 volt, 60 Hz
229514 380 volt, 50 Hz 229540 600 volt, 50–60 Hz
229515 400 volt, 50 Hz

6 1

Item Part Number Description Quantity

1 See table above Control transformer 1
2 027079 Fan: 450–550 cfm, 120 VAC 50–60 Hz 1
3 101205 Ignition enclosure panel (ignition) 1
4 428044 Inlet gas-plug replacement kit 1
5 015812 Adaptor:1/4 inch NPT o-ring x 5/16 inch 1
6 010875 Label: Danger voltage 1
Not shown 428054 Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit) 1
Not shown 015015 Adapter: 1/4 inch NPT, #6, Male, 90 degree 1
Not shown 015817 Adapter: 3/8 inch FNPT x 1/2 inch push-in tube 1

MAXPRO200 Instruction Manual 807700 183

Parts List

Ignition enclosure

1 2

5 4

Item Part Number Description Quantity

1 428040 I/O PCB replacement kit 1
2 428041 I/O panel replacement kit (includes PCB) 1
3 229487 Ignition transformer 1
4 109636 EMI filter 1
5 008482 Power cord strain relief (380V, 400V, 415V, 440V, 480V, and 600V power supplies) 1
008052 Power cord strain relief (200/208V, 220V, and, 240V power supplies) 1

184 MAXPRO200 Instruction Manual 807700

 Parts List

Height control connection kits

Sensor THC connection kit – 428023
Note: This kit should only be ordered when purchasing a Sensor THC torch height control and a Hypertherm
CNC that is shipped with a voltage divider card (packaged separately from the CNC). If you only need the voltage
divider card order part number 141201.
The kit contains two wire groups (229554 and 229602). A CNC interface cable is not supplied. The desired length
should be ordered separately.

Sensor PHC connection kit – 428022

The kit contains a PHC plasma interface assembly (228256) with a 1.3 m (5 feet) interface cable attached. A CNC
interface cable is not supplied. The desired length should be ordered separately.

Wire groups and harnesses

Part Number Description
229437 Main wire harness: all power supplies
229438 Primary power wire group for 380V, 400V, 415V, 440V, 480V, and 600V power supplies
229439 EMI filter wire group for 400V and 415V power supplies
229558 Contactor wire adaptors
229561 Primary power wire group for 200/208V, 220V, and 240V power supplies

USB cables for software updates

Cable for USB update – 223291
Note: This cable allows the system software to be upgraded using a USB memory stick.

Cable for USB update – 223273

Note: This cable allows the system software to be upgraded using a laptop.

MAXPRO200 Instruction Manual 807700 185

Parts List

Power supply gas hose kit – 228862

The kit contains:

Part Number Description Length

046077 Tubing: 1/4 inch OD, blue 1 foot
046078 Tubing: 1/4 inch OD, black 1 foot
046231 Tubing: 5/16 inch OD, black 2 feet

Machine torches
Straight torch

5 4 3 2

Item Part Number Description Quantity

1 428024 Machine torch assembly with 2.0 inch mounting sleeve 1
228937 Machine torch assembly with 1-3/4 inch mounting sleeve 1
2 220943 Torch Mounting sleeve: 2 inch 1
220942 Torch Mounting sleeve: 1-3/4 inch 1
3 420087 Straight torch main body 1
4 044026 O-ring: 1.239 inch x 0.070 inch 2
5 220521 Water tube 1

186 MAXPRO200 Instruction Manual 807700

 Parts List

Quick-disconnect torch

6 5 4 3 2

Item Part Number Description Quantity

1 428027 Quick-disconnect torch assembly with 2.0 inch mounting sleeve 1
428028 Quick-disconnect torch assembly with 1-3/4 inch mounting sleeve 1
2 220943 Torch Mounting sleeve: 2 inch 1
220942 Torch Mounting sleeve: 1-3/4 inch 1
3 420033 Quick-disconnect torch receptacle 1
4 220921 Quick-disconnect torch main body 1
5 044026 O-ring: 1.239 inch x 0.070 inch 2
6 220521 Water tube 1

MAXPRO200 Instruction Manual 807700 187

Parts List

Leads and cables

Machine torch leads
Part Number Length
229477 7.5 m (25 feet)
229478 15 m (50 feet)
229479 23 m (75 feet)
229480 30 m (100 feet)

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

Work leads
Part Number Length
223335 7.5 m (25 feet)
223336 15 m (50 feet)
223337 23 m (75 feet)
223338 30 m (100 feet)

Work clamp
Part Number Description
008539 Ground clamp

Hand torch leads

Part Number Length
229498 7.5 m (25 feet)
229499 15 m (50 feet)
229500 23 m (75 feet)
229501 30 m (100 feet)

Inline valve kit

Part Number Description
428055 Replacement for the valve located in the torch lead

Hand torch heat shield – 127389

188 MAXPRO200 Instruction Manual 807700

 Parts List

90 degree hand torch

1
2

3 2

Item Part Number Description Quantity

1 420108 90 degree hand torch assembly 1
228980 90 degree hand torch assembly with 7.5 m (25 feet) lead 1
228981 90 degree hand torch assembly with 15 m (50 feet) lead 1
228982 90 degree hand torch assembly with 23 m (75 feet) lead 1
228983 90 degree hand torch assembly with 30 m (100 feet) lead 1
2 228985 Handle replacement kit 1
001905 90 degree torch handle (left and right sides) 1
002244 Safety trigger 1
027254 Safety trigger spring 1
075841 Pan head screws 6
210185 Hand torch label 1
210209 Hypertherm IEC label 1
3 420070 Torch main body 1
4 044026 O-ring: 1.239 inch x 0.070 inch 2

MAXPRO200 Instruction Manual 807700 189

Parts List

65-degree hand torch

1 2

2
3

Item Part Number Description Quantity

1 420107 65 degree hand torch assembly 1
228976 65 degree hand torch assembly with 7.5 m (25 feet) lead 1
228977 65 degree hand torch assembly with 15 m (50 feet) lead 1
228978 65 degree hand torch assembly with 23 m (75 feet) lead 1
228979 65 degree hand torch assembly with 30 m (100 feet) lead 1
2 228986 Handle replacement kit 1
001906 65 degree torch handle (left and right sides) 1
002244 Safety trigger 1
027254 Safety trigger spring 1
075841 Pan head screws 6
210184 Hand torch label 1
210209 Hypertherm IEC label 1
3 420109 Torch main body 1
4 044026 O-ring: 1.239 inch x 0.070 inch 2

190 MAXPRO200 Instruction Manual 807700

 Parts List

Consumable parts kits

Mechanized torch consumable kit – 428013
Part number Description Quantity
020415 Electrode: 200A and 130A, N2 2
027055 Silicone lubricant: 1/4 ounce tube 1
044026 O-ring: 1.239 x 0.070 2
104119 Consumable tool 1
220487 Electrode: 130 A, O2/Air 4
220488 Swirl ring: 130 A, O2/Air and 200 A, Air 2
220491 Shield:130 A, O2 1
220521 Water tube 1
220528 Electrode 50 A, O2/Air 4
220529 Swirl ring: 50 A, O2/Air and 130A or 200A, N2 1
220532 Shield: 50A, O2/Air 1
220536 Shield:130A, Air/N2 1
220831 Nozzle: 200A, O2 2
220832 Shield: 200A, O2 1
220834 Swirl ring: 200A, O2 1
220890 Nozzle: 50A, Air 2
220891 Nozzle: 50A, O2 2
220892 Nozzle: 130A, Air/N2 2
220893 Nozzle: 130A, O2 2
220935 Shield cap: O2/Air/N2, clockwise 1
220936 Shield cap: O2/Air/N2, clockwise, with IHS tab 1
220937 Electrode: 200, O2/Air 6
420044 Nozzle: 200A, Air/N2 6
420045 Shield: 200A, Air/N2 2
428054 Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit) 1
881430 MAXPRO200 machine torch brochure 1

MAXPRO200 Instruction Manual 807700 191

Parts List

Hand torch consumable kit – 428014

Part number Description Quantity
027055 Silicone lubricant: 1/4 ounce tube 1
044026 O-ring: 1.239 x 0.070 2
104119 Consumable tool 1
220488 Swirl ring: 130A, O2/Air and 200 A, Air 2
220521 Water tube 1
220831 Nozzle: 200A, O2 2
220834 Swirl ring: 200A, O2 1
220935 Shield cap: O2/Air/N2, clockwise 2
220937 Electrode: 200A, O2/Air 8
420044 Nozzle: 200A, Air/N2 4
420058 Shield: 200A, Air/N2 2
420059 Shield: 200A, O2 1
420066 Nozzle: 200A, Air, Gouging 2
420067 Shield: 200A, Air, Gouging 2
428054 Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit) 1
881440 MAXPRO200 hand torch brochure 1

192 MAXPRO200 Instruction Manual 807700

 Parts List

Supply gas hoses

Caution: Never use PTFE tape on any joint preparation

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)

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)

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)

MAXPRO200 Instruction Manual 807700 193

Parts List

Recommended spare parts

Part number Description Quantity
003233 Contactor: 200/208V, 220V, and 240V power supplies 1
003249 Contactor: 380V, 400V, 415V, 440V, 480V, and 600V power supplies 1
011093 Air filter element 1
027005 Coolant filter element 1
027055 Silicone lubricant: 1/4 ounce tube 1
027079 Fan: 450–550 cfm, 120 VAC 50–60 Hz 1
028872 Coolant solution, 70/30 PG, 1 gallon 4
127091 Heat exchanger fan 1
141171 Control Board 1
220921 Quick-disconnect torch main body 1
220942 Torch Mounting sleeve: 1-3/4 inch 1
220943 Torch Mounting sleeve: 2 inch 1
420033 Quick-disconnect torch receptacle 1
420070 90 degree torch main body 1
420087 Straight torch main body 1
420109 65 degree torch main body 1
428034 Gas manifold replacement kit 1
428035 Castor wheel kit 1
428036 Chopper replacement kit 1
428037 Flow meter replacement kit 1
428038 Coolant filter replacement kit 1
428039 Pump motor replacement kit 1
428040 I/O PCB replacement kit 1
428041 I/O panel replacement kit (includes PCB) 1
428042 Pressure transducer replacement kit 1
428043 Pump replacement kit 1
428044 Inlet gas-plug replacement kit 1
428054 Kit: MAXPRO200 O2 S/A (Oxygen quick connect kit) 1
428055 In-line valve replacement kit 1

194 MAXPRO200 Instruction Manual 807700

 Section 6
Wiring Diagrams

This section contains the wiring diagrams for the system. When you trace a signal path, or reference the Parts List or
Troubleshooting sections, the following conventions will help you understand the organization of the wiring diagrams:

• Sheet numbers are located in the lower, right-hand corner of each page.
• References to other pages use the following connection symbol:

Sheet
C
4-D3

Sheet number Coordinates Reference block

Use the sheet number to find the reference sheet. Line up the coordinates A–D on the Y axis and numbers 1–4 on the
X axis of each sheet to find the reference blocks (similar to a road map).

MAXPRO200 Instruction Manual 807700 195

Wiring Diagrams

Wiring diagram symbols

Battery Ground clamp Receptacle

Cap, polarized Ground, chassis Relay, coil

Cap, not polarized Ground, earth Relay, normally closed

Cap, feed-through IGBT Relay, normally open

Circuit breaker Inductor Relay, solid state, AC

Coax shield LED Relay, solid state, DC

Current sensor Lamp Relay, solid state

Current sensor MOV Resistor

DC supply Pin SCR

Diode Socket Shield

Door interlock Plug Shunt

Fan PNP transistor Spark gap

Feed-through LC Potentiometer Switch, flow

Push button, Switch, level,

Filter, AC
normally closed normally closed

Push button, Switch, pressure,

Fuse
normally open normally closed

196 MAXPRO200 Instruction Manual 807700

 Wiring Diagrams

Switch, pressure, Time delay open,

Valve, solenoid
normally open NO/off

Time delay open,

Switch, 1 pole, 1 throw Voltage source
NC/on

Time delay closed,

Switch, 1 pole, 2 throw Zener diode
NO/off

Switch, 1 pole, 2 throw,

Transformer
center off

Switch, temperature,
Transformer, air core
normally closed

Switch, temperature,
Transformer, coil
normally open

Terminal block Triac

Time delay closed,

VAC source
NC/off

Torch symbols

Electrode

Nozzle

Shield

Torch

Torch, HyDefinition™

MAXPRO200 Instruction Manual 807700 197

Wiring Diagrams

198 MAXPRO200 Instruction Manual 807700

 MAXPRO 200
Gas Schematic

Air/Air N2/N2 O2/AIR

Air N2 Air 02

Filter Filter Filter

Regulator Regulator Regulator
Pressure gage Plugged
Pressure gage Pressure gage

Shield Plasma Shield Plasma Shield Plasma

Power Supply Power Supply Power Supply

B2 B1 B2 B1 B2 B1

P2 P1 P2 P1 P2 P1

I/O board I/O board I/O board

Shield Gas & Pilot Arc Plasma Gas Shield Gas & Pilot Arc Plasma Gas Shield Gas & Pilot Arc Plasma Gas
Blue Hose Black Hose Blue Hose Black Hose Blue Hose Black Hose

21', 46', 71', 96' 21', 46', 71', 96' 21', 46', 71', 96'

Torch Valve Torch Valve Torch Valve

4' 4' 4'

Hand/Mech Hand/Mech Hand/Mech

Torch Torch Torch

199
 4 3 2 1

D D

Torch Lead Assembly

Plasma Gas Lead Plasma Gas Lead
Gas Solenoid Valve Enable Gas Solenoid Valve Enable
Cooling Supply Lead Plasma
Solenoid
Cooling Return Lead Negative Lead
Gas 1 Shield Gas Lead
Gas 2 Unit 1 Start Trigger Pilot Arc Lead
Power Supply Lead Length ID
Unit M
C Torch C
Lifter
3 Phase (Optional Unit)
Power
w/ Ground
Torch
Work Lead
Workpiece

B B

CNC
CUSTOMER
SUPPLIED

A A

ELEC SCH:MAXPRO200 POWER SUPPLY

013384
SHEET 1 OF 9 B

4 3 2 1

200
 4 3 2 1
SHEET
CHOPPER PWR 3-D1 A
BLK RED J18
RED/BLK
J2.8 1
009045 2
RED

1
2
FILTER GRN
J8 3
15VAC
PWM CHP A SHEET
3-B1 B1 PWR IN E1 SHEET
3-A3
BUS VOLTAGE 1 2 G SHEET HF EN
3-D1
J2.3 J3 J10 J2.10
T1
RED BLU
D PWM CHP B SHEET B2 1 D+5V BUS VOLTAGE 1 129854 D
3-B1 CLR 2 PWM CHP A D1 GND 2 WHT
BLK
3 3
E2 SHEET
3-A3
CHOPPER TEMP
GND
SHEET RED D+5V
PILOT ARC ENABLE B3 4 4 J2
3-B1 CLR BLK J1
5 PWM CHP B D2 GND 5
BLK GND RED
6 TEMP ADC 6 109344
RED D+5V SHLD 5kV
7
CLR
7 * OPTIONAL
8 PILOT ARC EN D3 SG2 SG1
BLK ARC VOLTAGE WIRES NEED TO BE CONNECTED IF
9 GND
C5 C4 C3 A PLASMA INTERFACE BOARD IS INSTALLED.
TRANSFORMER TEMP 10 CHASSIS WIRE RUNS ARE TO A TERMINAL BLOCK NEAR
GND 009975 1400pF 20kV PLASMA INTERFACE BOARD MOUNTING LOCATION
SHEET CHOPPER
3-C4 C CHOPPER F SHEET
CURRENT A J3 B4 SHEET ARC VOLTAGE
3-A4 9-A3
141188 J1 J2.1

YEL/BLK
5
+15V RED T2
CONTACTOR ENABLE 1
I/O 009793

YEL
-15V 2 GRN
D SHEET CHOPPER CURRENT A GND BLK
3-D1 3 BOARD
SIG WHT INDUCTOR 1
RED
H SHEET
BLK
4
C 6 3-C4 TEMP 141216 J5 C
P+18V/-5V D14 RED
J11 1 J4
+18V D6 BLK PA LEAD TO TORCH
1
2
2
+15V D22
RED/BLK 20
19

C4
D+5V D10 J10 0.22uF
A+5V D20 NEG 1 (-) 009224
INPUT POWER J4 T2
CS1 1KV
RED

FROM FACILITY L1
T1 J7
PE L1 L2 L3 (-)NEGATIVE
1A 1A J3.7
V W J5
TORCH (-)
NEG 2 (-)
P1 1B
CS2 L2 T3
0 1B C6 R1 R2 R3
W L1 A4 J12 L SHEET INDUCTOR 2 350UF 9.1K 9.1K 9.1K
V L2 B4 1C 1C RED 3-C4 TEMP
1
U L3 C4 P2 0 BLK R4
2
2A 100K
PE 2A CHOPPER R5
PE J6 J2.6 M SHEET CURRENT B 10R
C7
0.22uF
CON1
5
3-A4
P3 2B 009224
0 2B +15V RED J3.10 1KV
1
-15V GRN
BLK L2
BLK L3

2C 2
2C CHOPPER CURRENT B GND BLK
3
B SIG WHT B
4 J3.6 (++)POSITIVE
T1
6
SHOWN WIRED FOR 480V
SEE PAGES 6 AND 7 FOR J2.9 C8 R6
F1 F2 WORK CS1 .022UF 10K
OTHER CONFIGURATIONS J9
H8 POSITIVE (+)
R34 R35 R36 WORK(+)
WHT

1R 1R 1R
GRY

J2.2 C9 R7
COLLECTOR

3
2
Shown for 480V .22UF 10K
J8

RED
BLU
BLK
PILOT ARC
CONTROLLER
CONTROL
H9 J2.7
TRANSFORMER COLD PLATE J2.9 J9 NOZZLE
T2 TEMP
1 A+5V
N SHEET WORK LEAD CURRENT
2 SIG
ORN 240VAC
RED 120VAC

3-A2
YEL 24VAC

A A
CONTROL
K SHEET
3-D4 XFORMER ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 2 OF 9 B
4 3 2 1
201
 4 3 2 1

A SHEET CHOPPER POWER

SHEET 2-D3
K J22 J1.22
CONTROL 2-A4 J1.9 J9 POWER SUPPLY CONTROL BOARD RED

1 2
TRANSFORMER YEL 1 +15VAC_2
24VAC YEL 24VAC 141171 BLK D SHEET
2-D4 CONTACTOR ENABLE
2
RED 3 B
120VAC RED 120VAC F2 120VAC SWITCHED
4
240VAC SWITCHED J14 J1.14 G SHEET HIGH FREQUENCY
D
D ORN 5 D26 15V 2-D1
240VAC ORN 240VAC F1 RED/BLK ENABLE
6 GND D51 CONTACTOR ENABLE 1
D31 240V FUSED AC INPUT RED/BLK
K1 D46 HIGH FREQ ENABLE 2
D33 3.3V RED/BLK RED/BLK
J4 J1.8 J8 MAGNETICS FANS 3 TRANSFORMER
POWER SWITCH OPTIONAL RED RED
CUSTOMER BLK D37 5V 4 FAN
1 +24V RED
2 REMOTE 24V 5
2 D40 AC RTN RED
3 ON/OFF 6
BLU 3 D41 120V FUSED AC INPUT RED
WHT 7 1 3 2 J14
8 4 D42 240V INPUT DETECTED WHT
G BLK POWER ON 8 PS
5 WHT WHT
7 D44 120V INPUT DETECTED 9

1 2
YLW

1 2
6 STANDBY RED/BLK BLK
A 6 RED 120VAC FUSED 10
7 BLK PUMP MOTOR
D70 PUMP MOTOR ENABLE 240VAC RELAY 11
D35 CHOPPER A OVER CURRENT BLK WHT
240VAC SWITCH OUT 12

1 2
1 2
BLK CLT SOL
TRANSFORMER D100 CHOPPER B OVER CURRENT
TEMP SHEET J1.12 J12 FA3.3V PS
2-D4 C RED 1 3 2 J13
1 WHT J17
BLK BLK HEAT XCHANGER
2 TRANSFORMER TEMPERATURE FAN
INDUCTOR 1 SHEET 3
TEMP 2-C2 H RED
C 4 SHEET GAS CONSOLE/ C
BLK B5 9-C1 PLASMA INTRFC
5 INDUCTOR 1 TEMPERATURE
INDUCTOR 2 SHEET 6 J16 J1.16
TEMP 2-B2 L RED 7 1 RED
BLK 8 RED
INDUCTOR 2 TEMPERTURE +24V 2
9 3
10 D104 PLASMA VALVE PWM 4 BLK
D105 SHIELD VALVE PWM 5 BLK
+15V 6
P1 J1.11 J11 7

D65
BRN RED 1 +24V 8 SV1
1 2 3 4

9
BLK
2 PLASMA VALVE

1 2 3
1 2 3
P1 RED RED

D68
BLU BLK

COOLANT TEMPERATURE
10 SV1
3 RED

WORK LEAD CURRENT

BLK YLW PLASMA PRESSURE P+5V 11 SHLD
4
CHOPPER CURENT B
CHOPPER CURENT A

12
RED
5 D106 TORCH VALVE ENABLE SV2
BLK

COOLANT FLOW
13 BLK

PILOT ARC TEMP

6
CHOPPER TEMP

BLK SHIELD VALVE

1 2 3
1 2 3
14
BUS VOLTAGE

BLK RED SV2

P2 J1.13 J13 15
CLR SHLD
BRN RED D101 CHOPPER A PWM
B 1 16 B
1 2 3 4

D102 CLR
CHOPPER B PWM

CLT +15V
2 17

WL +15V
P2 BLU BLK CLR
3 D103 PILOT ARC ENABLE 18 SHEET
FA3.3V B1 2-D3 PWM CHP A
F+15V

BLK YLW SHEILD

F-15V

TCHVLV+
PRESSURE

TCHVLV-
5
6 SHEET
B2 2-D3 PWM CHP B

SHEET
J15 J18 J21 J17 B3 2-D3 PILOT ARC ENABLE
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4
J1.15 J1.18 J1.21 J1.17

RED

RED

RED
CLR

BLU
BLK

BLK

BLK
RED
GRN
BLK
WHT
RED
GRN
BLK
WHT
BLK
RED
WHT
BLU

WHT
BLU

CHOPPER CURENT A SHEET F Z SHEET

TORCH VALVE
2-C2 4-A4
1 2
CHOPPER CURENT B SHEET
2-B2 M J9
FL1 3 2 1
1 2
A SHEET FL1 A
CHOPPER TEMP 2-D2 E2
3 2 1
BUS VOLTAGE 2-D2
SHEET
E1 ELEC SCH:MAXPRO200 POWER SUPPLY
COOLANT TEMP
013384
WORK LEAD CURRENT SHEET N
2-A1
SHEET 3 OF 9 B
4 3 2 1

202
 4 3 2 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10
J1 J20

J3

+3.3V
JTMS-SWDIO

JTMS-SWCLK

JTD0

JTDI

NRST

JCLK PE2

JCLK PE3

JCLK PE4

JCLK PE5

JCLK PE6

ISPTCK

ISPTMS

ISPTDI
+3.3V
ISPTDO
SDIO D2 1
SDIO D3 2
D SDIO CMD 3 D
JTAG CPLD +3.3V 4
JTAG MICRO SDIO CK 5
6
USB MICRO SD SDIO D0 7
SDIO D1 8
J6 SDIO CD
1 IN START + POWER SUPPLY CONTROL 9
10
D6
2
3
CNC START -
CNC HOLD +
141171
SEE PAGE 9 FOR CONNECTION D9 J19
TO SENSOR PHC. FOR CONNECTIONS 4 CNC HOLD -
TO A CNC PLEASE REFERENCE THEIR 5 CNC MOTION + CNC INTERFACE USB VBUS 1
D12 USB DM 2
MANUAL 6 CNC MOTION -
7 USB DP 3
CNC ERROR + D14 USB OTG USB ID 4
8 CNC ERROR -
USB GND 5
CNC HOLD OUT+ 6
D15
CNC HOLD OUT- 7

C C

MANUAL SHEET
TORCH 4-A2 Y J1.2 J2
START RED 1 CNC START +
WHT
2 IN START + J5
BLK
3 IN START -
BLK 1
4
RS422 TX- 2
5 +24V TORCH RS422 RX- 3
BLK
BLK
6 INTERFACE RS422 TX+ 4
7 TORCH ID0 D1
RED 5
GRN
8 TORCH ID1 D2 RS422 RS422 GND 6
9 TORCH ID2 D3
WHT D16 CAN RX RS422 RX+ 7
10 TORCH ID3 D4
8
B D17 CAN TX B
9

CAN +24V
PWR GND 10
11

CANH
CANL
CAN

J7
MANUAL 1 2 3 4 5
Y SHEET
4-C3 TORCH
WHT

FILTER
TORCH SHEET START
Z RED
VALVE 3-B1 1
FILTER 1 BLK
2
RED 2
1 3
BLK 2 1
GRN/YLW 2
3
WHT
WHT
GRN

RED
RED

RED

BLK
BLK

BLK
BLK
BLK

A POWER SUPPLY A
J7 TO TORCH LEADS
14 13 12 11 10 9 8 7 6 5 4 3 2 1 ELEC SCH:MAXPRO200 POWER SUPPLY
TORCH VLV -
TORCH VLV +

ID3
ID2
ID1
ID0
GND
GND
IN START -
IN START +
CNC START +

013384
MECHANIZED TORCH: PIN 1 SHORTED TO PIN 2
MANUAL TORCH: START SWITCH ACROSS PIN 1 AND PIN 3 SHEET 4 OF 9 B

4 3 2 1

203
 4 3 2 1

WIRED FOR 480V 60HZ WIRED FOR 240V 60HZ WIRED FOR 200V 50-60HZ

D D
T1 T1 T1
PE L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 1A
1A 1A
V W V W V W

1B 1B P1 0 1B
P1 0 P1 0
W W W L1 A4
L1 A4 L1 A4
1C 1C V L2 B4 1C
V L2 B4 V L2 B4 INPUT POWER
INPUT POWER INPUT POWER P2 0 U L3 C4 P2 0
U L3 C4 P2 0 U L3 C4 FROM FACILITY
FROM FACILITY FROM FACILITY PE 2A
PE 2A PE 2A PE CON1
PE CON1 PE CON1
P3 0 P3 0 2B
P3 0 2B 2B
F1 F2 F1 F2 F1 F2
2C 2C 2C

T1 T1 T1

WHT
BLK
WHT

WHT
GRY

BLK
T2 T2 T2

C C

WIRED FOR 400V 50-60HZ WIRED FOR 415V 50-60HZ

T1 T1
PE L1 L2 L3 1A PE L1 L2 L3 1A
V W V W
B 1B 1B
B
P1 0 P1 0
W L1 L1 A4 W L1 L1 A4
V L2 L2 B4 1C V L2 L2 B4 1C
INPUT POWER EMI FILTER INPUT POWER EMI FILTER
U L3 L3 C4 P2 0 U L3 L3 C4 P2 0
FROM FACILITY FROM FACILITY
PE CON1 2A PE CON1 2A
PE PE
P3 0 2B P3 0 2B
F1 F2 F1 F2
2C 2C

T1 T1
WHT

WHT
GRY
BLU

T2 T2

A A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 5 OF 9 B

4 3 2 1

204
 4 3 2 1

D WIRED FOR 440V 50-60HZ WIRED FOR 600V 60HZ D

T1 T1
PE L1 L2 L3 1A 1A
V W PE L1 L2 L3
1B V W 1B
P1 0
W L1 A4 P1 0
V L2 B4 1C W L1 A4 1C
INPUT POWER U L3 C4 P2 0 V L2 B4
FROM FACILITY INPUT POWER
PE 2A U L3 C4 P2 0 2A
PE CON1 FROM FACILITY
PE CON1
PE
P3 0 2B 2B
P3 0
F1 F2 2C 2C
F1 F2
C T1 T1
C

WHT
BLK

WHT
GRY
T2
T2

WIRED FOR 220V 50-60HZ WIRED FOR 380V 50-60HZ

T1
B T1 1A B
PE L1 L2 L3 1A PE L1 L2 L3
V W V W 1B
P1 0 1B P1 0
W L1 A4 W L1 A4 1C
V L2 B4 1C V L2 B4
INPUT POWER U INPUT POWER U
L3 C4 P2 0 L3 C4 P2 0 2A
FROM FACILITY FROM FACILITY
PE CON1 2A PE
PE PE CON1
2B
P3 0 2B P3 0
F1 F2 2C
2C F1 F2
T1
T1
WHT

WHT
BRN

BLK
T2 T2

A A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 6 OF 9 B

4 3 2 1
205
 4 3 2 1

Air/N2 N2/02
D D

SHIELD PLASMA
POWER SUPPLY

B2 B1

C P2 P1 C
I/O BOARD

21', 46', 71', 96'

B B

TORCH VALVE

Plasma 4'

A A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 7 OF 9 B

4 3 2 1
206
 4 3 2 1

Power supply
D D

CHECK VALVE
HEAT EXCHANGER

FLOW SENSOR
FINE FILTER
RESERVOIR

THERMISTOR

25', 50', 75' or 100'

C C

INTERNAL BYPASS
COLD PLATE

POWER LEAD
DRAIN

PUMP
COARSE
FILTER SHUT OFF VALVE

B B

TORCH

A A
ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 8 OF 9 B

4 3 2 1
207
 4 3 2 1

D D

POWER SUPPLY CONTROL SENSOR THC

SENSOR PHC 141171 PLASMA INTERFACE I/O
PLASMA INTERFACE I/O 141201

GAS CONSOLE/
J1
CNC INTERFACE B5 SHEET
3-C1 PLASMA INTRFC
1 J6
START RELAY J1 J12.1 J18
2 1 IN START + 229554
D6 RED RED
AC_LINE

1 2
3 2 CNC START -

2 1
+12V FIELD RED/BLK RED/BLK
C 4 3 CNC HOLD + AC_NEUT C
HOLD D9
OPTO 5 4 CNC HOLD -
5 CNC MOTION +
D12
6 CNC MOTION -
J3
7 CNC ERROR + D14
1 8 CNC ERROR -
XFER OPTO 2
3 CNC HOLD OUT+
D15
4 CNC HOLD OUT-

EMI GROUND
ELECTRODE
F
5

SHIELD
ARC VOLTAGE INPUT

WORK
ELECTRODE (NEG)

WORK (POS)

1 2 1 2 3 4 5
YEL

YEL/BLK
YEL/BLK

B B

YEL
CONNECTIONS SHOWN FOR
SENSOR OR SENSOR
PHC THC

YEL/BLK
YEL
25 YEL/BLK 26
YEL

A A
ARC
VOLTAGE
SHEET
2-C1 B4 ELEC SCH:MAXPRO200 POWER SUPPLY
013384
SHEET 9 OF 9 B

4 3 2 1
208
 Material Safety Data Sheet (MSDS) — Torch Coolant Safety Data

1 – Identification of the substance/mixture and of the company undertaking

Product identifier – Torch Coolant 30% PG Mixture
GHS Product Identifier – Not applicable.
Chemical Name – Not applicable.
Trade name – Torch Coolant 30% PG Mixture
CAS No. – Not applicable.
EINECS No. – Not applicable.
REACH Registration No. – Not available.
Relevant identified uses of the substance or mixture and uses advised against
Identified use(s) – Industrial use only.
Uses advised against – Not available.
Details of the supplier of the safety data sheet
Company Identification – Hypertherm
Telephone – +1 (603) 643-5638 (USA), +31 (0) 165 596 907 (Europe)
E-Mail (competent person) – [email protected]
Address – P.O. Box 5010, Hanover, NH 03755 USA (USA),
Vaartveld 9, 4704 SE Roosendaal, Nederlands (Europe)
Emergency telephone number – (800) 255-3924 (USA), +1 (813) 248-0585 (International)

2 – Hazards identification

EC Classification NONE GHS Classification NONE

Signal word (s)
NONE NONE NONE NONE
According to Regulation (EC) No. 1272/2008 (CLP) – NONE
According to Directive 67/548/EEC & Directive 1999/45/EC – NONE
Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Risk Phrases – NONE
Safety Phrases – NONE
Hazard statement(s) – NONE
Precautionary statement(s) – NONE

Hypertherm Plasma Systems 209

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

3 – Composition / Information on ingredients

HAZARDOUS INGREDIENT 1 % W/W CAS No. EC No. EC Classification

Propylene Glycol 30-50 57-55-6 200-338-0 NONE
GHS Classification
Not classified NONE
HAZARDOUS INGREDIENT 2 % W/W CAS No. EC No. EC Classification
Benzotriazole <1.0 95-14-7 202-394-1 Xn, F
GHS Classification
Acute Tox. 4 (Oral, Dermal, Inhalation)
WARNING H302, 312, 319, 332, 412
Eye Irrit. 2, Aquatic Chronic 3

For full text of R phrases see section 16. For full text of H/P phrases see section 16. Non-hazardous components are not listed.

4 – First Aid measures

Inhalation Unlikely to be hazardous by inhalation unless present as an aerosol.

Remove patient from exposure.
Skin Contact Wash skin with water.
Eye Contact If substance has gotten into the eyes, immediately wash out with plenty of water for
several minutes.
Ingestion Laxative. Do not induce vomiting. If swallowed, seek medical advice immediately and
show this container or label.
Further Medical Treatment Unlikely to be required but if necessary treat symptomatically.

5 – Fire-Fighting measures

Combustible but not readily ignited.

Extinguishing media Extinguish preferably with dry chemical, foam or water spray.
Unsuitable Extinguishing Media None known.
Fire Fighting Protective Equipment A self contained breathing apparatus and suitable protective clothing should be worn
in fire conditions.

6 – Accidental release measures

Personal Precautions Put on protective clothing.

Environmental Exposure Controls Absorb spillages onto sand, earth or any suitable adsorbent material.
Other None.

210 Hypertherm Plasma Systems

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

7 – Handling and storage

Handling Unlikely to cause harmful effects under normal conditions of handling and use.
Storage Keep container tightly closed and dry. Keep away from heat. Keep out of the reach of
children. Keep away from oxidizing agents.
Storage Temperature: Ambient.
Storage Life: Stable at ambient temperatures.
Specific Use: Industrial use only.

8 – Exposure controls / personal protection

Respirators Normally no personal respiratory protection is necessary. Wear suitable respiratory

protective equipment if exposure to levels above the occupational exposure limit is
likely. A suitable dust mask or dust respirator with filter type A/P may be appropriate.
Eye Protection Safety spectacles.

Gloves Wearing of chemical protective gloves is not necessary.

Body protection None.
Engineering Controls Ensure adequate ventilation to remove vapors, fumes, dust etc.
Other None.

OCCUPATIONAL EXPOSURE LIMITS

LTEL LTEL STEL STEL

SUBSTANCE CAS No. Note:
(8 hr TWA ppm) (8 hr TWA mg/m3) (ppm) (mg/m3)

AIHA WEEL
Propylene Glycol 57-55-6 NE 10* NE NE
in the USAA

Benzotriazole 95-14-7 NE NE NE NE None

9 – Physical and chemical properties

Information on basic physical and chemical properties

Appearance – Liquid Vapor Pressure (mm Hg) – Not available
Color – Pinkish-Reddish Vapor Density (Air=1) – Not available
Odor – Slight Density (g/ml) – 1.0 ± 0.1 g/ml
Odor Threshold (ppm) – Not available Solubility (Water) – Soluble
pH (Value) – 5.5-7.0 (Concentrated) Solubility (Other) – Not established
Melting Point (°C) / Freezing Point (°C) – < -0°C / (< 32°F) Partition Coefficient (n-Octanol/water) – Not available
Boiling point/boiling range (°C): >100°C (>212°F) Auto Ignition Temperature (°C) – Not available
Flash Point (°C) – >95°C (>203°F) Decomposition Temperature (°C) – Not available
Evaporation rate – Not available Viscosity (mPa.s) – Not available
Flammability (solid, gas) – Non-flammable Explosive properties – Not explosive
Explosive limit ranges – Not available Oxidizing properties – Not oxidizing
Other information – None

Hypertherm Plasma Systems 211

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

10 – Stability and reactivity

Reactivity None
Chemical stability Stable under normal conditions
Possibility of hazardous reactions None
Conditions to avoid None anticipated
Incompatible materials Keep away from oxidizing agents
Hazardous Decomposition Product(s) Carbon monoxide, Carbon dioxide, Nitrogen oxides

11 – Toxicological information

11.1.1 – Substances
Acute toxicity
Ingestion Low oral toxicity, but ingestion may cause irritation of the
gastrointestinal tract
Inhalation Unlikely to be hazardous by inhalation
Skin Contact Mild irritant to rabbit skin
Eye Contact Mild irritant to the eye
Hazard label(s) None
Serious eye damage/irritation Mild irritant to the eye
Respiratory or skin sensitization Mild irritant to rabbit skin
Mutagenicity Not known
Carcinogenicity IARC, NTP, OSHA, ACGIH do not list this product or any
components thereof as known or suspected carcinogen
Reproductive toxicity Not known
STOT – single exposure Not known
STOT – repeated exposure Not known
Aspiration hazard Not known

12 – Ecological information

Toxicity Do not let this chemical/product enter the environment.

Persistence and degradability Biodegradable
Bioaccumulative potential None anticipated
Mobility in soil The product is predicted to have moderate mobility in soil.
Results of PBT and vPvB assessment None assigned
Other adverse effects None anticipated

13 – Disposal considerations

Waste treatment methods – Disposal should be in accordance with local, state or national legislation. No special measures are
required. No specific waste water pretreatment required.
Additional Information – None

212 Hypertherm Plasma Systems

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

14 – Transport information

Not classified as dangerous for transport.

Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code.

15 – Regulatory information

USA
TSCA (Toxic Substance Control Act) – Listed.
SARA 302 – Extremely Hazardous Substances – Not applicable.
SARA 313 – Toxic Chemicals – Not applicable.
SARA 311/312 – Hazard Categories – None.
CERCLA (Comprehensive Environmental Response Compensation and Liability Act) – Not applicable.
CWA (Clean Water Act) – CWA 307 – Priority Pollutants – None.
CAA (Clean Air Act 1990) CAA 112 - Hazardous Air Pollutants (HAP) – None.
Proposition 65 (California) – Not applicable.
State Right to Know Lists – CAS No. 95-14-7 Listed in MA, NJ, PA.
Canada
WHMIS Classification (Canada) – Not classified.
CANADA INGREDIENT DISCLOSURE LIST – Not applicable.
Canada (DSL/NDSL) – Listed.
EU
EINECS (Europe) – Listed.
Wassergefährdungsklasse (Germany) – None.

Hypertherm Plasma Systems 213

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

16 – Other information

The following sections contain revisions or new statements: 1 – 16.

Legend
LTEL Long Term Exposure Limit
STEL Short Term Exposure Limit
STOT Specific Target Organ Toxicity
DNEL Derived No Effect Level
PNEL Predicted No Effect Concentration

References:
Risk Phrases and Safety Phrases
None. Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Hazard statement(s) and Precautionary statement(s).
None. Preparation is not classified as hazardous in the sense of directive 1999/45/EC and 2006/121/EC.
Training advice – None.
Additional Information
USA – NFPA (National Fire Protection Association) – NFPA Rating: Flammability – 1, Health – 0, Instability/Reactivity – 0.
Information contained in this publication or as otherwise supplied to Users is believed to be accurate and is given in good faith,
but it is for the Users to satisfy themselves of the suitability of the product for their own particular purpose. Hypertherm gives no
warranty as to the fitness of the product for any particular purpose and any implied warranty or condition (statutory or otherwise) is
excluded except to the extent that exclusion is prevented by law. Hypertherm accepts no liability for loss or damage (other than that
arising from death or personal injury caused by defective product, if proved), resulting from reliance on this information. Freedom
under Patents, Copyright and Designs cannot be assumed.

Note: Original safety data sheet authored in English

214 Hypertherm Plasma Systems

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

°C °F
4 40

-1 30

-7 20

-12 10

-18 0
Temperature

-23 -10

-29 -20

-34 -30

-40 -40

-46 -50

-51 -60

-57 -70
0 10 20 30 40 50 60

% of Propylene Glycol

Freezing Point of Propylene Glycol Solution

Hypertherm Plasma Systems 215

 Date SAFETY DATA SHEET Revision
6 Dec 2010 Torch Coolant 30% PG Mixture 2.01CLP

216 Hypertherm Plasma Systems