Hypertherm Powermax800 User manual

600 Volt Conversion

Installation Manual

803200 - Rev. 0

600 Volt Conversion

Kit: 128312

Installation Manual

IM-320

(P/N 803200)

HYPERTHERM and POWERMAX are trademarks of Hypertherm, Inc. and may be

registered in the United States and/or other countries

Revision 0 June, 1998

HYPERTHERM, Inc.

P.O. Box 5010

Hanover, New Hampshire 03755-5010

Tel.: (603) 643-3441

Fax: (603) 643-5352

http://www.hypertherm.com

email:[email protected]

Hypertherm Offices Worldwide

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

Tel.: (603) 643-3441 (Main Office)

Fax: (603) 643-5352 (All Departments)

Tel.: (800) 643-9878 (Technical Service)

Tel.: (800) 737-2978 (Customer Service)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D–63457 Hanau-Wolfgang, Germany

Tel.: 49 6181 58 2100

Fax: 49 6181 58 2134

European Technical Support Organization (ETSO)

Technologiepark Hanau

Rodenbacher Chaussee 6

D–63457 Hanau-Wolfgang, Germany

Tel.: 49 6181 58 2100

Fax: 49 6181 58 2134

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2

K.B. Warehouse Complex

Singapore 417847, Republic of Singapore

Tel.: 65 841 2489

Fax: 65 841 2490

Hypertherm U.K.

9 Berkeley Court • Manor Park

Runcorn, Cheshire, England WA7 1TQ

Tel.: 44 1928 579 074

Fax: 44 1928 579 604

Hypertherm France

10, Allée de I’lsara

F-95000 Cergy-Pontoise, France

Tel.: 33 1 34 24 03 05

Fax: 33 1 34 25 09 64

Hypertherm Italy

Via Stilicone 18

20154 Milan, Italy

Tel.: 39 2 34 53 22 11

Fax: 39 2 34 53 20 18

1-1

600V Installation Manual

SPECIFICATIONS

Section 1 SPECIFICATIONS

In this section:

Introduction ........................................................................................1-2

Specifications ..................................................................................... 1-2

600 Volt Powermax900 Power Supply ..........................................1-2

1-2 600V Installation Manual

SPECIFICATIONS

INTRODUCTION

The instructions in this manual will enable a qualified electronics technician to convert the

208/240/480 volt Powermax900 or 208/240/480 volt Powermax800 power supply into a 600 volt

power supply. The kit (128312) contains a transformer and case, wheels, castors, and 2 line cords -

one to hook up to a line disconnect box or 3-phase plug, and a shorter cord to connect from the

transformer case to the link box at the rear of the Powermax - See Figure 2-1. See also

Section 3 for a list of parts for the 600 volt conversion kit.

When installation is complete, refer to the Operator Manual for setup, operating instructions and

maintenance of the Powermax system.

SPECIFICATIONS See the operator manual for Powermax800 specifications

600 Volt Powermax900 Power Supply

Rated Open Circuit Voltage (OCV) (U0) ..............300VDC

Rated Output Current (I2) ....................................20-50 amps

Rated Output Voltage (U2) ..................................120VDC

Duty Cycle (X) @ 40°C .......................................50% (I2=55A, U2=120V) See data tag on power

supply for more information on duty cycle

Ambient temperature/duty cycle..........................Power supplies will operate between +14°

and 104°F (-10°and +40°C). Power

supplies operated in an ambient

temperature above 86°F (30°C) may show

some decrease in duty cycle.

Apparent Input Power (S1) ..................................11.4kVA (U1I1)

Input Voltage (U1)/Input Current (I1)

@ 6.6 kw Output .................................................600V/12A - 3φ, 60 Hz

Dimensions and Weight:

Depth...................................................................23.1" (590 mm)

Width ...................................................................15.25" (390 mm)

Height..................................................................27.7" (700 mm)

Weight .................................................................128 pounds (58 kg)

Gas Type.............................................................Air or Nitrogen

Gas Quality, Air ...................................................Clean, dry, oil-free

Gas Quality, Nitrogen..........................................99.995% pure

Gas Inlet Pressure ..............................................90 psi (6.2 bar)

Gas Flow .............................................................360 scfh/6 scfm at 90 psi (170 l/min

at 6.2 bar) supplied to power supply

pressure regulator

Power Supply pressure regulator setting ............70 psi (4.8 bar) flowing

600V INSTALLATION

600V Installation Manual 2-1

Section 2 600V INSTALLATION

In this section:

Installation .........................................................................................2-2

Installation of Wheels and Casters to Transformer Case..................2-4

Wheel Installation .........................................................................2-4

Caster Installation.........................................................................2-4

Attaching Power Supply Bracket to Powermax900 Chassis .............2-6

Attaching 600V Transformer Case Assembly to

Powermax900 Chassis .....................................................................2-8

Switching Voltage Configuration to 480V ..........................................2-9

Hooking Up the Three-Phase Transformer Secondary Power Cord

from 600V Transformer Case Assembly to Powermax900 ...............2-10

Choosing Plug, Power Cord and Line Disconnect Box Fuse ............2-11

Power Cord Plug......................................................................2-11

Power Cord - 600V ..................................................................2-11

Line Voltage Disconnect Box and Fuses .................................2-11

600V INSTALLATION

2-2 600V Installation Manual

WARNING

INSTALLATION MUST BE PERFORMED ONLY BY HYPERTHERM DISTRIBUTORS OR

QUALIFIED ELECTRONICS TECHNICIANS!!

SHOCK HAZARD: Always turn off power, unplug cord from wall and wait 5 minutes before

removing any cover of the power supply! If power unit is directly connected to a line

disconnect box, place line disconnect switch to OFF position. Lock out and tag out switch

before proceeding!

INSTALLATION

The installation of the 600V kit to the 208/240/480V Powermax900 involves 6 basic steps:

1. Installation of wheels and casters to the transformer case.

2. Attaching the 600V power supply bracket to the Powermax900 chassis.

3. Attaching the 600V case assembly to the Powermax900 chassis.

4. Switching the power supply voltage configuration to 480V.

5. Hooking up the three-phase transformer secondary power cord from the 600V

transformer case assembly to the Powermax900.

6. Choosing the plug, power cord and line disconnect box fuse.

WARNING

THE 208/240/480V POWERMAX900 POWER SUPPLY IS SET UP TO OPERATE AT 240V WITH

A SINGLE-PHASE INPUT. WHEN CONVERTED TO A 600V POWER SUPPLY, THE VOLT-

AGE CONFIGURATION IN THE POWER SUPPLY MUST BE SWITCHED TO 480V, AND THE

POWER CORD MUST BE HOOKED UP FOR THREE-PHASE OPERATION. See pages 2-9 to

2-10.

See Section 3 for a parts list of the 128312 Powermax 600V conversion kit.

Note: All graphics and text in this document refer to the Powermax900. Unless otherwise noted, all

instructions apply to either the Powermax800 or Powermax900.

600V INSTALLATION

600V Installation Manual 2-3

Figure 2-1 Powermax900 600V Power Supply Assembled

600V INSTALLATION

2-4 600V Installation Manual

INSTALLATION OF WHEELS AND CASTERS TO TRANSFORMER

CASE

Wheel Installation

1. Carefully turn transformer case assembly upside down.

2. Snap an 027249 retaining ring on one end of the 004672 wheel axle.

3. Slide one 027057 wheel on the axle.

4. Slide 008973 shoulder washer over the end of the axle with the larger diameter end of

the washer facing the mounted wheel.

5. Slide the axle through both holes in the rear of the transformer case assembly.

6. Slide the second 008973 shoulder washer over the end of the axle with the smaller

diameter end of the washer facing the transformer case.

7. Slide the second 027057 wheel onto the axle.

8. Snap the second 027249 retaining ring on the end of the axle to secure the second

wheel.

Caster Installation

1. Attach the 027299 casters to the case with the 075470 10-32 screws and 075174 star

washers as shown in Figure 2-2.

2. Turn transformer case back over on to wheels - Figure 2-3.

Wheel and caster installation complete.

600V INSTALLATION

600V Installation Manual 2-5

Figure 2-3 Wheels and Casters Installed on 600V Transformer Case

Figure 2-2 Wheel and Caster Installation

027249

Retaining

ring

008973

Shoulder

washer

027299

Caster

075470

10-32 screws (8)

004672

Axle

075174

10-32 star washers (8)

027057

Wheel 027057

Wheel

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