Hypertherm Manual Family Service Manual (SM)

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Plasma Arc Cutting System

Service Manual 802280 - Revision 4

EN50199 EN50192

Plasma Arc Cutting System

Service Manual

IM-228

(P/N 802280)

for systems beginning with serial number

800-010000

Revision 4 December, 1997

Hypertherm, Inc.

P.O. Box 5010

Hanover, New Hampshire 03755-5010

Tel.: (603) 643-3441 Fax: (603) 643-5352

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

registered in the United States and/or other countries

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

Ohmstrasse 6 D–63477 Maintal, Germany Tel.: 49 6181 94070 Fax: 49 6181 940719

European Technical Support Organization (ETSO)

Ohmstrasse 6 D–63477 Maintal, Germany Tel.: 49 6181 94070 Fax: 49 6181 940739

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

ELECTROMAGNETIC COMPATIBILITY

EMC INTRODUCTION

The 400V CE power supply has been built in compliance with standard EN50199. To ensure that the equipment works in a compatible manner with other radio and electronic systems, the equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN50199 may not be adequate to completely 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 use other measures to further reduce interference.

This plasma equipment should be used only in an industrial environment. It may be difficult to ensure electromagnetic compatibility in a domestic environment.

INSTALLATION AND USE

The user is responsible for installing and using the plasma equipment according to the manufacturer's instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see

Earthing of Workpiece

it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

ASSESSMENT OF AREA

Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids.

. In other cases

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.

METHODS OF REDUCING EMISSIONS

Mains Supply

Cutting equipment should be connected to the mains supply according to the manufacturer's recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure

Maintenance of Cutting Equipment

The cutting equipment should be routinely maintained according to the manufacturer's recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer's instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer's recommendations.

Cutting Cables

The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential Bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of 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 steelwork, 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 given in IEC TC26 (sec)94 and IEC TC26/108A/CD Arc Welding Equipment 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.

Service Manual

WARRANTY

WARNING

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.

GENERAL

HYPERTHERM, Inc. warrants that Products shall be free from defects in materials and workmanship, under proper and normal use for which such Equipment is recommended, for a period of two (2) years, except only with respect to the Torch, for which the warranty period shall be one (1) year, from the date of its delivery to you.

HYPERTHERM, at its sole option, shall repair, replace, or adjust, free of charge, any Products covered by this warranty which shall be returned with HYPERTHERM's prior authorization (which shall not be unreasonably withheld), properly packed, to HYPERTHERM's place of business in Hanover, New Hampshire, all costs, insurance and freight prepaid, and which examination proves not to be free from defects in materials and workmanship. HYPERTHERM shall not be liable for any repairs, replacements, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with HYPERTHERM's written consent. This warranty shall not apply to any Product which has been mishandled, incorrectly installed, modified or assembled by you or any other person. HYPERTHERM shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable warranty period specified herein above. THE FOREGOING SHALL CONSTITUTE THE SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF ITS WARRANTY.

PATENT INDEMNITY

Except only in cases of Products not manufactured by HYPERTHERM or manufactured by a person other than HYPERTHERM not in strict conformity with HYPERTHERM's specifications, and in cases of designs, processes, formulae or combinations not developed or purported to be developed by HYPERTHERM, HYPERTHERM agrees to indemnify, protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because of the use in or about the construction or operation of Equipment or any design, system, formula, combination, article or material which infringes or alleges to infringe on any patent or other right. Distributors shall notify HYPERTHERM promptly upon learning of any action or threatened action in connection with any such alleged infringement, and each party may appoint its own counsel for any such action or threatened action.

DISCLAIMER OF OTHER WARRANTIES

HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR OTHERS (INCLUDING WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN. This warranty is in lieu of any and all warranties, express or implied, by law or otherwise; and Distributors are not authorized to give any other warranty purporting to be binding upon HYPERTHERM upon resale of Products to their customers. IN NO EVENT shall HYPERTHERM be liable for incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any Equipment sold hereunder.

Service Manual

SECTION 1 SAFETY ......................................................................................................................1-1

About Notes, Cautions & Warnings .................................................................................................................... 1-2

Safety Instructions .............................................................................................................................................. 1-2

Eye Protection ............................................................................................................................................. 1-2

Skin Protection ............................................................................................................................................. 1-2

Toxic Fume Prevention .................................................................................................................................1-2

Fire Prevention ............................................................................................................................................. 1-2

Electric Shock Prevention ............................................................................................................................ 1-2

Explosion Prevention ................................................................................................................................... 1-3

Noise Prevention .......................................................................................................................................... 1-4

Grounding ..................................................................................................................................................... 1-4

Safety Reminders ......................................................................................................................................... 1-4

Electronic Health Support Equipment ...........................................................................................................1-4

SECTION 1A SÉCURITÉ.............................................................................................................. 1a-1

Au sujet des Notes, Attention et avertissement ............................................................................................... 1a-1

Consignes de sécurité ..................................................................................................................................... 1a-2

Protection des yeux .................................................................................................................................. 1a-2

Protection de la peau ................................................................................................................................ 1a-2

Prévention des vapeurs toxiques .............................................................................................................. 1a-2

Prévention des incendies .......................................................................................................................... 1a-2

Prévention des chocs électriques ............................................................................................................. 1a-2

Prévention des explosions ........................................................................................................................ 1a-3

Protection contre le bruit ........................................................................................................................... 1a-4

Mise à la masse et à la terre ..................................................................................................................... 1a-4

Rappels de sécurité .................................................................................................................................. 1a-4

Prothèses électroniques ........................................................................................................................... 1a-4

SECTION 2 DESCRIPTION & SPECIFICATIONS ....................................................................... 2-1

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

Specifications .......................................................................................................................................................2-3

PAC121 50A Torches .......................................................................................................................................... 2-4

IEC Symbols Used ...............................................................................................................................................2-6

SECTION 3 MAINTENANCE........................................................................................................ 3-1

Introduction .......................................................................................................................................................... 3-2

Routine Maintenance ........................................................................................................................................... 3-2

Theory of Operation ............................................................................................................................................. 3-4

Sequence of Operation ........................................................................................................................................ 3-6

Troubleshooting ................................................................................................................................................... 3-7

Power Board ...................................................................................................................................................... 3-26

Control Board .....................................................................................................................................................3-28

Torch Check ....................................................................................................................................................... 3-30

PAC121TS Torch Parts Removal and Replacement ......................................................................................... 3-32

PAC121MS Torch Parts Removal and Replacement ........................................................................................ 3-34

Quick Disconnect O-Ring Removal and Replacement ...................................................................................... 3-36

SECTION 4 PARTS LIST ............................................................................................................. 4-1

Power Supply - 208/240/480V

200/230/400V ............................................................................................................................. 4-2

PAC121TS Torch Assembly .............................................................................................................................. 4-10

PAC121MS Torch Assembly ............................................................................................................................. 4-11

Consumable Parts ............................................................................................................................................. 4-12

Powermax800 Field Upgrade Kits and Optional Parts ....................................................................................... 4-13

Power Supplies - 208/240/480V ........................................................................................................................ 4-13

Power Supplies - 200/230/400V ........................................................................................................................ 4-13

Recommended Spare Parts - Powermax800 - 208/240/480V ...........................................................................4-14

Recommended Spare Parts - Powermax800 - 200/230/400V ...........................................................................4-14

Service Manual

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TABLE OF CONTENTS

SECTION 5 PARTS LIST - CE .....................................................................................................5-1

Power Supply - 400V CE ..................................................................................................................................... 5-2

PAC121TS Torch Assembly .............................................................................................................................. 5-10

PAC121MS Torch Assembly ............................................................................................................................. 5-11

Consumable Parts - CE ..................................................................................................................................... 5-12

Powermax800 Field Upgrade Kits and Optional Parts ....................................................................................... 5-13

Power Supplies - 400V CE ................................................................................................................................ 5-13

Recommended Spare Parts - Powermax800 - 400V CE ...................................................................................5-14

SECTION 6 WIRING DIAGRAMS ................................................................................................ 6-1

Powermax800 Electrical Schematic: 208/240/480V ............................................................................................ 6-2

Powermax800 Electrical Schematic: 200/230/400V ............................................................................................ 6-3

Powermax800 Electrical Schematic: 400V CE .................................................................................................... 6-4

Powermax800 Troubleshooting Schematic 1 of 2 ............................................................................................... 6-5

Powermax800 Troubleshooting Schematic 2 of 2 ............................................................................................... 6-6

Powermax800 CE Troubleshooting Schematic 1 of 2 ......................................................................................... 6-7

Powermax800 CE Troubleshooting Schematic 2 of 2 ......................................................................................... 6-8

APPENDIX A AERATION MANIFOLD FOR CUTTING ALUMINUM ............................................ a-1

APPENDIX B STANDARDS INDEX............................................................................................... a-2

ILLUSTRATIONS

Figure 2-1 Powermax800 Hand Plasma Cutting System ................................................................................ 2-2

Figure 2-2 Powermax800 Power Supply with Dimensions .............................................................................. 2-3

Figure 2-3 PAC121TS Torch with Dimensions ................................................................................................ 2-4

Figure 2-4 PAC121MS Torch with Dimensions ............................................................................................... 2-4

Figure 2-5 S Mark Label ................................................................................................................................. 2-5

Figure 3-1 Filter Assembly ............................................................................................................................... 3-2

Figure 3-2 Air Filter Removal ........................................................................................................................... 3-3

Figure 3-3 Inverter Links .................................................................................................................................. 3-4

Figure 3-4 Single-Phase, 240 or 208V Block Diagram .................................................................................... 3-5

Figure 3-5 Back Side of Power Board - Test Points ...................................................................................... 3-27

Figure 3-6 Control Board Test Points ............................................................................................................ 3-29

Figure 3-7 PAC121TS Torch Main Body Removal ........................................................................................ 3-32

Figure 3-8 PAC121TS Torch Switch Removal .............................................................................................. 3-33

Figure 3-9 PAC121MS Torch Assembly ........................................................................................................ 3-35

Figure 3-10 Quick Disconnect O-Ring Removal and Replacement ................................................................. 3-36

Figure 4-1 Powermax800 - Front ..................................................................................................................... 4-3

Figure 4-2 Powermax800 - Top and Right Side .............................................................................................. 4-5

Figure 4-3 Powermax800 - Bottom and Left Side ............................................................................................ 4-7

Figure 4-4 Powermax800 - Rear ..................................................................................................................... 4-9

Figure 4-5 PAC121TS Torch Assembly and Leads ....................................................................................... 4-10

Figure 4-6 PAC121MS Torch Assembly and Leads ...................................................................................... 4-11

Figure 4-7 Consumable Parts ........................................................................................................................4-12

Figure 5-1 Powermax800 CE - Front ............................................................................................................... 5-3

Figure 5-2 Powermax800 CE - Top and Right Side ........................................................................................ 5-5

Figure 5-3 Powermax800 CE - Bottom and Left Side ...................................................................................... 5-7

Figure 5-4 Powermax800 CE - Rear ............................................................................................................... 5-9

Figure 5-5 PAC121TS Torch Assembly and Leads ....................................................................................... 5-10

Figure 5-6 PAC121MS Torch Assembly and Leads ...................................................................................... 5-11

Figure 5-7 Consumable Parts - CE ................................................................................................................ 5-12

Figure a-1 Aeration Manifold ........................................................................................................................... a-1

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Service Manual

Section 1 SAFETY

In this section:

SAFETY

About Notes< Cautions and Warnings .................... 1-1

Safety Instructions................................................... 1-2

Eye Protection .................................................. 1-2

Skin Protection ................................................. 1-2

Toxic Fume Prevention ..................................... 1-2

Fire Prevention ................................................. 1-2

Electric Shock Prevention................................. 1-2

Explosion Prevention ........................................ 1-3

Compressed Gas Cylinders .......................... 1-3

Pressure Regulators...................................... 1-3

Hoses ............................................................ 1-3

Noise Protection .................................................. 1-4

Grounding ............................................................ 1-4

Input Power ................................................... 1-4

Work Cable.................................................... 1-4

Work Table .................................................... 1-4

Safety Reminders ................................................ 1-4

Electronic Health Support Equipment .................. 1-4

Before using this plasma arc system. . . .

Each person who will operate this equipment, perform service or maintenance, or supervise its use must read the safety instructions and warnings in this manual and the labels on the equipment.

About Notes, Cautions and Warnings

Notes: Throughout this manual, useful information for operating the plasma system is presented in “notes”,

such as shown in this paragraph.

Cautions: Information in bold type and surrounded by a box describes a situation that may cause

damage to the plasma system.

WARNINGS

Warnings describe situations that present a physical danger to the operator, and advice to avoid or correct the situation. Each type of warning includes applicable danger symbols, such as a hand burn, electrical shock, fire, explosion, etc.

WARNING — Instant-On

Torches

Instant-on torches produce a plasma arc immediately after the torch switch is

pushed.

Always hold a hand torch away from your body as a precaution against accidental torch firing. Be aware of this hazard, which has potential for serious bodily injury.

• Never touch the torch body, workpiece or the water in a water table when operating the plasma system.

• When using a water table, be sure that it is correctly connected to earth ground.

• Operating the plasma system completes an electrical circuit between the torch and the workpiece and anything touching the workpiece. The workpiece is part of the electrical circuit.

WARNING — Electric Shock

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SAFETY

Eye Protection

• Wear dark safety glasses or goggles with side shields, or a welding helmet, in accordance with applicable national or local codes, to protect eyes against the plasma arc’s ultraviolet and infrared rays.

Lens Shade

Arc Current AWS (USA) ISO-4850

Up to 100 A No. 8 No. 11 100–200 A No. 10 No. 11-12 200–400 A No. 12 No. 13 Over 400 A No. 14 No. 14

• Replace the glasses, goggles or helmet when the lens becomes pitted or broken.

• Warn other people in the area not to look directly at the arc unless they are wearing glasses, goggles or a helmet.

• Prepare the cutting area in a manner that reduces the reflection and transmission of ultraviolet light: – Paint walls and other surfaces with dark colors to

reduce reflection.

– Install protective screens or curtains to reduce

ultraviolet transmission.

Skin Protection

• Wear protective clothing to protect against burns caused by ultraviolet light, sparks and hot metal: – Gauntlet gloves, safety shoes and hat. – Flame-retardant clothing which covers all

exposed areas.

– Cuffless trousers to prevent entry of sparks and

slag.

Toxic Fume Prevention

• Keep the cutting area well ventilated.

• Remove all chlorinated solvents from the cutting area before cutting. Certain chlorinated solvents decompose when exposed to ultraviolet radiation to form phosgene gas.

• Wear proper breathing mask and use proper ventilation when cutting galvanized metal.

• Do not cut containers with toxic materials inside. Clean containers that have held toxic materials thoroughly before cutting.

WARNING — Toxic Fumes

Do not cut metal or painted metals containing zinc, lead, cadmium or beryllium unless the operator, or anyone else subjected to the fumes, wears respiratory equipment or an air-supplied helmet.

Fire Prevention

• Make fire extinguishers available in the cutting area.

• Remove all combustible materials from the immediate cutting area to a distance of at least 35 feet (10 m).

• Quench freshly cut metal or allow metal to cool before handling it or bringing it into contact with combustible materials.

• Never use a plasma system to cut containers with potentially flammable materials inside. Such containers must be thoroughly cleaned prior to cutting.

• Ventilate potentially flammable atmospheres before cutting with a plasma system. When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.

• Never operate the plasma system in an atmosphere which contains heavy concentrations of dust, flammable gas or combustible liquid vapors unless properly vented.

Electric Shock Prevention

All Hypertherm plasma systems use high voltage (up to 280 VDC) to initiate the plasma arc. Take the following precautions when operating the plasma system:

• Wear insulated gloves and boots, and keep body and clothing dry.

• Do not stand, sit or lie on—or touch—any wet surface when using the plasma system.

• Maintain proper insulation against electrical shock. If you must work in or near a damp area, use extreme caution.

• Provide a wall-mounted disconnect switch with properly sized fuses close to the power supply. This switch allows the operator to turn the power supply off quickly in an emergency situation.

• Conform to all local electrical codes for primary wiring sizes and types.

• Inspect the primary power cord frequently for damage or cracking of the cover. Bare wiring can kill. Do not use a system with a damaged power cord. Replace a damaged power cord immediately.

• Inspect the torch leads. Replace if frayed or damaged.

• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.

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HYPERTHERM Plasma Systems

SAFETY

Electric Shock Prevention (continued)

• Before changing the torch parts, disconnect the main power or unplug the power supply. After changing torch parts and replacing the retaining cap, plug in the power supply again.

• Never bypass or shortcut the safety interlocks.

• Before removing a power supply cover for maintenance, disconnect the main power at the wall disconnect switch or unplug the power supply. To avoid exposure to severe electrical hazard, wait five minutes after disconnecting the main power to allow capacitors to discharge.

• Never operate the plasma system unless the power supply unit covers are in place. Exposed power supply connections present a severe electrical hazard.

Explosion Prevention

WARNING — Compressed Gas

The plasma system uses compressed gas. Observe proper precautions when handling and using compressed gas equipment and cylinders.

• Never use a cylinder that is not upright and secured in place.

• Never move or transport a cylinder without its protective valve cover in place.

• Never use a gas cylinder or its contents for any purpose other than that for which it is intended.

• Never lubricate cylinder valves with oil or grease.

• Never allow electrical contact between the plasma arc and a cylinder.

• Never expose cylinders to excessive heat, sparks, slag or open flame.

• Never use hammers, wrenches or other tools to open stuck cylinder valves.

Pressure Regulators

• Be certain that all pressure regulators are in proper working condition.

• Never use a regulator for any gas other than that for which it is intended.

• Never use a regulator that leaks, creeps excessively or is physically damaged in any way.

• Never attempt to lubricate a regulator with oil or grease.

• Do not use the plasma system if explosive dust or vapors may be present.

• Do not cut pressurized cylinders or any closed container.

WARNING —

Hydrogen Explosion Hazard

If your system uses hydrogen, remember that this is a flammable gas that presents an explosion hazard. Keep flames away from cylinders containing hydrogen mixtures and hoses that carry hydrogen mixtures. Also, keep flames and sparks away from the torch when using argonhydrogen as the plasma gas.

Compressed Gas Cylinders

Handle and use compressed gas cylinders in accordance with safety standards published by the U.S. Compressed Gas Association (CGA), American Welding Society (AWS), Canadian Standards Association (CSA) or applicable national or local codes.

• Never use a cylinder that leaks or is physically damaged.

WARNING — Hydrogen Detonation

with Aluminum Cutting

When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations.

Installing an aeration manifold on the floor of the water table is an effective way to eliminate the possibility of hydrogen detonation when cutting aluminum. Refer to the Appendix section of this manual for instructions on how to fabricate an aeration manifold.

Hoses

• Label and color-code all gas hoses in order to clearly identify the type of gas in each hose. Consult applicable national or local codes.

• Never use the oxygen hose for any gas other than oxygen.

• Examine hoses at regular intervals for leaks, wear, loose connections or other hazard.

• Replace hose that is damaged in any way.

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SAFETY

Hoses (continued)

• Keep hose lengths to a minimum to prevent damage, reduce pressure drop and to prevent possible flow restrictions.

• Prevent kinking by laying out hoses as straight as possible between termination points.

• Coil any excess hose and place it out of the way to prevent damage and to eliminate the danger of tripping.

Noise Protection

The plasma cutting process can generate high levels of noise. Depending on the arc current,

material being cut, acoustics and size of the cutting room, distance from the torch and other factors, acceptable noise levels as defined by national or local codes may be exceeded by your plasma system.

• Always wear proper ear protection when cutting or

gouging with the plasma system.

Grounding

Input Power

• Be sure to connect the power cord ground wire to the

ground in the disconnect box.

• If installation of the plasma system involves

connecting the power cord to the power supply, be sure to properly connect the power cord ground wire. Conform to Canadian Standards Association (CSA) standards by placing the power cord ground wire on the stud first; then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessive

heating.

Work Cable

• Attach the work cable securely to the workpiece or

the work table by making good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.

Work Table

• Connect the work table to a high-quality earth

ground, in accordance with the U.S. National Electrical Code, Article 250, Section H, Grounding Electrode System, or other appropriate national or local codes.

Safety Reminders

• Never bypass or shortcut the safety interlocks on any of the plasma system units.

• Except in Hypertherm’s largest mechanized systems, all Hypertherm torches are designed with a safety interlock that prevents firing of the plasma arc when the retaining cap is loosened.

• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a potentially dangerous situation to the operator and any personnel in the area. Hypertherm’s warranty does not cover problems caused by the use of torches not made by Hypertherm.

• Use only consumable parts and replacement parts made by Hypertherm. Hypertherm’s warranty does not cover problems caused by the use of parts not made by Hypertherm.

• Never operate the plasma system with any of its covers not in place. This would be hazardous to the operator and other people in the area, and prevents the proper cooling of the equipment.

Electronic Health Support Equipment

Plasma arc cutting and gouging systems create electric and magnetic fields that may interfere with the correct operation of electronic health support equipment, such as pacemakers or hearing aids. Any person who wears a pacemaker or hearing aid should consult a doctor before operating or being near any plasma system when it is in use. To minimize exposure to EMF:

• Keep both the work cable and the torch lead on one side of your body. Keep your body from coming in between the torch lead and the work cable.

• Route torch leads as close as possible to work cable.

• Do not wrap the torch lead or work cable around your body.

• Stay as far away from the power supply as possible.

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HYPERTHERM Plasma Systems

Section 1a SÉCURITÉ

SÉCURITÉ

IDENTIFIER LES CONSIGNES DE SÉCURITÉ

Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels. Si vous trouvez un symbole de sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques.

SUIVRE LES INSTRUCTIONS DE SÉCURITÉ

Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine.

• Les étiquettes de sécurité doivent rester lisibles. Remplacer immédiatement les étiquettes manquantes ou abîmées.

• Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. Ne laisser personne utiliser la machine sans connaître son fonctionnement.

• Garder la machine en bon état. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement.

DANGER AVERTISSEMENT PRÉCAUTION

Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux.

• Les étiquettes de sécurité DANGER et AVERTISSEMENT sont situées sur la machine pour signaler certains dangers spécifiques.

• Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement.

• Les messages de PRÉCAUTION précèdent les instructions d’utilisation contenues dans ce manuel et signalent que le matériel risque d’être endommagé si les instructions ne sont pas suivies correctement.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

Prévention des incendies

• Avant de commencer, s’assurer que la zone de coupage ne présente aucun danger. Conserver un extincteur à proximité.

• Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage.

• Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles.

• Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.

• Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma.

• Lors de l’utilisation d’oxygène comme gaz plasma, un système de ventilation par aspiration est nécessaire.

Prévention des explosions

• Ne pas couper en présence de poussière ou de vapeurs.

• Ne pas couper de bouteilles, de tuyaux ou autres récipients fermés et pressurisés.

• Ne pas couper de récipients contenant des matières combustibles.

AVERTISSEMENT

Risque d’explosion

Argon-hydrogène et méthane

L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane.

AVERTISSEMENT

Détonation de l’hydrogène lors du

coupage de l’aluminium

• Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche la partie inférieure de la pièce d’aluminium, de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma.

• Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération.

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SÉCURITÉ

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves.

• La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique.

• Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma.

Prévention des chocs électriques

Tous les systèmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 à 400 V).On doit prendre les précautions suivantes quand on utilise le système plasma :

• Porter des bottes et des gants isolants et garder le corps et les vêtements au sec.

• Ne pas se tenir, s’asseoir ou se coucher sur une surface mouillée, ni la toucher quand on utilise le système plasma.

• S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide, procéder avec une extrême prudence.

• Installer un sectionneur avec fusibles appropriés, à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence.

• En cas d’utilisation d’une table à eau, s’assurer que cette dernière est correctement mise à la terre.

• Installer et mettre à la terre l’équipement selon les

• Inspecter fréquemment le cordon d’alimentation primaire

• Inspecter et remplacer les câbles de la torche qui sont

• Ne pas saisir la pièce à couper ni les chutes lors du

• Avant de vérifier, de nettoyer ou de remplacer les pièces

• Ne jamais contourner ou court-circuiter les verrouillages

• Avant d’enlever le capot du système ou de la source de

• Ne jamais faire fonctionner le système plasma sans que

• Lors de l’installation des connexions, attacher tout d’abord

• Chaque système plasma Hypertherm est conçu pour être

instructions du présent manuel et conformément aux codes électriques locaux et nationaux.

pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.

usés ou endommagés.

coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage.

de la torche, couper l’alimentation ou débrancher la prise de courant.

de sécurité.

courant, couper l’alimentation électrique. Attendre ensuite 5 minutes pour que les condensateurs se déchargent.

les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux.

la prise de terre appropriée.

utilisé uniquement avec des torches Hypertherm spécifiques. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité.

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

Le coupage peut produire des vapeurs et des gaz toxiques qui réduisent le niveau d’oxygène dans l’air et peuvent provoquer des blessures, voire la mort.

• Conserver le poste de coupage bien aéré ou utiliser un masque respiratoire homologué.

• Ne pas procéder au coupage près d’endroits où s’effectuent le dégraissage, le nettoyage ou la vaporisation. Certains solvants chlorés se décomposent sous l’effet des rayons ultraviolets et forment du phosgène.

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• Ne pas couper des métaux peints ou contenant des matières toxiques comme le zinc (galvanisé), le plomb, le cadmium ou le béryllum, à moins que la zone de travail soit très bien ventilée et que l’opérateur porte un masque respiratoire. Les revêtements et métaux contenant ces matières peuvent produire des vapeurs toxiques lors du coupage.

• Ne jamais couper de récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.

HYPERTHERM Systèmes plasma

SÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané

L’arc plasma s’allume immédiatement après que la torche soit mise en marche.

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

Protection des yeux Les rayons de l’arc plasma

produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau.

• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.

• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux ou encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.

Puissance des verres teintés

Courant de l’arc AWS (É.-U.) ISO 4850

Jusqu’à 100 A No 8N 100-200 A No 10 No 11-12 200-400 A No 12 No 13 Plus de 400 A No 14 No 14

Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets, les étincelles et le métal brûlant :

L’arc plasma coupe facilement les gants et la peau.

• Rester éloigné de l’extrémité de la torche.

• Ne pas tenir de métal près de la trajectoire de coupe.

• Ne jamais pointer la torche vers soi ou d’autres personnes.

• Gants à crispin, chaussures et casque de sécurité.

• Vêtements ignifuges couvrant toutes les parties exposées du corps.

• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.

• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.

Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette :

• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.

• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.

• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.

MISE À LA MASSE ET À LA TERRE

Câble de retour Bien fixer le câble de retour (ou de

masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher.

Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés.

Alimentation

• S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur.

• S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système, s’assurer que le fil de terre est correctement branché.

• Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. Bien serrer l’écrou de retenue.

• S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe.

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SÉCURITÉ

SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ

• Ne jamais lubrifier les robinets des bouteilles ou les

régulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux et

accessoires appropriés et conçus pour chaque application spécifique.

• Entretenir l’équipement et les pièces d’équipement à gaz

comprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux de

gaz afin d’identifier le type de gaz contenu dans chaque tuyau. Se référer aux codes locaux ou nationaux en vigueur.

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES

Les bouteilles de gaz contiennent du gaz à haute pression. Si une bouteille est endommagée, elle peut exploser.

• Manipuler et utiliser les bouteilles de gaz comprimé

conformément aux codes locaux ou nationaux.

• Ne jamais utiliser une bouteille qui n’est pas placée à la

verticale et bien assujettie.

• Le capuchon de protection doit être placé sur le robinet

sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation.

• Éviter à tout prix le contact électrique entre l’arc plasma et

une bouteille.

• Ne jamais exposer des bouteilles à une chaleur

excessive, aux étincelles, aux scories ou aux flammes nues.

• Ne jamais utiliser des marteaux, des clés ou d’autres

outils pour débloquer le robinet des bouteilles.

PACEMAKERS ET PROTHÈSES AUDITIVES

Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs.

• Utiliser un casque de protection homologué lors de l’utilisation du système plasma.

• Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit.

Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma.

Pour réduire les risques associés aux champs magnétiques :

• Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche.

• Faire passer le faisceau de la torche le plus près possible du câble de retour.

• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps.

• Se tenir le plus loin possible de la source de courant.

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HYPERTHERM Systèmes plasma

DESCRIPTION & SPECIFICATIONS

Section 2

DESCRIPTION & SPECIFICATIONS

In this section

INTRODUCTION..................................................................................2-2

SPECIFICATIONS................................................................................2-3

PAC121 50A Torches ...........................................................................2-4

IEC SYMBOLS USED ..........................................................................2-6

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DESCRIPTION & SPECIFICATIONS

INTRODUCTION

The Powermax800 plasma cutting system uses an inverter power supply to provide a smooth DC output voltage producing excellent cut and gouge quality on mild steel, stainless steel, aluminum and other metals. The Powermax800 power supply provides constant-current output variable from 20 to 50 amps, for optimum performance on all thicknesses of metal up to 1/2 inch (12 mm) thick. At 50 amps, the Powermax800 can cut metals up to 3/4 inch (20 mm) thick and will sever metals up to 1 inch (25 mm) thick.

Air is the primary plasma gas, providing low operating cost combined with high-speed performance. Cylinder air or shop air can be used as long as it is clean, dry and oil-free. When properly set and maintained, the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality. The Powermax800 can also cut with nitrogen when extended electrode life is a priority.

This service manual provides information for qualified service technicians to troubleshoot and repair the power supply and torch. Sections 4 and 5 contain in-depth parts lists of the Powermax800 systems. This manual also provides a detailed list of safety practices, so that the system can be safely tested and maintained. READ THE SAFETY SECTION (Section 1) FIRST!

The Powermax800 operator manual provides setup and daily operating instructions.

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Figure 2-1 Powermax800 Hand Plasma Cutting System*

* Single-phase 208/240/480V power supply shown.

See Section 5 for part numbers and descriptions of other Powermax800 power supplies.

Service Manual

SPECIFICATIONS

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% (I

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

Apparent Input Power (S Input Voltage (U1)/Input Current (I1)

@ 6 kw Output .................................................... 208V/50A; 240V/43A; 480V/25A - 1φ, 60 Hz

Dimensions and Weight:

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

Width ...................................................................10.4" (260 mm) without wheels

Height .................................................................. 19.6" (500 mm) without wheels

10.4"

DESCRIPTION & SPECIFICATIONS

=50A, U2=120V)

100% (I2=44A, U2=97V) See data tag on power

supply for more information on duty cycle

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.

) .................................. 10.4kVA (U1I1)

208V/29A; 240V/25A; 480V/13A - 3φ, 60 Hz 200V/52A; 230V/45A; 400V/30A - 1φ, 50/60 Hz 200V/30A; 230V/26A; 400V/16A - 3φ, 50/60 Hz 400V (CE)/16A - 3φ, 50/60 Hz 600V/11A - 3φ, 60 Hz

15.25" (390 mm) with wheels

23.7" (620 mm) with wheels

27.7" (700 mm) for 600V power supply

23.1"

Figure 2-2 Powermax800 Power Supply with Dimensions

Service Manual

19.6"

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DESCRIPTION & SPECIFICATIONS

Weight ...........................................................................65 pounds (30 kg) without wheels

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 .......................................................................320 scfh/5.3 scfm at 90 psi (150 l/min at

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

PAC121 50A TORCHES

Maximum 50A Cutting Capacity (PAC121TS) ..............3/4" (20 mm) @ 50% duty cycle

Maximum 50A Cutting Capacity (PAC121MS)..............3/8" (10 mm) @ 50% duty cycle

Maximum 35A Cutting Capacity (PAC121MS)..............1/4" (6 mm) @ 100% duty cycle

Maximum current at 50% duty cycle .............................50 amps

Gas Flow .......................................................................320 scfh/5.3 scfm at 70 psi (150 l/min at

Gouging Capability (metal removal rate).......................6.3 pounds (2.9 kg)/hr

Weight PAC121TS ........................................................4.5 pounds (2 kg) with 25 ft (7.6 m) lead

Weight PAC121MS .......................................................7 pounds (3.2 kg) with 25 ft (7.6 m) lead

72 pounds (33 kg) with wheels 128 pounds (58 kg) for 600V power supply

6.2 bar) supplied to power supply pressure regulator

4.8 bar)

7 pounds (3.2 kg) with 50 ft (15 m) lead

9.5 pounds (4.3 kg) with 50 ft (15 m) lead

PAC121TS Hand Torch Assembly

8.72"

8.50"

3.10"

1.00"

Figure 2-3 PAC121TS Torch with Dimensions

PAC121MS Machine Torch Assembly

1.58"

15.06"

1.38"1.00"

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Figure 2-4 PAC121MS Torch with Dimensions

Service Manual

DESCRIPTION & SPECIFICATIONS

S MARK

The Powermax800 conforms to standard EN50192. The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. The torches must have shielded consumable parts to maintain S mark compliance. See warning below and Figure 2-5.

WARNING

The voltage between the tip of the torch and the workpiece will exceed 113VDC if shielded consumable parts are not installed in the torch. If using the 400V CE power supply, the PAC121TS torch must be operated with shielded parts to maintain the S mark and CE low-voltage compliance for hand held applications. See Figure 2-5 below and also Section 5: list of CE consumable parts. This requirement does not apply to machine torch applications.

Consumable Parts - For CE Compliance

for a

120601

120602

120608

Figure 2-5 S Mark Label.

Service Manual

120438

120573

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DESCRIPTION & SPECIFICATIONS

IEC SYMBOLS USED

Direct Current (DC)

Alternating current (AC)

Plasma cutting torch

AC input power connection

The terminal for the external protective (earth) conductor

An inverter-based power source

Anode (+) work clamp

Temperature switch

Pressure switch

Plasma torch in the TEST position (cooling and cutting gas exiting nozzle)

Power is on

Power is off

Volt/amp curve, "drooping" characteristic

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Service Manual

MAINTENANCE

Section 3 MAINTENANCE

In this section:

Introduction ..........................................................................................3-2

Routine Maintenance ...........................................................................3-2

Bowl Draining/Filter Element Cleaning ............................................3-2

Cooling Air Filter Removal, Cleaning and Replacement..................3-3

Theory of Operation .............................................................................3-4

Sequence of Operation ........................................................................3-6

Troubleshooting....................................................................................3-7

Test Equipment ................................................................................3-7

Troubleshooting Procedures............................................................3-7

Visual Inspection - External .............................................................3-7

Visual Inspection - Internal ..............................................................3-8

Initial Resistance Checks ................................................................ 3-9

Corrective Maintenance Checks....................................................3-17

Power Board ......................................................................................3-26

Control Board .....................................................................................3-28

Control Board LEDs.......................................................................3-28

Control Board Test Points ..............................................................3-29

Torch Check .......................................................................................3-30

Cap Sensor Circuit Check .............................................................3-30

Start Circuit Check.........................................................................3-31

PAC121TS Torch Parts Removal and Replacement ..........................3-32

Torch Main Body Removal and Replacement ............................... 3-32

Torch Switch Removal and Replacement ...................................... 3-33

PAC121MS Torch Parts Removal and Replacement .........................3-34

Removal ........................................................................................ 3-34

Replacement ................................................................................. 3-34

Quick Disconnect O-Ring Removal and Replacement ......................3-36

Service Manual

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MAINTENANCE

INTRODUCTION

This section provides service technicians with routine maintenance, theory of operation and troubleshooting of the power supply. Also included in this section is the sequence of operation, power board and control board test points, and the removal and replacement procedures for the

PAC121T trigger torch and PAC121M machine torch parts.

ROUTINE MAINTENANCE

Bowl Draining/Filter Element Cleaning

Moisture coming out of the torch can cause the torch to sputter and hiss. If there is moisture, purge the lines. If moisture builds up in the bowl of the filter at the rear of the power supply, drain the bowl and clean the filter element:

1. Shut the gas supply off and disconnect the gas supply hose from the filter assembly

before proceeding.

2. Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to

release water from the bowl.

Gas supply hose (disconnect)

Filter element

Filter Bowl

Cap

Figure 3-1 Filter Assembly

3. Unscrew the filter bowl.

4. Unscrew the filter element. See

Section 4 for part number information.

5. Clean filter element with alcohol, then blow out with air from the inside of the filter element.

Clean the bowl with household soap only.

6. Replace the filter element and filter bowl.

7. Reconnect the gas supply hose.

Powermax800 Field Upgrade Kits and Optional Parts

3-2

Service Manual

MAINTENANCE

Cooling Air Filter Removal, Cleaning and Replacement

Powermax800 systems are normally shipped without air filters. If your Powermax800 has the air filter option, it will need cleaning periodically. Excessively dirty or dusty environments can block the cooling air filter (if installed) and cause the power supply to overheat and shut down.

WARNING

SHOCK HAZARD: Always turn off power and unplug cord from wall and wait 5 minutes before removing any cover of the power supply. If power supply is directly connected to a line disconnect box, place line disconnect switch to OFF position. In the U.S., use a "lock-out / tag-out" procedure until the service or maintenance work is complete. In other countries, follow appropriate local or national safety procedures.

1. Turn the Powermax800 power switch to the OFF (0) position, unplug the power cable

from the wall receptacle and disconnect the gas supply. See warning above.

2. Remove the 22 screws that secure the power supply cover to the chassis.

3. Remove the cover, and remove the cooling air filter from the clips by sliding the filter to the left and then up - Fig. 3-2.

Air Filter

Figure 3-2 Air Filter Removal

4. Clean the air filter with either soap and water or with low pressure compressed air.

5. Replace the dry filter in the power unit with the wire mesh facing the fan.

6. Replace and re-fasten the power supply cover with the existing screws.

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MAINTENANCE

THEORY OF OPERATION

General

The Powermax800 is a multi-voltage, multi-phase power supply. The two inverter inputs are linked in

parallel

The inverters are linked in 400V units. The inverter links are located in the link box, behind the rear panel at TB3. See Fig. 3-3. The 400V CE power supply does not have a link box.

for 208 or 240V on the 208/240/480V units, and for 200 or 230V on the 200/230/400V units.

series

for 480V on the 208/240/480V units, and for 400V on the 200/230/

TB3

TB2 TB1

208 or 240V Links on 208/240/480V units

and

200 or 230V Links on 200/230/400V units

Figure 3-3 Inverter Links

TB2 TB1

480V Link on 208/240/480V units

and

400V Link on 200/230/400V units

TB3

Functional Description

Refer to block diagram 3-4, Figure 3-3 and the system wiring diagram. See Section 4: Parts List to identify system components referenced in this description.

AC power enters power switch S1 from terminal block TB1. The MOV and filter capacitor block MOV1 provides spike and noise suppression. A "soft start" is implemented via power board resistors R1 and R2 and relay RL1, and the main contactor CR1. Once the capacitors on the power board are charged up and incoming power is within limits, the control board turns on the main contactor. Diode bridge D1 rectifies the AC to DC. The DC voltage is then supplied to the inverters.

Each inverter consists of several components: an isolated gate bipolar transistor (IGBT - Q1 or Q2), a coil of the power transformer (T2), a current sense transformer (CS1 or CS2), and sections of the power board. The inverters operate as a pulse width modulator controlled half-bridge circuit. The inverters are capacitor fed and transformer coupled, switching at 20 KHZ. The inverter outputs are connected in series, and are rectified by output diodes D2 and D3.

The output circuitry consists of a current sensor CS4 and transfer sensor CS3 located on the control board, pilot arc relay CR2, and output inductor L1.

The feedback loop operates as follows: The amp adjust pot P1 is first set to the desired value. Current sensor CS4 measures the actual output current and compares it at the error amplifier with the user-set current setting. The error amplifier output is an analog indication of how wide the pulse width should be to maintain the current setting. The error amplifier output is then fed to the pulse width modulator chip PWM. The pulse width modulator sends the signal to the gate drive board transformers, and the gate drive boards in turn drive the inverter IGBTs Q1 and Q2.

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Service Manual

MAINTENANCE

SEQUENCE OF OPERATION

Shaded boxes represent operator action. Clear boxes represent results from operator action.

System off

• Connect gas supply to filter-regulator on power unit

• Apply power at line voltage disconnect box.

• Set power circuit breaker S1 to ON (1).

After five seconds, LINE VOLTAGE and TEMP LEDs turn off indicating line voltage and transformer temperatures are within operating limits. Fan M1 operates and POWER and GAS PRESSURE LEDs light indicating system is ready for operation.

• Push and hold GAS TEST switch to

check air pressure.

Gas solenoid valve V1 opens to purge system and to allow setting of pressure.

• Release GAS TEST switch.

Gas solenoid valve V1 closes. Gas flow stops.

• Connect work cable to workpiece and

position torch on workpiece.

• Depress plasma start switch on hand

torch or remote start switch for machine torch.

Gas solenoid valve V1 opens and gas flows Pilot arc relay CR1 closes and pilot arc starts. Cutting arc transfers to workpiece Pilot arc relay CR1 opens and pilot arc stops.

• Move torch to make cut. Workpiece

falls away after cut.

Gas solenoid VI closes and gas flow stops.

• Select cutting current with AMPS knob.

Power circuits ready.

3-6

Power circuits ready

Service Manual

TROUBLESHOOTING

MAINTENANCE

The troubleshooting procedures include the

Maintenance Checks.

The complexity of the circuits require that service technicians have a working knowledge of inverter power supply theory. In addition to being technically qualified, technicians must perform all testing with safety in mind.

If questions or problems arise during servicing, call the Hypertherm Technical Services Department at 1 800 643 9878.

These procedures are presented in a flow diagram format.

Initial Resistance Checks

and the

Corrective

Test Equipment

• Multimeter

Troubleshooting Procedures

Maintenance of the Powermax800 power supply consists of performing visual inspection and troubleshooting procedures.

• Refer to the system wiring diagram when performing the checkout procedures.

• To locate power supply and torch components refer to Section 4 for 208/240/480V and

200/230/400V power supplies, and Section 5 for 400V CE power supplies.

• After the problem has been located and repaired, refer to the

diagram in this section to test the power unit for proper operation.

Sequence of Operation

flow

Visual Inspection - External

1. Inspect the outside of the power supply for damage to the cover and external components.

2. Inspect the torch and the torch lead for damage.

Service Manual

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MAINTENANCE

Visual Inspection - Internal

WARNING

If power is required for servicing, be aware that dangerous voltages exist within the power supply which could cause serious injury or death. If questions or problems arise during servicing, call the Hypertherm Technical Services department at 1-800-643-9878.

WARNING

The aluminum heatsink on the power PC board is electrically live when the plasma is on. In case of an electrical failure of the inverter circuit, the heatsink may be live when the power is off.

SHOCK HAZARD: The large electrolytic capacitors, (blue-cased cylinders) located on the power PC board store large amounts of energy in the form of electrical voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals on the PC board and on certain areas of the PC board. Never discharge the capacitors with a screwdriver or other implement... explosion, property damage and/or personal injury will result.

Wait at least 5 minutes after turning the power supply off before touching the PC board or capacitors. If questions or problems arise during servicing, call Hypertherm Technical Services at 1-800-643-9878.

3-8

Service Manual

MAINTENANCE

WARNING

SHOCK HAZARD: Do not attempt repairs on the power board or control board. Do not in any way cut away or remove the protective conformal coating from either board. To do so will risk a short between the AC input circuit to the output circuit and may cause serious injury or death.

The power supply and PC boards are subjected to dielectric and insulation resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians.

Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty.

If questions or problems arise during servicing, call the Hypertherm Technical Services department at 1-800-643-9878.

1. Set the Powermax800 power switch to O (off), unplug the power cord, and disconnect the gas supply - see warnings.

2. Remove the cover of the power supply by removing 22 securing screws.

3. Visually inspect the inside of the power supply, especially on the side with the power board (see Figures 4-2 and 4-3). Look for broken or loose wiring connections, burn and char marks, damaged components, etc. Repair or replace as necessary.

Initial Resistance Checks

1. After visually inspecting the exterior and interior of the power supply, always perform the initial resistance checks before applying power to the power supply. If these checks are not

performed prior to power up, further damage to the power supply could result.

2. Perform the initial resistance checks beginning on the following page.

3. After the problem has been located and repaired, refer to the diagram in this section to test the power unit for proper operation.

Service Manual

Sequence of Operation

flow

3-9

MAINTENANCE

Single-Phase

Check # 1

Set power switch S1 to OFF (0)

Measure resistance between the conductors (line and neutral) on the plug of the power cord. Do not use the ground conductor on the plug as a measuring point.

Set power switch S1 to ON (1). Measure resistance between the conductors (line and neutral) on the plug of the power cord. This reading is the resistance across the control transformer primary for the selected input voltage.

page 3-13,

Check # 2

Yes

Meter

indicates an open

Yes

Meter indicates

18 ohms (200V)

20 ohms (208V) 22 ohms (230V) 22 ohms (240V) 56 ohms (400V) 65 ohms (480V)

Check power cord and power switch S1. Replace faulty component (Fig 4-4)

3-10

3-97

Yes

Isolate and check control transformer T1, power switch S1, input filter MOV1, capacitor C1, and associated wiring for shorts. Repair problem and repeat check.

Indicates

low ohms or

short

Indicates

high ohms or

infinity ?

Yes

Isolate and check control transformer T1, power switch S1, fuses F1 and F2 and associated wiring for opens. Repair problem and repeat check.

Service Manual

TB3

MAINTENANCE

Three-Phase

Check # 1

Set power switch S1 of OFF (0)

Measure resistance between the conductors connected to link box terminal TB1-1 & TB1-2, TB1-1 & TB1-3, and TB1-2 & TB1-3 on the plug of the power cord. Do not use the ground pin on the plug as a measuring point. Note: On the 400V CE power supply, there is no link box.

TB1

TB2

TB1-3

TB1-2

TB1-1

Link Box Behind Rear Panel

page 3-12

Meter

indicates an

open ?

Yes

Set power switch S1 to ON (1). Measure resistance between the conductors on the plug of the power cord. Do not use the ground pin on the plug as a measuring point. The reading between TB1-1 & TB1-2 is the resistance across the control transformer primary for the selected input voltage.

Meter indicates open between

TB1-1 & TB1-3, and open between

TB1-2 & TB1-3

Yes

Check power cord and power switch S1. Replace faulty component (Fig 4-4).

page 3-12

No Yes

Service Manual

TB1-1 & TB1-2 does meter indicate

Between

18 ohms (200V)

20 ohms (208V) 22 ohms (230V) 22 ohms (240V) 56 ohms (400V) 65 ohms (480V)

To page 3-13 Check # 2

3-11

3-97

MAINTENANCE

From

page 3-11

Indicates

low ohms or

short

Yes

Isolate and check control transformer T1, power switch S1, input filter MOV1, capacitors C1, C2 and C3, contactor CR1 and all associated wiring for shorts. Repair problem and repeat check.

From

page 3-11

To page 3-13 Check # 2

page 3-11

Three-Phase

Check # 1

Indicates

low ohms or short

Yes

Isolate and check control transformer T1, power switch S1, input filter MOV1, capacitor C1, and associated wiring for shorts. Repair problem and repeat check.

Indicates

high ohms or

infinity ?

Yes

Isolate and check control transformer T1, power switch S1, fuses F1 and F2, and associated wiring for opens. Repair problem and repeat check.

3-12

Service Manual

Disconnect torch lead. Place + lead of ohm meter to upper bar spanning output diodes D2 and D3. Place – lead of ohm meter to lower bar spanning output diodes D2 and D3.

Replace diodes D2 and D3.

Place – lead of ohm meter to upper bar spanning output diodes D2 and D3. Place + lead of ohm meter to lower bar spanning output diodes D2 and D3.

MAINTENANCE

Check #2

All Power

Supplies

Meter indicates

infinity or high

Kohms

Yes

Upper bar spanning D2&D3

Lower bar spanning D2&D3

Location of Bars Spanning D2 and D3

Meter indicates

1.7K ohms ?

Yes

To page 3-14 Check # 3

Replace diodes D2 and D3.

Service Manual

3-13

MAINTENANCE

Check # 3

All Power Supplies

Start

Measure resistance between the power supply chassis and the conductors on the plug of the power cord. Do not use the ground conductor on the plug as a measuring point.

Yes

Meter indicates

an open ?

There is an internal short in the power supply. Visually and with a meter, inspect the unit for pinched, broken, and loose wires and wires with damaged insulation contacting the chassis. Also check for loose hardware such as screws, nuts and bolts.

Problem found

and repaired ?

Yes

3-14

To page 3-15 Check # 4

Continue checking out unit until problem is found. Then repeat check.

Service Manual

Check # 4

All Power Suppli

Start

Measure resistance between the power supply chassis and the work cable clamp (Fig 4-1).

MAINTENANCE

Yes

Meter indicates

an open ?

Problem found

and repaired ?

Yes

To page 3-16 Check # 5

Continue checking out unit until problem is found. Then repeat check.

Service Manual

3-15

MAINTENANCE

Check # 5

All Power Supplies

Start

Measure resistance between the conductors on the plug of the power cord and the work cable clamp. Do not use the ground conductor on the plug as a measuring point.

Yes

Meter indicates

an open ?

Problem found and repaired ?

Yes

3-16

End of

resistance checks.

page 3-17

Continue checking out unit until problem is found. Then repeat check.

Service Manual

MAINTENANCE

Corrective Maintenance Checks

WARNING

The aluminum heatsink on the power PC board is electrically live when the plasma is on. In case of an electrical failure of the inverter circuit, the heatsink may be live when the power is off.

Service Manual

3-17

MAINTENANCE

WARNING

The power supply and PC boards are subjected to dielectric and insulation resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians.

Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty.

If questions or problems arise during servicing, call the Hypertherm Technical Services department at 1-800-643-9878.

If no problems were found during the initial resistance checks and the power supply still does not operate correctly, perform the following corrective maintenance checks.

Note: The corrective maintenance flow charts are "best-guess" solutions. Study the system wiring diagram and understand the theory of operation before troubleshooting. Before purchasing a major replacement component, check with Hypertherm's Technical Service group at 1 800 643 9878 or the nearest Hypertherm repair facility.

1. Connect the torch lead to the power supply.

2. Connect the power cord into the line voltage disconnect switch box or plug into a properly grounded outlet.

3. Connect the gas supply to the pressure regulator at the rear of the power supply.

4. Perform the corrective maintenance checks starting on the following page.

5. After the problem has been located and repaired, refer to the section for the normal operation of the power supply from power up to cutting.

Sequence of Operation

in this

3-18

Service Manual

Start

MAINTENANCE

page 3-20

Set power switch S1 to ON (1)

S1 shuts OFF

Yes

LINE VOLTAGE LED

lights briefly

before shutdown

At torch, check that retaining cap is on tightly and that consumables are properly installed. Loosen retaining cap and listen for cap sense microswitch to open (click). Tighten retaining cap and listen for switch to close

Replace torch main body and switch.

Microswitch

opens & closes

Yes

With retaining cap tightened, disconnect connector JP8 at Control PCB (Fig 4-2). Measure resistance between JP8 sockets 9&10. Ensure cap sense microswitch is closed.

Replace

Power Board

Control board

replacement fix

page 3-20

problem

Yes

Correct voltage links. See label in linkbox and Powermax800 Operator Manual (IM227) Section 3. Note: 400V CE power supplies have no link box

Power supply

linked for proper

line voltage?

Correct supply voltage

Yes

Is line voltage for:

200V > 235V?

208V > 239V? 230V > 270V? 240V > 276V? 400V > 470V? 480V > 552V? 600V > 690V?

Replace Control Board

and repeat test

Yes No

See Torch Check, Cap

Sensor Circuit later in this section.

Service Manual

Meter

indicates 0 ohms

Replace torch main body and switch or torch lead. See also,

Torch Check, Cap Sensor Circuit later in

this section.

Disconnect torch lead. Measure resistance between pins 2 & 8 of torch lead plug.

Meter

indicates 0 ohms

Yes

Check connectors, wires W94 and W95 and solder joints. Repair as needed. See also, Torch Check, Cap Sensor Circuit later in this section.

3-19

9-96

MAINTENANCE

From

page 3-19

POWER ON

LED On ?

Unplug power cord. Measure resistance of fan M1 208/240/480V units- approx. 190 ohms 200/230/400V units- approx. 130 ohms

Yes

Fan M1 On

Yes

Resistance

correct ?

Replace M1

page

3-21

Yes

Check connectors & wires between fan and control board

connector JP2 pins 12 & 14.

Fan M1 On ?

Yes

Measure input line voltage at power switch S1: Single-phase units - between P1 & P2. Three-phase units - between P1 & P2, P2 & P3 and P1 & P3.

Voltage

correct ?

Yes

Measure input line voltage at control board connector JP2 pins 1 & 2 for 24VAC; JP2 pins 6 & 7 for 27VAC; JP2 pins 9 & 11 for 120VAC.

Yes

At control board connector JP2, check terminals 1 & 2 for 24VAC and terminals 6 & 7 for 27VAC.

Voltages

correct?

Check main

power coming into power supply.

Wires and

connectors

Repair or replace as needed

Yes

Check wiring between T1 and control board. If wiring is OK, replace T1.

Replace control board

OK?

3-20

3-96

Voltages correct ?

Yes

Replace control board

Unplug power cord. Measure resistances of fuses F1 & F2

Meter indicates 0 ohms ?

Yes

Check connectors & wires between fuses and T1. Repair as needed.

Service Manual

Replace F1 and/or F2.

From

page 3-20

Yes

MAINTENANCE

LINE VOLTAGE

LED Off?

Check for low input voltage at TB1

Is line voltage for:

200V < 170V? 208V < 178V? 230V < 195V? 240V < 204V? 400V < 340V? 480V < 408V? 600V < 510V?

Yes

Check connectors & wires between fuses and T1. Repair as needed.

Correct supply voltage

Yes

Meter

indicates

0 ohms ?

page 3-22

NoYes

Replace F1 and/or F2.

Check to see if D27 is illuminated

D27

illuminated?

Yes

Replace control board

Check control board JP2:

24VAC at pins 1 & 2; 27VAC at pins 6 & 7

Service Manual

Unplug power cord. Measure resistances of fuses F1 & F2

Voltages

correct?

Yes

Replace control board

3-21

9-96

MAINTENANCE

From

page 3-21

Yes

GAS PRESSURE

LED On ?

Yes

page 3-23

Check pressure regulator gauge for 70 psi

70 psi?

Yes

Disconnect wires W92 & W93 on pressure switch PS1. Measure voltage.

24 VAC ?

Adjust pressure regulator for 70 psi

Yes

Replace

PS1.

Yes

Pressure

corrected?

Check inlet gas supply pressure to pressure regulator. It should be a minimum of 90 psi (6.2 bar)

Inlet Pressure

Ok ?

Yes

Adjust inlet pressure for 90 psi (6.2bar)

Unplug power cord. Reconnect wires W92 & W93 to PS1. Disconnect JP8 from control PCB. Measure resistance between JP8 sockets 7 & 8.

3-22

0 ohms ?

Yes

Replace control PCB.

Check hose from supply to regulator, pressure regulator filter element and pressure regulator. Replace as required.

Check connections and

wiring between control board JP8 and terminals on PS1.

Service Manual

From

page 3-22

Yes

TEMP LED

Off ?

Unplug power cord. Allow power supply to cool down to room temperature. Plug in power cord and turn power supply on.

TEMP

LED remains

Off ?

Yes

Replace temperature switch TS1. If TS1 opens again after replacement, replace heat sink SA.

Yes

0 ohms?

Yes

MAINTENANCE

page 3-24

Disconnect temperature switch TS2 wires W88 & W99 at power transformer T2. Measure resistance across wires coming from transformer.

Unplug power cord. Allow power supply to cool down to room temperature. Disconnect JP8 from control PCB. Measure resistance between JP8 sockets 1 & 2 and 3 & 4.

0 ohms ?

Yes

Temperature switches are functioning. Problem is either with transformer T2, heatsink SA, control board or associated wiring.

Problem is either with transformer T2, heatsink SA, control board or associated wiring.

Disconnect temperature switch TS1 wires W86 & W87 at heatsink SA. Measure resistance across temperature switch.

Yes

0 ohms?

Replace transformer T2.

Service Manual

3-23

MAINTENANCE

From

page 3-23

Yes

Press & hold GAS TEST switch S2. Adjust pressure regulator for 70 psi (4.8 bar) indication (dynamic) on gauge.

70 psi (4.8 bar)

dynamic ?

Yes

No Yes

Indicates 0 psi

Check JP4 sockets and control board pins 5 & 6. Check wires W65 & W66. Check gas solenoid V1 & pressure regulator. If no problems are found replace control PCB.

Ensure GAS TEST switch S2 has been released. Press torch start switch to fire pilot arc.

Pilot arc

fires ?

Yes

page 3-25

Check control board TP2 for 12V when torch start switch is pressed.

12V?

Yes

Check JP4 sockets and control board pins 1 & 2. Check wires W61 & W62. Check pilot arc relay CR2. Repair or replace as needed.

Check regulator & hoses for leaks.

Air coming

out of torch?

Yes

Relay CR2

closes when

torch start

switch is

pressed

Yes

Unplug power supply. Disconnect control board connector JP8. Measure resistance between JP8 sockets 5 & 6 while pressing torch start switch.

Disconnect torch lead and check pins 6 & 7 of torch lead plug when torch start button is pressed.

Check wiring from power supply quick disconnect to control board JP8.

Check consumables and replace nozzle, if necessary.

0 ohms ?

Yes

Wiring

OK?

Repair wiring

as needed.

See Torch

Check Start Circuit later in

this section.

See Torch

Check Start Circuit later

NoYes

in this section.

Yes

See Torch

Check Start Circuit later

in this section.

3-24

9-96

Service Manual

From

page 3-24

Yes

Connect work clamp to workpiece. Set AMPS control P1 to minimum (20 amps). Depress torch start switch to transfer arc to workpiece.

MAINTENANCE

Arc transfers

Replace control board

Yes

Set AMPS control to maximum (50 amps). Depress torch start switch to transfer arc to workpiece to see if cutting current is adjustable.

Check TP1 of

control board for 12V.

Yes

12V?

Check that work clamp is making good metal-to-metal contact.

Work

clamp

OK?

Repair or replace work cable and clamp.

Yes

Replace consumables.

If arc does not transfer after changing consumables, replace control board.

Replace AMPS control pot P1. If new pot does not fix problem, replace control board.

Cutting current

adjustable ?

Yes

Corrective maintenance checks complete.

Service Manual

3-25

MAINTENANCE

POWER BOARD

The power board contains part of a "soft start' or "in-rush" circuit, an over-voltage shut down circuit, and the high-voltage power circuits for left and right inverters. Voltages can be taken at the rear of the power PCB to check these functions.

WARNING

SHOCK HAZARD: The "E" terminals and J1 are accessible from the back side of the power PCB. Use extreme caution when taking these readings. Voltages up to 300 VDC are present at the rear of the power PCB.

The large electrolytic capacitors, (blue-cased cylinders) located on the front side of the power PC board store large amounts of energy in the form of electrical voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals on the PC board and on certain areas of the PC board. Never discharge the capacitors with a screwdriver or other implement... explosion, property damage and/or personal injury will result.

Wait at least 5 minutes after turning the power supply off before handling the PC board or capacitors. If questions or problems arise during servicing, call Hypertherm Technical Services at 1-800-643-9878.

Use extreme caution when taking the voltage readings on the back of the power PCB - see warning above. Use an isolated or "floating" digital volt meter, since high voltages are present. The following table lists the test points, their descriptions and values. Refer also to Figure 3-5 to locate test points.

Power Board Test Points

Test Point Description Value

E1 to E3 High-voltage power - Left Inverter +300VDC E14 to E3 One-half of High-voltage power - Left Inverter +150VDC E4 to E5 High-voltage power - Right Inverter +300VDC E15 to E5 One-half of High-voltage power - Right Inverter +150VDC J1-5 to J1-4 "Soft start" signal from control PCB. After incoming voltage is +12VDC 5 sec. after

accepted by control board, control board sends +12VDC to relay throwing power switch RL1 on power board. LINE VOLTAGE LED will remain lit until "soft S1. start" signal is complete (about 5 seconds after S1 is thrown).

J1-6 to J1-4 Shut down signal from power board. Protection circuit on power +12 VDC normally.

board will go low (≈ 0 VDC) to control board to shut down power ≈ 0 VDC if voltage too

9-96 supply if it detects over voltage. high.

3-26

9-96

Service Manual

MAINTENANCE

WARNING

The power supply and PC boards are subjected to dielectric and insulation resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians.

Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty.

If questions or problems arise during servicing, call the Hypertherm Technical Services department at 1-800-643-9878.

E14 - YEL

E10

E15 - BLK/WHT

E12

Figure 3-5 Back Side of Power Board - Test Points

Service Manual

3-27

9-96

MAINTENANCE

CONTROL BOARD

Control Board LEDs

There are 4 control board LEDs visible from the Powermax800 front panel. There are 6 more LEDs that are visible only when the cover is removed. See Figure 3-6 for location of LEDs.

• D8 POWER ON: Illuminates when power is applied.

• D15 LINE VOLTAGE: Illuminates when the input voltage is out of limits. This LED will remain

on if the line voltage is too low, and go on briefly before the power supply shuts down if the line voltage is too high. Note: LINE VOLTAGE LED always remains on for about 5 seconds after the power supply is turned on and before a "soft start" signal is sent from the control board to the power board. The upper and lower range for line voltages are as follows:

Lower Limit Line Voltage Upper Limit 170VAC 200VAC 235VAC 178VAC 208VAC 239VAC 195VAC 230VAC 270VAC 204VAC 240VAC 276VAC 340VAC 400VAC 470VAC 408VAC 480VAC 552VAC 510VAC 600VAC 690VAC

Note: To avoid performance deterioration of the Powermax800, input voltage should be within 10% of the specified system line voltage setting.

• D24 OVERCURRENT: Illuminates when CS1 or CS2 senses current above 70 amps.

• D25 PILOT ARC RELAY: Illuminates when pilot arc relay CR2 is energized.

• D26 GAS SOLENOID: Illuminates when gas solenoid is energized (when GAS TEST switch is

pressed or when plasma start is pressed).

• D27 MAIN CONTACTOR: Illuminates when contactor CR1 is energized (following "soft start").

• D29 TEMP LED: Remains off when temperature is within operating limits. It Illuminates when

the thermostat in the power transformer opens (over 110° C (230° F)) or if the heatsink becomes too hot (over 85°C (185° F)). Overheating can be caused by exceeding the duty cycle rate.

• D35 GAS PRESSURE: Illuminates when incoming gas pressure sensed by PS1 is within

operating limits (over 39 psi (2.7 bar)).

• D38 ARC TRANSFER: Illuminates when arc transfers to the workpiece.

• D42 PLASMA START: Illuminates when the torch start button is pushed or when start button is

activated from the machine interface.

The control board also controls the sequence required to generate plasma:

• Turns on the inverter when the torch switch button is pressed

• After a short delay, turns on the gas solenoid valve V1 to blow back the electrode

• Monitors the pilot arc for arc transfer

• Ramps the current control command from the pilot arc level (20 amps) to the cut current

selected by the operator

• Turns the inverter off if the arc transfer does not occur within 5 seconds

• Turns the power supply off when the retaining cap is loose or when line voltage is too high

3-28

9-96

Service Manual

MAINTENANCE

Control Board Test Points

Test Point Description Value

TP1 Transfer signal. A logic high (12V) indicates that the arc is transferred. TP2 Start signal. A logic high (12V) indicates that the torch start switch is on. TP3 GND TP4 +12V TP5 Unregulated DC voltage. Approximately 30VDC at nominal input voltage. TP6 +18V TP7 INV-ON signal. A logic high (12V) indicates that the inverter is on. TP8 Transfer latch signal. A logic high (12V) indicates that unit is in transferred mode. TP9 Temp OK signal. A logic high (12V) indicates that all temperatures are OK. TP10 Continuous PA threshold voltage. Set to 3.55V by P3. TP11 7.0V TP15 Error amplifier reference voltage. During inverter operation this signal is 1.915V at 50A current

setting and .75V at 20A current setting. TP16 Error amplifier output voltage TP17 Reference voltage 2.50V TP18 Output current value signal 38.3mv/amp TP19 Wiper voltage. 2.5V at 50A current setting and 1.00V at 20A current setting. TP20 GND TP21 Buffered, inverted, capacitor feed version of pulse width modulator B signal. TP22 Buffered, inverted version of pulse width modulator A signal.

Fuses

F1,F2 Cap sensor circuit protection .5A (see Parts List for part number and specifications) F3,F4 Start circuit protection .5A (see Parts List for part number and specifications)

D15

D29

D35

TP8

TP7

TP1

TP9

D38

TP2

TP17

TP4

TP18

TP10

TP3

TP5

TP6

D24

TP11

TP15 TP16

TP19 TP20

Figure 3-6 Control Board Test Points and LED Locations

TP21

D25

TP22

D26

F2 F3

D27

D42

Service Manual

3-29

9-96

MAINTENANCE

TORCH CHECK

A failure of the torch cap sensor circuit will cause the Powermax800 power supply to shut down, and a failure of the torch start circuit will prevent the torch from firing. If your Powermax800 has either of these problems and you have followed the proceed with the following checks.

Cap Sensor Circuit Check

If the torch retaining cap is screwed down tightly and the ON/OFF power switch shuts off, there could be a problem with the torch cap sensor circuit.

Set the Powermax800 power switch to O (off), unplug the power cable, and disconnect the gas supply. Always wait 5 minutes before removing any cover of the power supply.

Corrective Maintenance Checks

WARNING

beginning on page 3-17,

1. Disconnect power and gas. See warning above.

2. Remove the power supply cover.

3. Locate fuses F1 and F2 on the control board. See Fig. 3-6.

4. Check to see if the fuses are open.

If the fuses are open, replace the torch, the torch leads and the control board fuse(s). See Section 4: Parts List or Section 5: Parts List - CE to order new components.

If the fuses are OK, the retaining cap microswitch is working, the line voltage is OK, and the power supply continues to shut off, replace the control board.

3-30

9-96

Service Manual

MAINTENANCE

TORCH CHECK (cont.)

Start Circuit Check

If the torch start trigger is pressed and there is no pilot arc, there could be a problem with the torch start circuit.

WARNING

Set the Powermax800 power switch to O (off), unplug the power cable, and disconnect the gas supply. Always wait 5 minutes before removing any cover of the power supply.

1. Disconnect power and gas. See warning above.

2. Remove the power supply cover.

3. Locate fuses F3 and F4 on the control board. See Fig. 3-6.

4. Check to see if the fuses are open.

If the fuses are open, replace the torch, the torch leads and the control board fuse(s). See Section 4: Parts List or Section 5: Parts List - CE to order new components.

If the fuses are OK, the gas supply is OK, pressing the torch switch closes the connection between JP8 sockets 5 & 6, and the torch does not start, replace the control board.

If the fuses are OK, the gas supply is OK, pressing the torch switch does not close connection between JP8 sockets 5 & 6, and the torch does not start, replace the torch and the torch leads.

Service Manual

3-31

9-96

MAINTENANCE

PAC121TS TORCH PARTS REMOVAL AND REPLACEMENT

Torch Main Body Removal and Replacement

To remove and replace the torch main body, order the torch main body with cap-on sensor switch and refer to the following procedure and Figures 3-7 and 3-8.

1 Set the Powermax800 power switch to O (off), unplug the power cable, and disconnect

the gas supply. Disconnect the torch lead quick disconnect from the power supply.

2. Remove the five screws that secure the handle halves together and remove handles from torch main body, torch switch and safety trigger (Fig. 3-8).

3. Remove the red wires attached to the pilot arc tab (Fig. 3-7).

Note for step 4: Disconnect wires by pulling on terminals. Do not pull on wires.

4. Disconnect the two lead terminals (blue wire in each terminal) from the two white wires of the cap sensor microswitch (Fig. 3-7).

5. Disconnect the plunger wire from the torch main body by holding the plunger nut with a 1/4" (6mm) wrench or nut driver and removing the plunger screw (Fig. 3-7).

6. Disconnect the torch main body and torch lead gas fittings using 5/16" (8mm) and 7/16" (11mm) open-end wrenches.

7. Replace with the new torch main body by reversing these instructions. Note: When connecting the plunger wire, be certain to keep the plunger wire terminal at the proper angle as shown in Fig. 3-7 inset. Tighten the plunger screw with 8 lb-in (9 kg-cm) of torque.

8. Install the torch main body and torch switch back into handle (Fig. 3-8). Be certain that torch switch slides into position above safety trigger, and that trigger movement activates the switch pushbutton and then releases. While positioning the handle halves together, be careful not to pinch any wires.

9. Replace the five screws to secure the handle halves together.

White Wires (8)

Torch Lead

Proper plunger terminal mounting angle

Pilot Arc Tab

Cap Sensor Microswitch White Wires (2)

Plunger Terminal

Plunger Nut

Torch Main Body

Blue Wires (2)

Cap Sensor Microswitch

Plunger Screw

Red Wires (2)

Plunger Wire

3-32

12-97

Figure 3-7 PAC121TS Torch Main Body Removal

Service Manual

MAINTENANCE

Torch Switch Removal and Replacement

To remove and replace the torch switch, order the torch switch and two splices (074069) and refer to the following procedure and Figure 3-8. See page 4-10 for a complete torch parts list.

1. Ensure the Powermax800 power switch is set to O (off), unplug the power cable, and

disconnect the gas supply.

2. Remove the five screws that secure the handle halves together.

3. Remove the torch switch from the handle.

4. Remove the torch switch by cutting the two splices at the torch lead (violet wires).

5. Replace the torch switch by crimping the switch wires and the violet wires from the torch lead

together with the splices.

6. Install the torch switch back into handle. Be certain that torch switch slides into position

above safety trigger, and that trigger movement activates the switch pushbutton and then releases. While positioning the handle halves together, be careful not to pinch any wires.

7. Replace the five screws to secure the handle halves together.

Handle

Spring

Safety Trigger

Torch Switch

Splices

Figure 3-8 PAC121TS Torch Switch Removal

Violet Wires (2)

Handle

Screw (5)

Service Manual

3-33

12-97

MAINTENANCE

PAC121MS TORCH PARTS REMOVAL AND REPLACEMENT

Repair of the PAC121MS machine torch normally requires replacement of the torch main body and/or the torch lead. Order the torch main body with switch. Refer to Figure 3-9 and perform the steps below. See page 4-11 for a complete torch parts list.

Removal

1. Set the Powermax800 power switch to O (off), unplug the power cable, and disconnect the gas supply. Disconnect the torch lead quick disconnect from the power supply.

2. Unscrew the retaining cap and remove the remaining parts (nozzle, electrode and swirl ring).

3. Remove the O-ring from the torch main body.

4. Remove the three screws securing the torch sleeve to the torch main body.

5. Unscrew the torch position sleeve from the torch sleeve and slide it back out of the way.

6. Remove the screw securing the red wires from the torch lead to the torch main body.

Note for steps 7 and 8: Disconnect wires by pulling on terminals. Do not pull on wires.

7. Disconnect the two lead terminals (four white wires in each terminal) from the two black plunger wire terminals of the torch main body.

8. Disconnect the two lead terminals (blue wire in each terminal) from the two white wires of the cap sensor microswitch.

9. Disconnect the torch main body and torch lead gas fitting using the 5/16" (8 mm) and 7/16" (11 mm) open-end wrenches.

Replacement

1. Remove the O-ring from the replacement torch main body.

Caution: Use caution when removing the O-ring, it can easily be damaged.

2. Connect the torch main body to the torch lead gas fitting using open-end wrenches.

3. Connect the two lead terminals (blue wire in each terminal) to the two white wires of the cap sensor microswitch.

4. Connect the two lead terminals (four white wires in each terminal) to the two black plunger wires of the torch main body.

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9-96

Service Manual

MAINTENANCE

Shield

Retaining Cap

Torch Main Body

Black Plunger Wires (2)

Red Wires (2)

Screw

White Wires (2)

Blue Wires (2)

White Wires (4 ea.)

Torch Position Sleeve

Torch Lead

O-Ring

Cap Sensor Microswitch

Screw (3)

Torch Sleeve

Figure 3-9 PAC121MS Torch Assembly

5. Secure the red wires from the torch lead to the torch main body with screw.

6. Position the torch sleeve onto the torch main body and secure it with the three screws.

7. Use caution when installing the O-ring onto the torch main body, it can be easily damaged.

Lightly coat with silicone.

8 Screw the torch position sleeve and the torch sleeve together.

9. When the nozzle, electrode and swirl ring are properly in place, replace the retaining cap with

shield. When the retaining cap is tightened, the microswitch will click, indicating that the torch main body has been replaced correctly.

10. Align the connector plug key (on torch lead) with the connector receptacle key slot (on power

supply) and push it in until the pins seat.

11. Turn the connector securing ring 1/4 turn counterclockwise to ensure that the securing ring

threads and the connector receptacle threads are aligned prior to tightening. Turn the connector securing ring clockwise to tighten.

Service Manual

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9-96

MAINTENANCE

QUICK DISCONNECT O-RING REMOVAL AND REPLACEMENT

The quick disconnect O-ring on the PAC121 torch leads provides a tight seal between the quick disconnect plug and the power supply receptacle. This O-ring prevents plasma gas from leaking during cutting. To remove and replace the O-ring in the event of damage or wear, proceed as follows and refer to Figure 3-10.

1. Turn the Powermax800 power switch OFF (0).

2. Unplug the power cable or set line disconnect switch to off, and disconnect gas supply.

3. Unscrew and remove the torch lead quick disconnect plug from the receptacle on the power supply.

4. Remove the O-ring from the quick disconnect as shown in Figure 3-10 using needle nose pliers, tweezers, etc.

5. Replace O-ring. Ensure it seats properly.

Quick Disconnect

Power/Gas Gland

Figure 3-10 Quick Disconnect O-Ring Removal and Replacement

O-Ring (044009)

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Service Manual

PARTS LIST

Section 4 PARTS LIST

In this section:

Power Supply - 208/240/480V

200/230/400V ............................................................ 4-2

Front ............................................................................................... 4-2

Top and Right Side ......................................................................... 4-4

Bottom and Left Side ...................................................................... 4-6

Rear ................................................................................................ 4-8

PAC121TS Torch Assembly .............................................................. 4-10

PAC121MS Torch Assembly.............................................................. 4-11

Consumable Parts............................................................................. 4-12

Powermax800 Field Upgrade Kits and Optional Parts ...................... 4-13

Power Supplies - 208/240/480V........................................................ 4-13

Power Supplies - 200/230/400V........................................................ 4-13

Recommended Spare Parts - Powermax800 - 208/240/480V .......... 4-14

Recommended Spare Parts - Powermax800 - 200/230/400V .......... 4-14

Service Manual

4-1

6-96

PARTS LIST

POWER SUPPLY - 208/240/480V

200/230/400V

Note: See Section 5 Parts List

400V CE for parts and

components of the 400V CE Powermax800 system.

Front

Index No. Part No. Description Ref. Desig. Quantity

1 001502 Pnl:PMX800 Pwr Unit Plastic Front 1 2 001522 Chassis:PMX800 Pwr Unit 1 3 004675 Spacer:PMX800 Pressure Gauge 1 4 008965 Knob:.850 Dia. 1/4 SFT Blk/Sil 1 4A 075498 Flat washer: .257 .500 .062 Black Nylon 1 5 010917 Label:PMX800 Pwr Unit Control Panel 1 6 023922 Cable w/Clamp:PMX800 Work 20' 1 7 008279 Strain Relief:PG9 X .187-.312 Nylon 1

029955 Manifold SA:PMX800 Pwr Unit 1 8 005112 Pressure Switch:39 Psi .013 Orifice PS1 1 9 006054 Sol. Valve:100# 1/8FPT 24VAC NC V1 1 10 011073 Regulator:0-125 Psig 1/8FPT 1 11 011074 Nut:Regulator Panel Mounting 1 12 015282 Female Elbow:1/8NPTX1/4Push in tube 1 13 015283 Male Elbow:1/8NPX1/4Push in tube 1 14 015285 Male Conn.:1/8NPTX1/4Push in tube 3 15 015517 Nip:1/8 X CL Hex Brass 1 16 015540 Tee:1/8 Brass 1 17 015588 Nip:1/8 X 2"L Brass 1 18 022027 Press. Gauge:160# 1.5" 1/8CBM Panel 1 19 046077 Tubing:1/4"OD .04W Blue Nylon 2.3 ft

029956 Harness:PMX800 Power Unit 1 20 009480 Pot:250-Ohm 1W 10% 1T Cerm P1 1 21 029962 Recept. SA:PMX800 Pwr Unit Quick Disc. 1 22 004532 Locknut:42/43 Quick Disc. Recept. 1 23 008606 Socket:MS Cont 7 24 015282 Female Elbow:1/8NPTX1/4Push in tube 1 25 075362 Flat Washer:1/2 .500 1.50 .125 Nylon 1

Notes: Bold part numbers and descriptions are subassemblies.

Indented normal type items are components of subassemblies

All mounting hardware in power supply drawings shown for reference only.

4-2

7-97

Service Manual

POWER SUPPLY - 208/240/480V

200/230/400V

PARTS LIST

Figure 4-1 Powermax800 - Front

Service Manual

4-3

7-97

PARTS LIST

POWER SUPPLY - 208/240/480V

200/230/400V

Top and Right Side

Note: See Section 5 Parts List

400V CE for parts and

components of the 400V CE Powermax800 system.

Index No. Part No. Description Ref. Desig. Quantity

1 001521 Pnl:Powermax800 Pwr Unit Center 1 2 003078 Relay:30A NO Mag Blwt QDisc Term CR2 1 3 029674 MOV/Cap Assy:MAX42/43/70 3PH MOV1 1

029957 Heatsink SA:Powermax800 Power Unit 1 4 004721 Heatsink:Powermax800 Pwr Unit 1 5 008904 Thermal Pad:AL-340-180 1 6 008905 Thermal Pad:AL-370-134 2 7 008906 Thermal Pad:AL-380-100 2 8 009849 Resistor:20-Ohm 50W 5% NON-IND 4 9 009850 Resistor:20-Ohm 25W 5% NON-IND 4 10 009918 Capacitor:.012UF 1000WV 10% Poly 4 10A 009968 Capacitor:6800PF 1000WV 10% Poly 4 11 005178 Temp. Switch Opens 85°/Closes 75°C TS1 1 12 029998† IGBT Gate Drive SA:Powermax800 Q1 1 13 029998† IGBT Gate Drive SA:Powermax800 Q2 1 14 109018† Diode:600V 100A UFast Recovery Dual D2 1 15 109018† Diode:600V 100A UFast Recovery Dual D3 1 16 109019† Diode:1600V 100A 3PH Module D1 1 17 041472*** PCB Assy:Pwrmx800 Control - 208/240/480V 1

008989 Fuse:500ma 250V IEC 127-3 Fast F1-F4 (pcb fuse) 4 17 041517**** PCB Assy:Pwrmx800 Control - 200/230/400V 1

008989 Fuse:500ma 250V IEC 127-3 Fast F1-F4 (pcb fuse) 4 18 041532***** PCB Assy:Powermax800-ZB Power 1 19 014137 Current Sense Transformer, 40A CS1 1 20 014137 Current Sense Transformer, 40A CS2 1 21 008301 Fuse Holder:2P 30A 13/32 X 1-1/2 1 22 008809*** Fuse:1A 600V 13/32 X 1-1/2 Slo F1,F2 2 22 008958**** Fuse:1A 500V 10mmX38mm Slo F1,F2 2

029978* Heatsink SA:Powermax800 PA Cont PCB Q3

23 004673* Heatsink:Powermax800 PA Cont 24 008905* Thermal Pad:AL-370-134 25 109020†* Diode:600V 100A Fast IGBT Module 26 041486* PCB Assy:Powermax800 PA Cont

028905** Kit:Powermax800 Machine Interface 208/240/480V

128035** Kit:Powermax800 Machine Interface 200/230/400V 27 041494** PCB Assy:Powermax800 Machine Interface

4-4

9-96

Notes: Bold part numbers and descriptions are subassemblies.

Indented normal type items are components of subassemblies. All mounting hardware in power supply drawings shown for reference only.

† Order corresponding thermal pads when ordering these items

* Available only on power supplies with the pilot arc control option

** Available only on power supplies with the machine interface option

*** Used only on 208/240/480V power supplies

**** Used only on 200/230/400V power supplies

*****For power supplies with serial numbers before 800-010000, order 128108 power board kit to

replace power board.

Service Manual

POWER SUPPLY - 208/240/480V

200/230/400V

PARTS LIST

10A

Figure 4-2 Powermax800 - Top and Right Side

Service Manual

4-5

9-96

PARTS LIST

POWER SUPPLY - 208/240/480V

200/230/400V

Note: See Section 5 Parts List

400V CE for parts and

components of the 400V CE Powermax800 system.

Bottom and Left Side

Index No. Part No. Description Ref. Desig. Quantity

1 001521 Panel:Powermax800 Pwr Unit Center 1 2 001522 Chassis:Powermax800 Pwr Unit 1 3 004667 Bracket:Powermax800 Pwr Unit Fan 1 4 014207*** Xfmr:Powermax800 208-240-480 Control T1 1 4 014208**** Xfmr:Powermax800 200-230-400 Control T1 1 5 014210*** Xfmr:Powermax800 208-240-480 Power T2 (w/TS2) 1 5 014211**** Xfmr:Powermax800 200-230-400 Power T2 (w/TS2) 1 6 014186 Inductor:Powermax800 2MH 50A L1 1 7 027080*** Fan:225CFM 120VAC 50-60HZ M1 1 7 027443**** Fan:260CDM 120VAC 50-60HZ M1 1

029957 Heatsink SA:Powermax800 Power Unit 1 8 004721 Heatsink:Powermax800 Power Unit 1 9 041532***** PCB Assy:Powermax800-ZB Power 1

029978* Heatsink SA:Pwrmx800 PA Cont PCB Q3

10 004673* Heatsink:Powermax800 PA Cont 11 028908** Kit:Powermax800 Cooling Fan Filter

Notes: Bold part numbers and descriptions are subassemblies.

Indented normal type items are components of subassemblies

All mounting hardware in power supply drawings shown for reference only.

* Available only on power supplies with the pilot arc control option

** Available only as an option

*** Used only on 208/240/480V power supplies

**** Used only on 200/230/400V power supplies

***** For power supplies with serial numbers before 800-010000, order 128108 power

board kit to replace power board.

4-6

Service Manual

9-96

POWER SUPPLY - 208/240/480V

200/230/400V

PARTS LIST

Figure 4-3 Powermax800 - Bottom and Left Side

Service Manual

4-7

9-96

PARTS LIST

POWER SUPPLY - 208/240/480V

200/230/400V

Note: See Section 5 Parts List

400V CE for parts and

components of the 400V CE Powermax800 system.

Rear

Index No. Part No. Description Ref. Desig. Quantity

1 001503 Pnl:Powermax800 Pwr Unit Plastic Rear 1 2 001522 Chassis:Powermax800 Pwr Unit 1 3 129068 Circuit Breaker SA:4Pole 480V W/TC S1 1 4 129151 Contactor SA:Powermax800 CR1 1

029955 Manifold SA:Powermax800 Pwr Unit 1 5 011072 Filter:20 Micron 1/8FPT 1 6 015285 Male Connector:1/8NPTX1/4Push in Tube 1 7 011079 Filter Element for 011072 Filter 1

029964 Linecord Panel SA:Powermax800 208/240/480V 1 8 001506* Panel:Powermax800 Power Cord 1 9 008228 Cord Grip:1NPT .690-.990 2Screws 1 10 129114**** Power Cord SA:Powermax800 1

129055 Linecord Panel SA:Powermax800 200/230/400V 1 8 001506** Panel:Powermax800 Power Cord 1 9 008228 Cord Grip:1NPT .690-.990 2Screws 1 10 129115***** Power Cord SA:Powermax800 200V 1

029982 Link Box SA:Powermax800 208/240/480V 1

129058 Link Box SA:Powermax800 200/230/400V

11 001500 Box:Powermax800 Pwr Cord 1 12 008900 Terminal Board:4-Terminal with protector TB3 1 13 008926 Terminal Board:4-Terminal with protector TB2 1 14 008933 Terminal Board:3-Terminal with protector TB1 1 15 008279*** Strain Relief:PG9/5X.187-.312 Nylon 16 123099*** Cable: Powermax800 Machine Interface

008201*** Receptacle Shell: 17-14 Reverse Sex

008186*** Socket:24-20 AWG Type III

Notes: Bold part numbers and descriptions are subassemblies.

Indented normal type items are components of subassemblies

All mounting hardware in power supply drawings shown for reference only.

* Use 129134 to order power cord rear panel for 208/240/480V power supplies if you

have the machine interface option.

** Use 129135 to order power cord rear panel for 200/230/400V power supplies if you

have the machine interface option.

*** Available only with the machine interface option.

**** Single-phase cord with plug used on 208/240/480V systems.

***** 200/230/400V Three-phase cord without plug (129115) not shown in Figure 4-4.

4-8

11-96

Service Manual

POWER SUPPLY - 208/240/480V

200/230/400V

PARTS LIST

10*****

***** 200/230/400V Three-phase power cord not shown in Figure 4-4

Figure 4-4 Powermax800 - Rear

Service Manual

4-9

9-96

PARTS LIST

PAC121TS Torch Assembly and 25' (7.6 m) Lead - 083003 PAC121TS Torch Assembly and 50' (15.2 m) Lead - 083004

Part Number Description

001288 ...................................... Handle, PAC121T

002244 ...................................... Safety Trigger, PAC121T

005094 ...................................... Switch, Torch Pushbutton

020351 ...................................... Electrode, Air

020361 ...................................... Ring, Swirl

027254 ...................................... Trigger Spring, PAC 121T

027466 ...................................... Ring, Gutcha

075340 ...................................... Screws, P/S, # 4 x 5/8, PH, RND, S/B

120282 ...................................... Nozzle:PAC121 50A Shield

120283 ...................................... Shield:PAC121 50A

120301 ...................................... Cap, Retaining

120556 ...................................... Torch Main Body w/Switch, PAC121T

044016 ............................................ O-Ring:BUNA 90Duro .614X.070

129001* ..................................... Torch Lead, 25 ft. (7.6 m)

129002** ................................... Torch Lead, 50 ft. (15.2 m)

044009 ............................................ Quick Disconnect O-Ring

(not shown)

* Used only in 083003 ** Used only in 083004 Note: See page 4-12 for detail of consumable parts

Handle 001288

Trigger Spring 027254

Safety Trigger 002244

Torch Main Body w/Switch 120556

O-Ring 044016

Torch Pushbutton Switch 005094

Torch Lead 129001, 25' (7.63 m) 129002, 50' (15.25 m)

Gutcha Ring 027466

Handle 001288

Screw (5) 075340

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12-97

Figure 4-5 PAC121TS Torch Assembly and Leads

Service Manual

PARTS LIST

PAC121MS Torch Assembly and 14 ft (4.3 m) Lead - 083049 w/pigtail, 083054 no pigtail PAC121MS Torch Assembly and 25 ft (7.6 m) Lead - 083011 w/pigtail, 083056 no pigtail PAC121MS Torch Assembly and 35 ft (10.6 m) Lead - 083044 w/pigtail, 083057 no pigtail PAC121MS Torch Assembly and 50 ft (15.2 m) Lead - 083012 w/pigtail, 083058 no pigtail

Part Number Description

020351 ...................................... Electrode

020361 ...................................... Ring, Swirl

020559 ...................................... Sleeve, Machine Torch, PAC121M

020620 ...................................... Sleeve, Torch Position, PAC121M

028923 ...................................... Torch Lead w/pigtail, 14 ft (4.3 m)

028918 ...................................... Torch Lead w/pigtail, 25 ft (7.6 m)

028926 ...................................... Torch Lead w/pigtail, 35 ft (10.6 m)

028919 ...................................... Torch Lead w/pigtail, 50 ft (15.2 m)

128123 ...................................... Torch Lead, no pigtail, 14 ft (4.3 m)

128125 ...................................... Torch Lead, no pigtail, 25 ft (7.6 m)

128126 ...................................... Torch Lead, no pigtail, 35 ft (10.6 m)

128127 ...................................... Torch Lead, no pigtail, 50 ft (15.2 m)

044009 ............................................ Quick Disconnect O-Ring (not shown)

075321 ...................................... Socket Cap, 4-40 X 1/2, HX, SS

075322 ...................................... M/S, 4-40 X 1/4, SL, SZ

120282 ...................................... Nozzle: PAC121 50A Shield

120326 ...................................... Shield: PAC121M Machine Torch

120301 ...................................... Cap, Retaining

120558 ...................................... Torch Main Body w/ Switch, PAC121M

044016 ............................................ O-Ring: BUNA 90 Duro .614X.070

Note: See page 4-12 for detail of consumable parts

Torch Main Body 120558

Screw (3) 075321

Torch Sleeve 020559

O-Ring 044016

On/Off Pendant (not part of machine torch assembly See

Powermax800 Field Upgrade Kits and Optional Parts

in this section for part numbers)

Screw 075322

Figure 5-8 PAC121MS Torch Assembly and Leads

later

Torch Position Sleeve 020620

Torch Lead 028923, with pigtail, 14 ft (4.3 m) 028918, with pigtail, 25 ft (7.6 m) 028926, with pigtail, 35 ft (10.6 m) 028919, with pigtail, 50 ft (15.2 m) 128123, no pigtail, 14 ft (4.3 m) 128125, no pigtail, 25 ft (7.6 m) 128126, no pigtail, 35 ft (10.6 m) 128127, no pigtail, 50 ft (15.2 m)

Pigtail

Service Manual

4-11

12-97

PARTS LIST

CONSUMABLE PARTS

Shields

120601

Shielded

Nonshielded

120602

Deflector

120303

Gouging Shield

120608

Retaining Cap

120301

Nozzles

120282

50A

120438

40A

020395

120281

Note: See Section 5 Parts List

400V CE for parts and components of the 400V CE Powermax800 system.

Figure 4-7 Consumable Parts

Swirl

Electrodes

Ring

120573(Air)

020480 (N2)

020361

PAC121 Torch

Gouging

Deflector

120303

120301

Extended

Consumable Spare Parts Kit (028904)

Part Number Description (Qty.)

001285 ............... Box, Consumable Parts (1)

120573 ............... Electrode (3)

120574 ............... Electrode, Extended (1)

120282 ............... Nozzle, 50A, Shielded (3)

120281 ............... Nozzle, 50A, Gouging (1)

120305 ............... Nozzle, Pipe Saddle, Extended (1)

120601 ............... Shield, T torch, (1)

120608 ............... Shield, Gouging (1)

120303 ............... Deflector (1)

044016 ............... O-Ring (3)

015152 ............... Nipple, 1/8 NPT,QDisc, Steel (1)

015570 ............... Bushing, Reducer, 1/4 X 1/8, Brass (1)

015604 ............... Reducer, 1/4 FPT X 1/8 NPT, Brass (1)

027055 ............... Lubricant, Silicone 1/4 Oz Tube (1)

O-Ring

044016

120304

120574

120305

Mach. Consumable Spare Parts Kit (128030)

Part Number Description (Qty.)

001285 ............... Box, Consumable Parts (1)

120573 ............... Electrode, (4)

120574 ............... Electrode, Extended (2)

120282 ............... Nozzle, 50A, Shielded (2)

120438 ............... Nozzle, 40A, Shielded (2)

120305 ............... Nozzle, Pipe Saddle, Extended (2)

120602 ............... Shield, M torch (1)

120303 ............... Deflector (1)

044016 ............... O-Ring (3)

015152 ............... Nipple, 1/8 NPT,QDisc, Steel (1)

015570 ............... Bushing, Reducer, 1/4 X 1/8, Brass (1)

015604 ............... Reducer, 1/4 FPT X 1/8 NPT, Brass (1)

027055 ............... Lubricant, Silicone 1/4 Oz Tube (1)

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Service Manual

PARTS LIST

POWERMAX800 FIELD UPGRADE KITS AND OPTIONAL PARTS

Part Number Description

028714 .................................. On/Off Pendant w/Lead, 25 ft. (7.6 m) (Also comes standard with most

machine torch system configurations. See note below.)

128061 .................................. On/Off Pendant w/Lead, 50 ft. (15.2 m)

128062 .................................. On/Off Pendant w/Lead, 75 ft. (23 m)

028864 .................................. Kit: Powermax800 Pwr Unit Wheels

028898 .................................. Pilot Arc Controller Kit

028905 .................................. Machine Interface Kit, 208/240/480V

128035 .................................. Machine Interface Kit, 200/230/400V

028907 .................................. Work Cable, 50' (15.2 m)

028908 .................................. Cooling Fan Filter Kit:Powermax800

011079 .................................. Gas Filter Element

129019 .................................. Jumper:Powermax800 Link Box

128032 .................................. Kit: Powermax800 600V

008809 .................................. Fuse:1A 600V 13/32 X 1-1/2 Slo (Used on 208/240/480V power supplies)

008958 .................................. Fuse:1A 500V 10mm X 38mm Slo (Used on 200/230/400V and 400V CE

power supplies)

023206 .................................. Cable: Machine Interface, 25 ft (7.6 m) (Comes standard with machine torch

system configurations and with machine interface kits.)

POWER SUPPLIES - 208/240/480V, 1φ/3φ, 60 HZ

Part For With Pilot Arc With Machine Number Torch Type Control Interface

083002 Hand No No 083015 Hand Yes No 083016 Machine No Yes 083017 Machine Yes Yes

POWER SUPPLIES - 200/230/400V, 1φ/3φ, 50/60 HZ

Part For With Pilot Arc With Machine Number Torch Type Control Interface

083030 Hand No No 083033 Hand Yes No 083036 Machine No Yes 083039 Machine Yes Yes

Notes: Contact your distributor or call the nearest Hypertherm office for hand and machine

torch system configurations.

See Section 5 Parts List 400V CE for parts and components of the 400V CE Powermax800 system.

Service Manual

4-13

9-96

PARTS LIST

RECOMMENDED SPARE PARTS - POWERMAX800- 208/240/480V

Part Number Description Page Reference

003078 ........................................... Relay:30A NO Mag Blwt QDisc Term ........................................................ 4-5

129068 ........................................... Circuit Breaker SA:4Pole 480V W/TC ........................................................ 4-9

129151 ........................................... Contactor SA:Powermax800 ...................................................................... 4-9

008809 ........................................... Fuse:1A 600V 13/32X1-1/2Slo (2) ............................................................. 4-4

014207 ........................................... Xfmr:Powermax800 208-240-480 Control .................................................. 4-7

014210 ........................................... Xfmr:Powermax800 208-240-480 Power ................................................... 4-7

014186 ........................................... Inductor:Powermax800 2MH 50A .............................................................. 4-7

023922 ........................................... Cable w/Clamp:PMX800 Work 20' ............................................................. 4-3

027080 ........................................... Fan:225CFM 120VAC 50-60HZ ................................................................. 4-7

005112 ........................................... Pressure Switch:39 Psi .013 Orifice ........................................................... 4-3

006054 ........................................... Sol. Valve:100# 1/8FPT 24VAC NC ........................................................... 4-3

011072 ........................................... Filter:20 Micron 1/8FPT .............................................................................. 4-9

011079 ........................................... Filter Element for 011072 Filter .................................................................. 4-9

011073 ........................................... Regulator:0-125 Psig 1/8FPT ..................................................................... 4-3

022027 ........................................... Press. Gauge:160# 1.5" 1/8CBM Panel ..................................................... 4-3

029957 ........................................... Heatsink SA:Powermax800 Power Unit ..................................................... 4-5

109018/008906 .............................. Diode:600V 100A UFast Recovery Dual (2)/Thermal Pad:AL-380-100 (2) 4-5

109019/008904 .............................. Diode:1600V 100A 3PH Module/Thermal Pad:AL-340-180 ....................... 4-5

005178 ........................................... Temp. Switch Opens 85°/Closes 75°C ...................................................... 4-5

009849/008903 .............................. Resistor:20-Ohm 50W 5% NON-IND (4)/Thermal Pad: AL 197-114 (4) .... 4-5

009850/008902 .............................. Resistor:20-Ohm 25W 5% NON-IND (4)/Thermal Pad:AL 103-108 (4) ..... 4-5

009918 ........................................... Capacitor:.012UF 1000WV 10% Poly (4) ................................................... 4-5

009968 ........................................... Capacitor:.6800PF 1000WV 10% Poly (4) ................................................. 4-5

029998/008905 .............................. IGBT Gate Drive SA:Powermax800 (2)/Thermal Pad:AL-370-134 (2) ....... 4-5

041472 ........................................... PCB Assy:Powermax800 Control ............................................................... 4-5

041532 ........................................... PCB Assy:Powermax800-ZB Power .......................................................... 4-5, 4-7

129114 ........................................... Cord/Plug:42 1Phase 8-3SO 3Prong 7'3" .................................................. 4-9

029674 ........................................... MOV/Cap Assy:MAX42/43/70 3PH ............................................................ 4-5

028908 ........................................... Kit:Powermax800 Cooling Fan Filter .......................................................... 4-7

RECOMMENDED SPARE PARTS - POWERMAX800- 200/230/400V

Part Number Description Page Reference

003078 ........................................... Relay:30A NO Mag Blwt QDisc Term ........................................................ 4-5

129068 ........................................... Circuit Breaker SA:4Pole 480V W/TC ........................................................ 4-9

129151 ........................................... Contactor SA:Powermax800 ...................................................................... 4-9

008958 ........................................... Fuse:1A 500V 10mmX38mm SLO (2) ........................................................ 4-4

014208 ........................................... Xfmr:Powermax800 200-230-400 Control .................................................. 4-7

014211 ........................................... Xfmr:Powermax800 200-230-400 Power ................................................... 4-7

014186 ........................................... Inductor:Powermax800 2MH 50A .............................................................. 4-7

023922 ........................................... Cable w/Clamp:PMX800 Work 20' ............................................................. 4-3

027443 ........................................... Fan:260CDM 120VAC 50-60HZ ................................................................. 4-7