Hypertherm Powermax600 Service Manual

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powermax600

Plasma Arc Cutting System

Service Manual 803400 Revision 2

powermax600

Plasma Arc Cutting System

Service Manual

IM-340

(P/N 803400)

Revision 2 - NOVEMBER 1999

Hypertherm, Inc.

Hanover, NH USA http://www.hypertherm.com email:info@hypertherm.com

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) email: info@hypertherm.com (General Information) email: service@hypertherm.com (Technical/Customer Services)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D–63457 Hanau-Wolfgang, Germany Tel.: 49 6181 58 2100 Fax: 49 6181 58 2134

European Technical Support Organization (ETSO)

Technologiepark Hanau Rodenbacher Chaussee 6 D–63457 Hanau-Wolfgang, Germany Tel.: 49 6181 58 2100 Fax: 49 6181 58 2134

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore Tel.: 65 841 2489 Fax: 65 841 2490

Hypertherm U.K.

9 Berkeley Court • Manor Park Runcorn, Cheshire, England WA7 1TQ Tel.: 44 1928 579 074 Fax: 44 1928 579 604

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

Italy

Via Torino 2 20123 Milan, Italy Tel.: 39 02 725 46 312 Fax: 39 02 725 46 400

The Netherlands

Burg, Haverkampstraat 13 7091 CN Dinxperlo, Holland Tel.: 31 315 655866 Fax: 31 315 655886

ELECTROMAGNETIC COMPATIBILITY

EMC INTRODUCTION

The CE power supplies have 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.

. In other cases

e. Health of the people around, for example the use of pacemakers and hearing aids. f. Equipment used for calibration or measurement. g. Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

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.

powermax600 Service Manual

WARRANTY

WARNING

Genuine Hypertherm parts are the factoryrecommended 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.

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.

UPON RECEIPT

1. Verify that all parts and items on your order have been received. Alert your distributor if any parts or items are damaged or missing.

2. Inspect the power supply for any physical damage that may have occurred during shipping. If there is evidence of damage, refer to the communications regarding this equipment must include the model number and serial number located on the back of the Powermax600.

3. Before setting up and operating the Powermax600, read the Safety section of this manual.

Claims

section below. All

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

CLAIMS

Claims for damage during shipment — If your unit was

damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call Customer Service listed in the front of this manual, or your authorized Hypertherm distributor.

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

powermax600 Service Manual

TABLE OF CONTENTS

Electromagnetic Compatibility .................................................................................................................................. i

Warranty ............................................................................................................................................................ ii

SECTION 1 - SAFETY

RECOGNIZE SAFETY INFORMATION ...............................................................................................................1-2

FOLLOW SAFETY INSTRUCTIONS ...................................................................................................................1-2

CUTTING CAN CAUSE FIRE OR EXPLOSION .................................................................................................. 1-2

ELECTRIC SHOCK CAN KILL.............................................................................................................................1-3

CUTTING CAN PRODUCE TOXIC FUMES ........................................................................................................1-3

PLASMA ARC CAN CAUSE INJURY AND BURNS ............................................................................................ 1-4

ARC RAYS CAN BURN EYES AND SKIN ........................................................................................................... 1-4

GROUNDING SAFETY ........................................................................................................................................1-4

COMPRESSED GAS EQUIPMENT SAFETY...................................................................................................... 1-5

GAS CYLINDERS CAN EXPLODE IF DAMAGED ..............................................................................................1-5

NOISE CAN DAMAGE HEARING ....................................................................................................................... 1-5

PACEMAKER AND HEARING AID OPERATION ................................................................................................1-5

ADDITIONAL SAFETY INFORMATION ...............................................................................................................1-5

WARNING LABEL................................................................................................................................................ 1-6

SECTION 1a - SÉCURITÉ

IDENTIFIER LES CONSIGNES DE SÉCURITÉ................................................................................................ 1a-2

SUIVRE LES INSTRUCTIONS DE SÉCURITÉ ................................................................................................. 1a-2

LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION .................................................... 1a-2

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS ..................................................................................1a-3

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES........................................................................ 1a-3

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES ............................................ 1a-4

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU..........................................................1a-4

MISE À LA MASSE ET À LA TERRE ................................................................................................................. 1a-4

SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ ...................................................................................... 1a-5

LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES ......................... 1a-5

LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS .......................................................................1a-5

PACEMAKERS ET PROTHÈSES AUDITIVES.................................................................................................. 1a-5

ÉTIQUETTE DE SÉCURITÉ .............................................................................................................................. 1a-6

SECTION 2 SPECIFICATIONS

SPECIFICATIONS, POWER SUPPLY.................................................................................................................. 2-2

SPECIFICATIONS, PAC123 TORCHES ............................................................................................................... 2-3

SETUP SPECIFICATIONS ................................................................................................................................... 2-4

INSTALL POWER CORD PLUG ........................................................................................................................... 2-4

CHECK REQUIRED INPUT VOLTAGE ................................................................................................................ 2-4

S MARK (230/400 VOLT ONLY) ....................................................................................................................... 2-4

GROUNDING REQUIREMENTS .......................................................................................................................... 2-5

POWER CORD / EXTENSION CORD.................................................................................................................. 2-5

GAS REQUIREMENTS......................................................................................................................................... 2-6

LINE VOLTAGE DISCONNECT BOX ................................................................................................................... 2-6

powermax600 Service Manual

iii

TABLE OF CONTENTS

SECTION 3 MAINTENANCE

CONTROLS AND INDICATORS ........................................................................................................................... 3-2

INDICATOR LAMPS ............................................................................................................................................. 3-2

CONTROLS. ......................................................................................................................................................... 3-2

THEORY OF OPERATION ................................................................................................................................... 3-3

GENERAL ............................................................................................................................................................. 3-3

230/400 VOLT FUNCTIONAL DESCRIPTION...................................................................................................... 3-4

208-240/480 VOLT FUNCTIONAL DESCRIPTION .............................................................................................. 3-6

SEQUENCE OF OPERATION .............................................................................................................................. 3-8

TROUBLESHOOTING .......................................................................................................................................... 3-9

TEST EQUIPMENT............................................................................................................................................... 3-9

TROUBLESHOOTING PROCEDURES AND SEQUENCE .................................................................................. 3-9

VISUAL INSPECTION - EXTERNAL .................................................................................................................... 3-9

VISUAL INSPECTION - INTERNAL ................................................................................................................... 3-10

RESISTANCE CHECKS ......................................................................................................................................3-11

TROUBLESHOOTING GUIDE............................................................................................................................ 3-14

VOLTAGE CHECKS............................................................................................................................................ 3-21

COMPONENT REPLACEMENT ......................................................................................................................... 3-26

POWER CORD REPLACEMENT ....................................................................................................................... 3-26

TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT) ............................................... 3-27

AIR FILTER ELEMENT REPLACEMENT ........................................................................................................... 3-28

WORK CABLE REPLACEMENT ........................................................................................................................ 3-30

CAPACITOR REPLACEMENT ........................................................................................................................... 3-31

HEAT SINK COMPONENT REPLACEMENT ..................................................................................................... 3-32

SECTION 4 PARTS LIST - 400/230V CE

POWER SUPPLY – EXTERIOR ........................................................................................................................... 4-2

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE.......................................................................................... 4-3

POWER SUPPLY – BACK INTERIOR RIGHT SIDE ............................................................................................ 4-4

POWER SUPPLY – INTERIOR FAN SIDE ........................................................................................................... 4-5

POWER SUPPLY – HEAT SINK ASSEMBLY ....................................................................................................... 4-6

RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V ....................................................................... 4-7

SECTION 5 PARTS LIST - 208-240/480V

POWER SUPPLY – EXTERIOR ........................................................................................................................... 5-2

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE.......................................................................................... 5-3

POWER SUPPLY – BACK INTERIOR RIGHT SIDE ............................................................................................ 5-4

POWER SUPPLY – INTERIOR FAN SIDE ........................................................................................................... 5-5

POWER SUPPLY – HEAT SINK ASSEMBLY ....................................................................................................... 5-6

RECOMMENDED SPARE PARTS - POWERMAX600- 208-240/480V ................................................................ 5-7

SECTION 6 PARTS LIST - TORCH AND CONSUMABLES

PAC123T HAND TORCH ASSEMBLY (NO QUICK DISCONNECT) .................................................................... 6-2

PAC123T HAND TORCH ASSEMBLY (WITH QUICK DISCONNECT) ................................................................ 6-4

PAC123M MACHINE TORCH ASSEMBLY (NO QUICK DISCONNECT) ............................................................. 6-6

PAC123M MACHINE TORCH ASSEMBLY (WITH QUICK DISCONNECT) ......................................................... 6-8

TORCH CONSUMABLES ................................................................................................................................... 6-10

RECOMMENDED SPARE PARTS - PAC123 TORCH ........................................................................................6-11

SECTION 7 WIRING DIAGRAMS

powermax600 Service Manual

AFETY

Section 1

SAFETY

In this section:

Recognize Safety Information ................................................................................1-2

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

Cutting Can Cause Fire or Explosion ..................................................................... 1-2

Electric Shock Can Kill ...........................................................................................1-3

Cutting Can Produce Toxic Fumes......................................................................... 1-3

Plasma Arc Can Cause Injury and Burns ...............................................................1-4

Arc Rays Can Burn Eyes and Skin ........................................................................1-4

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

Compressed Gas Equipment Safety ...................................................................... 1-5

Gas Cylinders Can Explode if Damaged................................................................ 1-5

Noise Can Damage Hearing ..................................................................................1-5

Pacemaker and Hearing Aid Operation..................................................................1-5

Additional Safety Information .................................................................................1-5

Warning Label ........................................................................................................1-6

Hypertherm Plasma Systems

1-1

AFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.

• Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.

• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction.

• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

• DANGER and WARNING safety labels are located on your machine near specific hazards.

• WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly.

• CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly.

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire Prevention

• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the cutting area.

• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.

• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.

• Ventilate potentially flammable atmospheres before cutting.

• When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.

Explosion Prevention

• Do not use the plasma system if explosive dust or

vapors may be present.

• Do not cut pressurized cylinders, pipes, or any closed container.

• Do not cut containers that have held combustible materials.

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.

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.

• Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Refer to the Appendix section of this manual for aeration manifold details.

1-2

11-98

Hypertherm Plasma Systems

ELECTRIC SHOCK CAN KILL

AFETY

Touching live electrical parts can cause a fatal shock or severe burn.

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

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

Electric Shock Prevention All Hypertherm plasma systems use high voltage in

the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:

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

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

• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

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

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

• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.

• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

• Inspect and replace any worn or damaged torch leads.

• 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.

• Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.

• Never bypass or shortcut the safety interlocks.

• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.

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

• When making input connections, attach proper grounding conductor first.

• 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 safety hazard.

CUTTING CAN PRODUCE TOXIC FUMES

Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death.

• Keep the cutting area well ventilated or use an approved air-supplied respirator.

• Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.

• Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or

Hypertherm Plasma Systems

beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut.

• Never cut containers with potentially toxic materials inside – they must be emptied and properly cleaned first.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.

1-3

8-99

AFETY

PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches

Plasma arc comes on immediately when the torch switch is activated.

ARC RAYS CAN BURN EYES AND SKIN

Eye Protection Plasma arc rays produce intense

visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

• Use eye protection in accordance with applicable national or local codes.

• Wear eye protection (safety glasses or goggles with side shields, or a welding helmet) with appropriate lens shading to protect your eyes from the 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

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

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 to cover all exposed areas.

• Cuffless trousers to prevent entry of sparks and slag.

• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:

• Paint walls and other surfaces with dark colors to

reduce reflection.

• Use protective screens or barriers to protect others

from flash and glare.

• Warn others not to watch the arc. Use placards or

signs.

GROUNDING SAFETY

Work Cable Attach the work cable securely to the

workpiece or the work table with 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 an earth ground, in accordance with appropriate national or local electrical codes.

1-4

4-99

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 connect-

ing the power cord to the power supply, be sure to connect the power cord ground wire properly.

• Place the power cord's ground wire on the stud first,

then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessive

heating.

Hypertherm Plasma Systems

AFETY

COMPRESSED GAS EQUIPMENT SAFETY

• Never lubricate cylinder valves or regulators with oil or grease.

• Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application.

• Maintain all compressed gas equipment and associated parts in good condition.

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

NOISE CAN DAMAGE HEARING

GAS CYLINDERS CAN EXPLODE IF DAMAGED

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

• Handle and use compressed gas cylinders in accordance with applicable national or local codes.

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

• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.

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

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

• Never use a hammer, wrench or other tool to open a stuck cylinder valve.

PACEMAKER AND HEARING AID OPERATION

Prolonged exposure to noise from cutting or gouging can damage hearing.

• Use approved ear protection when using plasma system.

• Warn others nearby about the noise hazard.

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2,

Welding Processes

1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1,

Educational Eye and Face Protection

Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1,

Welding and Cutting of Containers and Piping That Have Held Hazardous Substances

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

Recommended Safe Practices for the Preparation for

Safety in Welding and Cutting

Fire Prevention in the Use of Cutting and

, American National Standards Institute

Safe Practices for Occupation and

, American National

, American Welding Society

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

To reduce magnetic field hazards:

• Keep both the work cable and the torch lead to one side, away from your body.

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

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

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

5. AWS F5.2,

Cutting

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1,

Cylinders

1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978, Protection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, U.S. Government Printing Office, Washington, D.C. 20402

Recommended Safe Practices for Plasma Arc

, American Welding Society

, Compressed Gas Association

Safety and Health Standards

Safe Handling of Compressed Gases in

Code for Safety in Welding and Cutting

Cutting and Welding Processes

National Electrical Code

, 29FR 1910

, National

, National Fire

Hypertherm Plasma Systems

1-5

11-98

AFETY

WARNING LABEL

This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label.

1. Cutting sparks can cause explosion or fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, and have a watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury and burns.

2.1 Turn off power before disassembling torch.

2.2 Do not hold the material near cutting path.

2.3 Wear complete body protection.

3. Electric shock from torch or wiring can kill. Protect yourself from electric shock.

3.1 Wear insulating gloves. Do not wear wet or damaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power before working on machine.

4. Breathing cutting fumes can be hazardous to your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Use ventilating fan to remove the fumes.

5. Arc rays can burn eyes and injure skin.

5.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

6. Become trained and read the instructions before working on the machine or cutting.

7. Do not remove or paint over (cover) warning labels.

1-6

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Hypertherm Plasma Systems

ÉCURITÉ

Section 1a

SÉCURITÉ

Cette section comprend:

IDENTIFIER LES CONSIGNES DE SÉCURITÉ..............................................1a-2

SUIVRE LES INSTRUCTIONS DE SÉCURITÉ ...............................................1a-2

LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION ..1a-2

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS................................1a-3

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES......................1a-3

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES

OU DES BRÛLURES .......................................................................................1a-4

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU........1a-4

MISE À LA MASSE ET À LA TERRE ...............................................................1a-4

SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ ....................................1a-5

LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE

DOMMAGES ...............................................................................................1a-5

LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS .....................1a-5

PACEMAKERS ET PROTHÈSES AUDITIVES ................................................1a-5

ÉTIQUETTE DE SÉCURITÉ ............................................................................1a-6

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ÉCURITÉ

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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HYPERTHERM Systèmes plasma

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

ÉCURITÉ

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

• Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.

• Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés.

• Ne pas saisir la pièce à couper ni les chutes lors du coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage.

• Avant de vérifier, de nettoyer ou de remplacer les pièces de la torche, couper l’alimentation ou débrancher la prise de courant.

• Ne jamais contourner ou court-circuiter les verrouillages de sécurité.

• Avant d’enlever le capot du système ou de la source de courant, couper l’alimentation électrique. Attendre ensuite 5 minutes pour que les condensateurs se déchargent.

• Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux.

• Lors de l’installation des connexions, attacher tout d’abord la prise de terre appropriée.

• Chaque système plasma Hypertherm est conçu pour être 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.

• 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.

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ÉCURITÉ

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 N 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.

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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.

HYPERTHERM Systèmes plasma

ÉCURITÉ

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.

HYPERTHERM Systèmes plasma 1a-5

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ÉCURITÉ

Étiquette de sécurité

Cette étiquette est apposée sur certaines sources de courant. Il est important que l’utilisateur et le technicien de maintenance comprenne la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images.

1. Les étincelles produites par le coupage peuvent provoquer une explosion ou un incendie.

1.1 Pendant le coupage, éloigner toute matière inflammable.

1.2 Conserver un extincteur à proximité et s’assurer qu’une personne soit prête à l’utiliser.

1.3 Ne jamais couper de récipients fermés.

2. L’arc plasma peut provoquer des blessures et des brûlures.

2.1 Couper l’alimentation avant de démonter la torche.

2.2 Ne pas tenir la surface à couper près de la trajectoire de coupe.

2.3 Porter des vêtements de protection couvrant tout le corps.

3. Un choc électrique causé par la torche ou les câbles peut être fatal. Se protéger contre les risques de chocs électriques.

3.1 Porter des gants isolants. Ne pas porter de gants mouillés ou abîmés.

3.2 S’isoler de la surface de travail et du sol.

3.3 Débrancher la prise ou la source de courant avant de manipuler l’équipement.

4. L’inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé.

4.1 Garder le visage à l’écart des vapeurs.

4.2 Utiliser un système de ventilation par aspiration ou d’échappement localisé pour dissiper les vapeurs.

4.3 Utiliser un ventilateur pour dissiper les vapeurs.

5. Les rayons de l’arc peuvent brûler les yeux et provoquer des lésions de la peau.

5.1 Porter un casque et des lunettes de sécurité. Se protéger les oreilles et porter une chemise dont le col peut être déboutonné. Porter un casque de soudure dont la protection filtrante est suffisante. Porter des vêtements protecteurs couvrant la totalité du corps.

6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage.

7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité.

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HYPERTHERM Systèmes plasma

SPECIFICATIONS

Section 2

SPECIFICATIONS

In this section:

SPECIFICATIONS, POWER SUPPLY ...................................................................... 2-2

SPECIFICATIONS, PAC123 TORCHES ................................................................... 2-3

SETUP SPECIFICATIONS........................................................................................ 2-4

INSTALL POWER CORD PLUG ............................................................................... 2-4

CHECK REQUIRED INPUT VOLTAGE .................................................................... 2-4

S MARK (230/400 VOLT ONLY) ........................................................................... 2-4

GROUNDING REQUIREMENTS .............................................................................. 2-5

POWER CORD / EXTENSION CORD...................................................................... 2-5

GAS REQUIREMENTS............................................................................................. 2-6

LINE VOLTAGE DISCONNECT BOX ....................................................................... 2-6

powermax600 Service Manual

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PECIFICATIONS

PMX600.14

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Section 2 SPECIFICATIONS

SPECIFICATIONS, POWER SUPPLY

Powermax600 Power Supply Dimensions and Weight

20 in

510 mm

47 lb

21 kg

Weight with hand torch

and 15 ft / 4.5 m lead.

9.5 in

240 mm

17 in

430 mm

2-2

Figure 2-1 Powermax600 Power Supply Dimensions

powermax600 Service Manual

11-99

SPECIFICATIONS, PAC123 TORCHES

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PAC123T

PAC123T.04

PAC123M.07

SPECIFICATIONS

Dimensions

8.72" / 221 mm

8.5" / 216 mm

1.58" 40 mm

3.10" 79 mm

1.00" 25 mm

Figure 2-2 PAC123T Hand Torch Dimensions

1.00" 25 mm

15.06" 383 mm

1.38" 35 mm

Figure 2-3 PAC123M Machine Torch Dimensions

powermax600 Service Manual

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PECIFICATIONS

COMP.01

S MARK (230/400 VOLT ONLY)

The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. The hand torches must have shielded consumable parts to maintain S mark compliance.

SETUP SPECIFICATIONS

Check Required Input Voltage

Look at U1 on the data plate to check input voltage requirements. The data plate is on the back of the power supply. See Figure 2-4.

Install Power Cord Plug

Use a power cord plug that is certified by national or local electrical codes. The plug should be connected to the power cord by a licensed electrician.

Figure 2-4 Data Plate Input Voltage

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powermax600 Service Manual

SPECIFICATIONS

PMX600.02

Power Cord / Extension Cord

Use a cord that is certified by national or local codes. The cord should be installed by a licensed electrician. Refer to the length requirements listed below.

< 10 ft 10-25 ft 25-50 ft 50-100 ft 100-150 ft < 3 m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45 m

Input Voltage Phase Recommended Cord Gauge Size (mm2)

208-240 VAC 1 10 10 10 16 16 230 VAC 3 4 6 6 10 10 400 VAC 3 2.5 2.5 4 6 6 480 VAC 3 4 4 4 4 6

Recommended Cord Gauge Size (AWG) 208-240 VAC 1 8 8 8 6 6 230 VAC 3 12 10 10 8 8 400 VAC 3 14 14 12 10 10 480 VAC 3 12 12 12 12 10

Grounding Requirements

To ensure personal safety, proper operation and to reduce electromagnetic interference (EMI), the Powermax600 must be properly grounded:

• The power supply chassis is electrically conductive and can present a shock hazard if it is not

properly grounded through the line voltage disconnect box.

• The power supply must be properly grounded through the power cord according to national or

local electrical codes.

• Three-phase service must use a 4-wire cord that includes a protective earth ground.

• Also see

Grounding Safety

, in Section 1 of this manual.

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PECIFICATIONS

PMX600.03

PMX600.04

Line Voltage Disconnect Box

Use a line disconnect box for each power supply so that the operator can turn the power supply off quickly in an emergency situation. Locate the switch near the power supply so that it is easily accessible to the operator. The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses. Use slow-blow fuses as listed below.

Input Input Current Recommended

Voltage Phase @ 5.6 kw Output Slow-Blow Fuse Size

208-240 VAC 1 46-40A 100A 230 VAC 3 17A 40A 400 VAC 3 9.7A 25A 480 VAC 3 12A 25A

Gas Requirements

Air must be filtered to remove all dirt, water and oil. Contaminants can damage the power supply, torch and consummables.

The power supply will not power-up if the gas inlet pressure is below minimum.

CAUTION: Do not exceed 120 psi / 8.3 bar pressure at the power supply

gas inlet. Damage to system may result from higher pressures.

Minimum Gas Inlet Pressure 90 psi / 6.2 bar

Gas Flow 6 scfm @ 90 psi / 170 l/min @ 6.2 bar

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powermax600 Service Manual

MAINTENANCE

Section 3

MAINTENANCE

In this section:

CONTROLS AND INDICATORS ............................................................................... 3-2

INDICATOR LAMPS.................................................................................................. 3-2

CONTROLS. ............................................................................................................. 3-2

THEORY OF OPERATION ....................................................................................... 3-3

GENERAL ................................................................................................................. 3-3

230/400 VOLT FUNCTIONAL DESCRIPTION.......................................................... 3-4

208-240/480 VOLT FUNCTIONAL DESCRIPTION .................................................. 3-6

SEQUENCE OF OPERATION .................................................................................. 3-8

TROUBLESHOOTING .............................................................................................. 3-9

TEST EQUIPMENT................................................................................................... 3-9

TROUBLESHOOTING PROCEDURES AND SEQUENCE ...................................... 3-9

VISUAL INSPECTION - EXTERNAL ........................................................................ 3-9

VISUAL INSPECTION - INTERNAL.......................................................................... 3-10

RESISTANCE CHECKS ........................................................................................... 3-11

TROUBLESHOOTING GUIDE.................................................................................. 3-14

VOLTAGE CHECKS .................................................................................................. 3-21

COMPONENT REPLACEMENT ............................................................................... 3-26

POWER CORD REPLACEMENT ............................................................................. 3-26

TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT)...... 3-27

AIR FILTER ELEMENT REPLACEMENT ................................................................. 3-28

WORK CABLE REPLACEMENT .............................................................................. 3-30

CAPACITOR REPLACEMENT.................................................................................. 3-31

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MAINTENANCE

PMX600.05

OFF

CONTROLS AND INDICATORS

Indicator Lamps

Green POWER IS ON

When illuminated, indicates that AC voltage is supplied to the power supply and that the ON/OFF switch is in the ON position.

Green SYSTEM READY

When illuminated, indicates that circuits are activated and that all fault conditions are clear (none of the yellow lamps are illuminated).

Yellow LOW LINE VOLTAGE

When illuminated, indicates that the AC line voltage is: 1) below operating limits ,or 2) is missing 1 phase (230V and 400V systems only).

Yellow LOW GAS PRESSURE

When illuminated, indicates that the incoming gas pressure is below operating limits.

Yellow TORCH PARTS ARE LOOSE OR REMOVED

When illuminated, indicates that the torch consumables are loose or not installed.

Yellow HIGH TEMPERATURE

When illuminated, indicates that the power supply temperature has exceeded operating limits.

Controls - See Figure 3-1.

Pressure Gauge

Pressure Regulator

Current

Adjustment

Knob

Pilot Arc

Control Switch

(208-240, 480V)

ON (I)/OFF (0) Switch

Figure 3-1 Powermax600 Controls

3-2

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powermax600 Service Manual

MAINTENANCE

THEORY OF OPERATION

General

Refer to Functional Description, Figures 3-2.1 and 3-2.2, Sequence of Operation and the

system wiring diagram.

powermax600 Service Manual

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MAINTENANCE

230/400 Volt Functional Description

3-4

10-99

See Figure 3-2.1.

Three phase AC power enters the system through the power switch S1 and supplies the

EMI filter board PCB1. The filter board provides noise suppression and spike protection.

The DC voltage output from the diode bridge D1 supplies the inverter and supplies the

flyback system power supply (DC to DC converter) on the power board PCB2. A “soft start”

is implemented via power board resistor RT5 and relay K1.

The inverter consists of several components: an isolated gate bipolar transistor (IGBT Q2),

the power transformer (T2), a current sense transformer (LEM), power factor choke and

sections of the power board. The inverter operates as a pulse width modulator controlled

bridge circuit and is rectified by the output diode D2.

The output circuitry consists of 2 current transfer sensors located on the power board, the

pilot arc IGBT Q3 and the output choke L2.

The control board microprocessor monitors and regulates system operation and safety

circuits. The current is set to the desired value by adjusting the current adjust potentiom-

eter. The system compares the set point to the output current by monitoring the current

sensor and adjusting the pulse width output of the inverter IGBT Q2.

powermax600 Service Manual

Cap Switch

Start Switch

TS1

TS2

Board

Power

PCB2

Board

EMI Filter

PCB1

On Rear of Board

Start

LED6 LED7 LED8

Power

O.K.

Low Volt

Low Pres

Cap Off

Over Temp

Bridge

Input

Diode

Regulator

Switch (gas)

Pressure

PS1

Valve (gas)

Soleniod

Filter

Air/Gas

Source

Air/Gas

Torch

LEDs

Gas Test

Current Adjust

PCB3 Control Board

sensors

xfer

Nozzle

Work

IGBT

xfmr

Power

Diode

Output

TB1

Workpiece

Electrode

Torch

Module

IGBT

Designator Component

D1 .................... Input diode bridge

D2 .................... Output diode

L1 ..................... Input choke inductor

L2 ..................... Output choke inductor

M1 .................... Fan

PCB1 ................ Filter board

PCB2 ................ Power board

PCB3 ................ Control board

PS1 .................. Pressure switch

Q2 .................... IGBT module

Q3 .................... Pilot arc IGBT

S1 ..................... Breaker

TB1 .................. Terminal block

TS1 .................. Heatsink temperature sensor

TS2 .................. Transformer temperature sensor

T2 ..................... Power transformer

V1 ..................... Solenoid valve

MAINTENANCE

Figure 3-2.1 Powermax600 230/400 Volt Block Diagram

powermax600 Service Manual

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MAINTENANCE

208-240/480 Volt Functional Description

3-6

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See Figure 3-2.2.

AC power enters the system through the power switch S1 to the input diode bridge D18.

The DC voltage output from the diode bridge D1 supplies the inverter and supplies the

flyback system power supply (DC to DC converter) on the power board PCB2. The power

board provides noise suppression and spike protection. A “soft start” is implemented via

power board resistor RT5 and relay K1.

The inverter consists of several components: an isolated gate bipolar transistor (IGBT Q2),

the power transformer (T2), a current sense transformer (LEM), power factor choke and

sections of the power board. The inverter operates as a pulse width modulator controlled

bridge circuit and is rectified by the output diode D2.

The output circuitry consists of 2 current transfer sensors located on the power board, the

pilot arc IGBT Q3 and the output choke L2.

The control board microprocessor monitors and regulates system operation and safety

circuits. The current is set to the desired value by adjusting the current adjust potentiom-

eter. The system compares the set point to the output current by monitoring the current

sensor and adjusting the pulse width output of the inverter IGBT Q2.

The control board PCB3 includes a pilot arc control switch, allowing the operator to turn the

pilot arc ON (useful when cutting expanded metal) or OFF for maximum consumable life.

powermax600 Service Manual

Cap Switch

Start Switch

TS1

TS2

Board

Power

PCB2

On Rear of Board

Start

LED6 LED7 LED8

Power

O.K.

Low Volt

Low Pres

Cap Off

Over Temp

Bridge

Input

D18

Diode

Regulator

Switch (gas)

Pressure

PS1

Valve (gas)

Soleniod

Filter

Air/Gas

Source

Air/Gas

Torch

LEDs

Gas Test

Current Adjust

PCB3 Control Board

sensors

xfer

Nozzle

Work

IGBT

xfmr

Power

Diode

Output

TB1

Workpiece

Electrode

Torch

Module

IGBT

Pilot Arc

Switch

Designator Component

D18 .................. Input diode bridge

D2 .................... Output diode

L2 ..................... Output choke inductor

M1 .................... Fan

PCB2 ................ Power board

PCB3 ................ Control board

PS1 .................. Pressure switch

Q2 .................... IGBT module

Q3 .................... Pilot arc IGBT

S1 ..................... Breaker

TB1 .................. Terminal block

TS1 .................. Heatsink temperature sensor

TS2 .................. Transformer temperature sensor

T2 ..................... Power transformer

V1 ..................... Solenoid valve

MAINTENANCE

Figure 3-2.2 Powermax600 208-240/480 Volt Block Diagram

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MAINTENANCE

• Connect gas supply to filter-regulator on power unit

• Connect work lead to workpiece

• Apply power at line voltage disconnect box

• Set circuit breaker S1 to ON (I)

Fan M1 operates and POWER and OK LEDs illuminate, indicating system is ready for operation. Other LEDs should be OFF (see troubleshooting if ON).

• Position torch on workpiece.

• Depress plasma start switch on hand torch or remote start switch for machine torch.

• Move torch to make cut.

• Workpiece falls away after cut.

• Release plasma start switch on hand torch or remote start switch for machine torch.

Sequence of Operation

System off

• Turn current adjust knob fully counter clockwise to gas test position.

• Check air pressure setting.

Fan continues to operate and LOW VOLT LED illuminates for approximately 5 sec. All LED's are OFF.

• Set circuit breaker S1 to OFF (0).

Gas solenoid V1 closes. Gas flow stops.

Arc extinguishes. Post flow continues for 10 seconds.

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

• Set gas pressure to 70 psi (4.5 bar).

• Select cutting amps with current adjust knob.

Gas solenoid valve V1 closes. Gas flow stops.

Power circuits ready.

Cutting arc transfers to workpiece. Pilot arc stops. Cut arc starts.

Gas solenoid valve V1 opens. Gas flow starts. Pilot arc starts.

3-8

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powermax600 Service Manual

MAINTENANCE

TROUBLESHOOTING

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 the phone numbers listed in the front of this manual.

Test Equipment

• Multimeter

Troubleshooting Procedures and Sequence

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

• To locate power supply components refer to Section 4. Refer to Section 5 for torch components.

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

Sequence of Operation

flow diagram in this

section to test the power supply for proper operation.

Visual Inspection - External

Power OFF & Disconnected

Visual Inspection

External

Visual Inspection

Internal

Resistance Checks

Power ON

Troubleshooting

Guide

Voltage Checks

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.

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MAINTENANCE

ELECTRIC SHOCK CAN KILL

• Turn off the power and remove the input power plug from its receptacle

before removing the cover from the power supply. If the power supply is directly connected to a line disconnect box, switch the line disconnect to OFF (O). In the U.S., use a "lock-out / tag-out" procedure until the service or maintenance work is complete. In other countries, follow appropriate national or local safety procedures.

• Do not touch live electrical parts! If power is required for servicing, use

extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

• Do not attempt to repair the power board or control board. Do not cut away

or remove any protective conformal coating from either board. To do so will risk a short circuit between the AC input circuit and the output circuit and may result serious injury or death.

WARNING

HOT PARTS CAN CAUSE SEVERE BURNS

• Allow the power supply to cool before servicing.

MOVING FAN CAN CAUSE INJURY

• Keep hands away from moving parts.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS

• Put on a grounded wrist strap BEFORE handling PC boards.

Visual Inspection - Internal

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

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

3. Inspect the inside of the power supply, especially on the side with the power board. Look for broken or loose wiring connections, burn and char marks, damaged components, etc. Repair or replace as necessary.

3-10

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powermax600 Service Manual

MAINTENANCE

PMX600-SM.01

2.5M

208V - 240V

300-500K

>50M

230V and 400V

3.5 - 4.5M

>50M

480V

>50M

Resistance Checks

All resistance values were taken with the power cord disconnected and all internal power supply wires attached. Perform Visual Inspection - Internal before continuing in this section.

• If your resistance values are not close to the values given in this section, isolate the problem

by removing wires attached to the resistance check points or component until the problem is found.

• After the problem has been located and repaired, refer to the Sequence of Operation flow

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

Resistance Check #1 - Figure 3-3

1. Turn switch ON (power disconnected).

2. Check resistance across input leads.

3. Check resistance from

input leads to ground.

Figure 3-3 Resistance Check #1 - Across Input Leads and Input to Ground

powermax600 Service Manual

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MAINTENANCE

230V and 400V

208-240V and 480V

PMX600.20

Resistance Check #2 - Figure 3-4

• Check resistance from power board connection to chassis.

> 10MΩ

3-12

10-99

> 10MΩ

Figure 3-4 Resistance Check #2 - Power Board to Chassis

powermax600 Service Manual

230V and 400V

208-240V and 480V

PMX600.21

Resistance Check #3 - Figure 3-5

• Check resistance across output diode bridge.

MAINTENANCE

6 to 9 KΩ

4 to 7 KΩ

Figure 3-5 Resistance Check #3 - Output Diode Bridge

powermax600 Service Manual

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MAINTENANCE

Troubleshooting Guide

WARNING

ELECTRIC SHOCK CAN KILL

• Use extreme caution when working near live electrical circuits. Dangerous volt-

ages exist inside the power supply that can cause serious injury or death.

• See warnings on page 3-6 before proceeding.

If no problems were found during the initial resistance checks and the power supply still does not operate correctly, follow the

Troubleshooting Guide

Note: The wiring diagram and understand the theory of operation before troubleshooting. Before purchasing a major replacement component, verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility.

Troubleshooting Guide

provides most probable cause and solutions. Study the system

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powermax600 Service Manual

MAINTENANCE

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MAINTENANCE

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powermax600 Service Manual

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MAINTENANCE

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MAINTENANCE

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MAINTENANCE

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MAINTENANCE

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3-20

10-99

powermax600 Service Manual

Voltage Checks

ELECTRIC SHOCK CAN KILL

• Use extreme caution when working near live electrical circuits. Dangerous volt-

• See warnings on page 3-6 before proceeding.

MAINTENANCE

WARNING

ages exist inside the power supply that can cause serious injury or death.

Before performing voltage checks, complete the troubleshooting guide.

• Connect the power cord into the line voltage disconnect switch box or plug into a properly

grounded outlet.

• Connect the gas supply to the power supply.

• Switch the power supply on.

Visual Inspection - Internal, Resistance Checks

and

powermax600 Service Manual

3-21

10-99

MAINTENANCE

230V and 400V

208-240V and 480V

PMX600.22

= Line Voltage

= Line Voltage*

= Line Voltage

= Line Voltage*

*480V Only

Voltage Check #1 - Figure 3-5

• Check input voltage to the input diode bridge. The AC voltage between any 2 input wires should equal the line voltage.

3-22

10-99

Figure 3-5 Voltage Check #1 - Input of Input Diode Bridge

powermax600 Service Manual

Voltage Check #2 - Figure 3-6

230V and 400V

208-240V and 400V

PMX600.23

230 VAC 400 VAC

208-240 VAC

480 VAC

325 VDC 565 VDC

300-330 VDC

660 VDC

• Check output voltage of the input diode bridge.

Line Voltage Output at Bridge

MAINTENANCE

powermax600 Service Manual

Figure 3-6 Voltage Check #2 - Output of Input Diode Bridge

3-23

10-99

MAINTENANCE

230V and 400V

208-240V and 480V

PMX600.24

A 160 280 165 330

C 325 565 330 660

B 160 280 165 330

230 VAC 400 VAC

208-240 VAC

480 VAC

Voltage Check #3 - Figure 3-7

• Check voltage across IGBT module.

Line Voltage VDC Across Connections

3-24

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Figure 3-7 Voltage Check #3 - Across IGBT Module

powermax600 Service Manual

Voltage Check #4 - Figure 3-8

230V and 400V

208-240V and 480V

PMX600.25

230 VAC 400 VAC

208-240 VAC

480 VAC

290 VDC 290 VDC

165-165 VDC

330 VDC

• Check voltage across power supply capacitors.

Line Voltage VDC Across Connections

MAINTENANCE

powermax600 Service Manual

Figure 3-8 Voltage Check #4 - Across Power Supply Capacitors

3-25

10-99

MAINTENANCE

208V - 240V

230V and 400V

PMX600.12

480V

230V 400V

COMPONENT REPLACEMENT

WARNING

ELECTRIC SHOCK CAN KILL

• Disconnect electrical power before performing any maintenance.

• See warnings on page 3-6 before proceeding.

Power Cord Replacement

Disconnect electrical power and gas supply before removing the old power cord.

Installation - See Figure 3-10.

1. Insert the new power cord through the strain relief.

2. Pass all 4 wires through the toroid, as shown (230 and 400 volt only).

3. Install the power cord connections where shown.

4. Tighten the strain relief onto the power cord.

5. Install the power supply cover.

6. Reconnect electrical power and gas supply.

BROWN

BLUE

BLACK

YELLOW GREEN

WHITE

Pass all 4 wires through the toroid 2 times.

NOTE: Toroid must be installed for power

supply to be in compliance with EMC standard EN50199.

Pass all 4 wires through the toroid 3 times.

BLACK

WHITE

RED

3-26

10-99

GREEN

Figure 3-10 Power Cord Replacement

powermax600 Service Manual

GREEN

Torch Lead Replacement (For models without quick disconnect)

Disconnect electrical power and gas supply before removing the old torch lead.

Installation - Refer to Figure 3-11.

CAUTION:Do not tighten the strain relief collar (4) onto the torch lead until

the gas fitting (3) is tight, or the gas connection may leak.

Install the strain relief (1) and secure with nut (2).

Connect and tighten the gas fitting (3).

Tighten the strain relief collar (4) onto the lead.

Connect the electrical connections (5), (6) and (7). Tighten terminal block screws to 10 in-lb (12 kg cm) of torque.

Install the power supply cover.

Early Configuration

MAINTENANCE

CAUTION: These are high current connections.

Proper torque is critical.

Figure 3-11 Torch Lead Replacement

powermax600 Service Manual

3-27

10-99

MAINTENANCE

Air Filter Element Replacement

Removal

• Disconnect electrical power.

• Disconnect gas supply.

• Remove the power supply cover.

Refer to Figure 3-12.

Compress the hose fitting collar and pull the gas hose from the hose fitting.

Pull the drain hose from the grommet in the floor of the power supply.

Unscrew the filter bowl. Do not discard the O-ring.

Remove the filter element from the filter housing.

NOTE: Do not allow the filter element to turn when loosening the screw.

Figure 3-12 Air Filter Element Removal

3-28

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powermax600 Service Manual

Air Filter Element Replacement (continued)

Installation - Refer to Figure 3-13.

Install the new filter element into the filter housing. Secure with screw and retainer.

Install the filter bowl and O-ring into the filter housing.

MAINTENANCE

Push the pressure line fully into the hose fitting.

Install the drain hose into the grommet.

•

Install the power supply cover.

• Connect electrical power.

• Connect gas supply.

Figure 3-13 Air Filter Element Installation

powermax600 Service Manual

3-29

10-99

MAINTENANCE

PMX600.15

Work Cable Replacement

Disconnect electrical power and gas supply before removing the old work cable.

Installation - Refer to Figure 3-14.

Install the strain relief (1) to the power supply and secure with nut (2).

Install work cable (3) through the strain relief.

Tie a knot (4) in the end of the work cable.

Tighten the strain relief collar (5) onto the cable.

Connect the work cable to the terminal block (6). Tighten terminal block screw to 10 in-lb (12 kg cm) of torque.

Install the power supply cover.

Early Configuration

CAUTION: This is a high current connection.

Proper torque is critical.

3-30

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Figure 3-14 Work Cable Replacement

powermax600 Service Manual

MAINTENANCE

Correct Installation

Capacitor Replacement

Removal - Refer to Figure 3-15.

Disconnect electrical power and gas supply before removing the power supply cover.

Remove screws securing capacitor to PC board.

Remove capacitor from fan side of power supply.

Capacitor Identification

Installation - Refer to Figure 3-15.

Check capacitor identification and install as shown below.

Power Capacitor Supply Marking

208/240V 250V 6800uf

Install new capacitor and secure with 2 screws. Tighten screws to 20 inch pounds (2.26 N-m / 24 kg cm).

Install the power supply cover.

Remove and install

capacitors from fan side.

230V 250V 4700uf

400V 400V 1800uf

480V 450V 1500uf

powermax600 Service Manual

Figure 3-15 Capacitor Replacement

+ Positive

3-31

11-99

MAINTENANCE

129529exploded.eps

Reference

Notes:

A Apply thermal grease and Torque to 20 in-lb / 23 kg cm B Apply thermal grease and Torque to 8 in-lb / 9 kg cm C Torque to 8 in-lb / 9 kg cm

DC-120

PMX600.28

Heat Sink Component Replacement

Installation - Refer to Figure 3-16.

Install components to the heat sink as shown below.

Use a new thermal pad on components C.

Thermal Pad

Use thermal grease on components A and B. Apply a thin coat to the component, install with screws, and tighten to required torque.

Re-torque after 2 minutes. Repeat until torque is maintained. Clean excess grease from heat sink.

Thermal Grease

Figure 3-16 Heat Sink Component Replacement

3-32

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powermax600 Service Manual

PARTS LIST - 400/230V CE

Section 4

PARTS LIST - 400/230V

In this section:

POWER SUPPLY – EXTERIOR ..................................................................................................... 4-2

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE.................................................................... 4-3

POWER SUPPLY – BACK INTERIOR RIGHT SIDE ...................................................................... 4-4

POWER SUPPLY – INTERIOR FAN SIDE ..................................................................................... 4-5

POWER SUPPLY – HEAT SINK ASSEMBLY ................................................................................. 4-6

RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V ................................................. 4-7

powermax600 Service Manual

4-1

11-99

PARTS LIST - 400/230V CE

POWER SUPPLY – EXTERIOR

4-2

10-99

Part

Item Number Description Designator Qty.

1 001669 Rear end panel 1 2 001668 Front end panel (Also order 110242) 1 3 110242 Operation lable 1

4 129488 Power supply cover 1 5 008965 Knob 1

6 110261 Warning label 1 7 110258 Instruction label 1 8 110996 Pressure warning label 1

powermax600 Service Manual

PARTS LIST - 400/230V CE

PMX600.26

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE

Early Configuration

Part

Item Number Description Designator Qty.

1 041593 Control PCB assembly PCB3 1 2 108090 Terminal block 1 3 129374 Solenoid valve V1 1 4 123375 Work Cable with clamp, 4.6 m/15 ft 1

powermax600 Service Manual

4-3

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PARTS LIST - 400/230V CE

POWER SUPPLY – BACK INTERIOR RIGHT SIDE

4-4

10-99

Part

Item Number Description Designator Qty.

1 003193 Circuit breaker, 400 V S1 1

003195 Circuit breaker, 230 V S1 1

2 041566 EMI Filter PCB, 400 V PCB1 1

041587 EMI Filter PCB, 230 V PCB1 1

3 129368 Power cable, 400 V 1

129410 Power cable, 230 V 1

4 008389 Strain relief, 400 V 1

108107 Strain relief, 230 V 1

5 109070 Toroid 1

powermax600 Service Manual

POWER SUPPLY – INTERIOR FAN SIDE

PARTS LIST - 400/230V CE

Part

Item Number Description Designator Qty.

1 005112 Pressure Switch PS1 1 2 022027 Pressure gauge 1 3 014232 Inductor, output choke .80MH 40A L2 1 4 014234 Power transformer, 400V T2 1

014238 Power transformer, 230V T2 1

5 009999 Capacitor, 1800/1900UF, 400V 2

109118 Capacitor, 1800/1900UF, 230V 2

6 014231 Inductor, input choke 5MH 11A, 400V L1 1

014241 Inductor, input choke 5MH 11A, 230V L1 1 7 011083 Filter regulator subassembly 1 8 011086 Air filter element 1 9 011087 O-ring 1 10 129366 Fan subassembly M1 1

powermax600 Service Manual

4-5

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PARTS LIST - 400/230V CE

DC-120

PMX600.28

POWER SUPPLY – HEAT SINK ASSEMBLY

Item Number Description Designator Qty.

4-6

11-99

Part

1 109088 Output diode D2 1 2 129406 EMI suppression capacitor 1 3 009849 Resistor, 20 OHM 2 4 109080 IGBT, pilot arc Q3 1 5 005222 Temp switch TS1 1 6 109079 IGBT module Q2 1 7 009849 Resistor, 20 OHM 1 8 109067 MOV 1 9 109090 Input diode bridge, 400V D1 1

- 109134 Input diode bridge, 230V D1 1 10 041568 Power PCB, 400V PCB2 1

- 041607 Power PCB, 230V PCB2 1 11 008903 Thermal pad 3 12 027662 Thermal grease, 5 oz. tube 5 places

powermax600 Service Manual

PARTS LIST - 400/230V CE

RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V

Part Number Description Page Reference

001668 ............................... Front end panel............................................................................. 4-2

001669 ............................... Rear end panel ............................................................................. 4-2

008965 ............................... Knob ............................................................................................. 4-2

110242 ............................... Operation lable ............................................................................. 4-2

110258 ............................... Instruction label............................................................................. 4-2

110261 ............................... Warning label ................................................................................ 4-2

129488 ............................... Power supply cover ...................................................................... 4-2

041593 ............................... Control PCB assembly.................................................................. 4-3

108090 ............................... Terminal block .............................................................................. 4-3

123375 ............................... Work Cable with clamp, 4.6 m/15 ft .............................................. 4-3

129374 ............................... Solenoid valve .............................................................................. 4-3

003193 ............................... Circuit breaker, 400 V ................................................................... 4-4

003195 ............................... Circuit breaker, 230 V ................................................................... 4-4

041566 ............................... EMI Filter PCB, 400 V................................................................... 4-4

041587 ............................... EMI Filter PCB, 230 V................................................................... 4-4

129368 ............................... Power cable, 400 V....................................................................... 4-4

129410 ............................... Power cable, 230 V....................................................................... 4-4

005112 ............................... Pressure Switch ............................................................................ 4-5

009999 ............................... Capacitor, 1800/1900UF, 400V .................................................... 4-5

011083 ............................... Filter regulator subassembly......................................................... 4-5

011086 ............................... Air filter element ............................................................................ 4-5

011087 ............................... O-ring, Air filter element ................................................................ 4-5

014231 ............................... Inductor, input choke 5MH 11A, 400V .......................................... 4-5

014232 ............................... Inductor, output choke .80MH 40A ............................................... 4-5

014234 ............................... Power transformer, 400V .............................................................. 4-5

014238 ............................... Power transformer, 230V .............................................................. 4-5

014241 ............................... Inductor, input choke 5MH 11A, 230V .......................................... 4-5

022027 ............................... Pressure gauge ............................................................................ 4-5

109118 ............................... Capacitor, 1800/1900UF, 230V .................................................... 4-5

129366 ............................... Fan subassembly.......................................................................... 4-5

005222 ............................... Temp switch.................................................................................. 4-6

009849 ............................... Resistor, 20 OHM ......................................................................... 4-6

041568 ............................... Power PCB, 400V ......................................................................... 4-6

041607 ............................... Power PCB, 230V ......................................................................... 4-6

109067 ............................... MOV.............................................................................................. 4-6

109079 ............................... IGBT module................................................................................. 4-6

109080 ............................... IGBT, pilot arc ............................................................................... 4-6

109088 ............................... Output diode ................................................................................. 4-6

109090 ............................... Input diode bridge, 400V............................................................... 4-6

109134 ............................... Input diode bridge, 230V............................................................... 4-6

129406 ............................... EMI suppression capacitor ........................................................... 4-6

027662 ............................... Thermal grease, 5 oz. DC-340 ..................................................... 4-6

008903 ............................... Thermal pad.................................................................................. 4-6

powermax600 Service Manual

4-7

11-99

PARTS LIST - 400/230V CE

Blank

4-8

powermax600 Service Manual

In this section:

PARTS LIST - 208-240/480V

Section 5

PARTS LIST - 208-240/480V

POWER SUPPLY – EXTERIOR ..................................................................................................... 5-2

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE.................................................................... 5-3

POWER SUPPLY – CIRCUIT BREAKER AND POWER CABLE ................................................... 5-4

POWER SUPPLY – INTERIOR FAN SIDE ..................................................................................... 5-5

POWER SUPPLY – HEAT SINK ASSEMBLY ................................................................................. 5-6

RECOMMENDED SPARE PARTS - POWERMAX600- 208-240/480V .......................................... 5-7

powermax600 Service Manual

5-1

11-99

PARTS LIST - 208-240/480V

POWER SUPPLY – EXTERIOR

5-2

10-99

Part

Item Number Description Designator Qty.

1 001669 Rear end panel 1 2 001668 Front end panel (also order 110271) 1 3 110271 Operation lable 1

4 129594 Power supply cover 1 5 008965 Knob 1

6 010287 Warning label 1 7 110276 Instruction label 1 8 110996 Pressure warning label 1

powermax600 Service Manual

PARTS LIST - 208-240/480V

PMX600.27

POWER SUPPLY – FRONT INTERIOR RIGHT SIDE

Part

Item Number Description Designator Qty.

1 041654 Control PCB assembly PCB3 1 2 108090 Terminal block 1 3 129534 Quick disconnect assembly 1 4 129533 Solenoid valve V1 1 5 123375 Work Cable with clamp, 4.6 m/15 ft 1

powermax600 Service Manual

5-3

10-99

PARTS LIST - 208-240/480V

208V - 240V

480V

POWER SUPPLY – CIRCUIT BREAKER AND POWER CABLE

Part

Item Number Description Designator Qty.

1 003193 Circuit breaker, 480V S1 1

003202 Circuit breaker, 208-230V S1 1

2 023519 Power cable, 480V 1

129530 Power cable, 208-230V 1

3 108124 Strain relief, 480V 1

108122 Strain relief, 208-230V 1

5-4

10-99

powermax600 Service Manual

POWER SUPPLY – INTERIOR FAN SIDE

PARTS LIST - 208-240/480V

Part

Item Number Description Designator Qty.

1 005112 Pressure Switch PS1 1 2 022027 Pressure gauge 1 3 014232 Inductor, output choke .80MH 40A L2 1 4 014252 Power transformer, 480V T2 1

014251 Power transformer, 208-230V T2 1 5 109179 Capacitor, 1800/1900UF 450V, 480V 2

109187 Capacitor, 1800/1900UF 250V, 208-230V 2 6 011083 Filter regulator subassembly 1 7 011086 Air filter element 1 8 011087 O-ring 1 9 129366 Fan subassembly, 480V M1 1

027654 Fan assembly, 208-230V M1 1

powermax600 Service Manual

5-5

10-99

PARTS LIST - 208-240/480V

129528

DC-120

PMX600.28

POWER SUPPLY – HEAT SINK ASSEMBLY

Item Number Description Designator Qty.

5-6

11-99

Part

1 109088 Output diode D2 1 2 009849 Resistor, 20 OHM 2 3 109080 IGBT, pilot arc Q3 1 4 005222 Temp switch TS1 1 5 109079 IGBT module, 480V Q2 1

109183 IGBT module, 208-240V Q2 1 6 009849 Resistor, 20 OHM 1 7 109175 Input diode bridge, 480V D18 1

- 109174 Input diode bridge, 208-240V D18 1 8 041652 Power PCB, 480V PCB2 1

- 041650 Power PCB, 208-240V PCB2 1 9 008903 Thermal pad 3 10 027662 Thermal grease, 5 oz. tube 5 places

powermax600 Service Manual

PARTS LIST - 208-240/480V

RECOMMENDED SPARE PARTS - POWERMAX600- 208-240/480V

Part Number Description Page Reference

001668 ........................... Front end panel ....................................................................5-2

001669 ........................... Rear end panel .................................................................... 5-2

008965 ........................... Knob .....................................................................................5-2

010287 ........................... Warning label .......................................................................5-2

110271 ........................... Operation lable .....................................................................5-2

129594 ........................... Power supply cover ..............................................................5-2

041654 ........................... Control PCB assembly .........................................................5-3

108090 ........................... Terminal block...................................................................... 5-3

123375 ........................... Work Cable with clamp, 4.6 m/15 ft ..................................... 5-3

129533 ........................... Solenoid valve ......................................................................5-3

129534 ........................... Quick disconnect assembly ................................................. 5-3

003193 ........................... Circuit breaker, 480 V .......................................................... 5-4

003202 ........................... Circuit breaker, 208-230V ....................................................5-4

023519 ........................... Power cable, 480V ...............................................................5-4

129530 ........................... Power cable, 208-230V ........................................................5-4

005112 ........................... Pressure Switch ...................................................................5-5

011083 ........................... Filter regulator subassembly ................................................5-5

011086 ........................... Air filter element ...................................................................5-5

011087 ........................... O-ring, Air filter element .......................................................5-5

014232 ........................... Inductor, output choke .80MH 40A ...................................... 5-5

014251 ........................... Power transformer, 208-240V ..............................................5-5

022027 ........................... Pressure gauge ....................................................................5-5

027654 ........................... Fan assembly.......................................................................5-5

014252 ........................... Power transformer, 480V .....................................................5-5

109179 ........................... Capacitor, 1800/1900UF 450V, 480V ..................................5-5

109187 ........................... Capacitor, 1800/1900UF 250V, 208-230V ........................... 5-5

129366 ........................... Fan subassembly, 480V ...................................................... 5-5

005222 ........................... Temp switch .........................................................................5-6

009849 ........................... Resistor, 20 OHM ................................................................ 5-6

041650 ........................... Power PCB, 208-240V .........................................................5-6

041652 ........................... Power PCB, 480V ................................................................5-6

109079 ........................... IGBT module, 480V ............................................................. 5-6

109080 ........................... IGBT, pilot arc ......................................................................5-6

109088 ........................... Output diode ........................................................................ 5-6

109174 ........................... Input diode bridge, 208-240V ...............................................5-6

109175 ........................... Input diode bridge, 480V ......................................................5-6

109183 ........................... IGBT module, 208-240V ...................................................... 5-6

027662 ........................... Thermal grease, 5 oz. DC-340 .............................................5-6

008903 ........................... Thermal pad .........................................................................5-6

powermax600 Service Manual

5-7

11-99

PARTS LIST - 208-240/480V

Blank

5-8

powermax600 Service Manual

PARTS LIST - TORCH AND CONSUMABLES

Section 6

PARTS LIST - TORCH AND CONSUMABLES

In this section:

PAC123T HAND TORCH ASSEMBLY (NO QUICK DISCONNECT) .................................................... 6-2

PAC123T HAND TORCH ASSEMBLY (WITH QUICK DISCONNECT) ................................................ 6-4

PAC123M MACHINE TORCH ASSEMBLY (NO QUICK DISCONNECT) ............................................. 6-6

PAC123M MACHINE TORCH ASSEMBLY (WITH QUICK DISCONNECT) ......................................... 6-8

TORCH CONSUMABLES ................................................................................................................... 6-10

RECOMMENDED SPARE PARTS - PAC123 TORCH ....................................................................... 6-11

powermax600 Service Manual

6-1

10-99

PARTS LIST - TORCH AND CONSUMABLES

PAC123T Hand Torch Assembly (No Quick Disconnect)

Item Part Number Description Quantity

086001* PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect) 086002* PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)

086003* PAC123T Hand Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect) 1 001288 Handle, 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch (switch and wire splices) 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring, Gutcha 1 6 075339 Screws, P/S, # 4 X 1/2, PH, RND, S/B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O-Ring: BUNA 90 Duro .614X.070 1 9 129475 Replacement Hand Torch Lead, 15 ft / 4.5 m 1 9 129476 Replacement Hand Torch Lead, 25 ft / 7.5 m 1 9 129477 Replacement Hand Torch Lead, 50 ft / 15 m 1

Top assembly includes the following consumables:

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120828 Shield 1

6-2

10-99

powermax600 Service Manual

PARTS LIST - TORCH AND CONSUMABLES

PAC123T.01

Included with replacement

lead assembly.

PAC123T Hand Torch and Lead Assembly - No Quick Disconnect

powermax600 Service Manual

6-3

10-99

PARTS LIST - TORCH AND CONSUMABLES

PAC123T Hand Torch Assembly (With Quick Disconnect)

Item Part Number Description Quantity

086023* PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead and Quick Disconnect

086024* PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead and Quick Disconnect

086025* PAC123T Hand Torch Assembly with 50 ft / 15 m Lead and Quick Disconnect 1 001288 Handle, 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch (switch and wire splices) 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring, Gutcha 1 6 075339 Screws, P/S, # 4 X 1/2, PH, RND, S/B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O-Ring: BUNA 90 Duro .614X.070 1 9 129599 Replacement Hand Torch Lead, 15 ft / 4.5 m 1 9 129600 Replacement Hand Torch Lead, 25 ft / 7.5 m 1 9 129601 Replacement Hand Torch Lead, 50 ft / 15 m 1

Top assembly includes the following consumables:

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120828 Shield 1

6-4

10-99

powermax600 Service Manual

PARTS LIST - TORCH AND CONSUMABLES

PAC123T.02

PAC123T Hand Torch and Lead Assembly - With Quick Disconnect

powermax600 Service Manual

* Included with replacement

lead assembly.

6-5

10-99

PARTS LIST - TORCH AND CONSUMABLES

PAC123M Machine Torch Assembly (No Quick Disconnect)

Item Part Number Description Quantity

086004* PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect) 086005* PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)

086006* PAC123M Machine Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect) 1 120613 Sleeve, Machine Torch 1 2 020620 Sleeve, Torch Position 1 3 128374 Replacement Torch Lead, 15 ft / 4.5 m 1 3 128375 Replacement Torch Lead, 25 ft / 7.5 m 1 3 128376 Replacement Torch Lead, 50 ft / 15 m 1 4 027599 Snap Ring 1 5 120583 Torch Main Body with Safety Switch 1 6 044016 O-Ring: BUNA 90 Duro 0.614 X 0.070 inch 1 7 028714 On/Off Pendant with Lead, 25 ft / 7.5 m

128061 On/Off Pendant with Lead, 50 ft / 15 m

128062 On/Off Pendant with Lead, 75 ft / 23 m

Top assembly includes the following consumables:

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120827 Shield 1

6-6

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powermax600 Service Manual

PAC123M.03

* Included with replacement

lead assembly.

PARTS LIST - TORCH AND CONSUMABLES

PAC123M Machine Torch Assembly and Leads - No Quick Disconnect

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PARTS LIST - TORCH AND CONSUMABLES

PAC123M Machine Torch Assembly (With Quick Disconnect)

Item Part Number Description Quantity

086026* PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead and Quick Disconnect 086027* PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead and Quick Disconnect

086029* PAC123M Machine Torch Assembly with 50 ft / 15 m Lead and Quick Disconnect 1 120613 Sleeve, Machine Torch 1 2 020620 Sleeve, Torch Position 1 3 128572 Replacement Torch Lead w/Quick Disconnect, 15 ft / 4.5 m 1 3 128573 Replacement Torch Lead w/Quick Disconnect, 25 ft / 7.5 m 1 3 128574 Replacement Torch Lead w/Quick Disconnect, 50 ft / 15 m 1 4 027599 Snap Ring 1 5 120583 Torch Main Body with Safety Switch 1 6 044016 O-Ring: BUNA 90 Duro 0.614 X 0.070 inch 1 7 028714 On/Off Pendant with Lead, 25 ft / 7.5 m

128061 On/Off Pendant with Lead, 50 ft / 15 m

128062 On/Off Pendant with Lead, 75 ft / 23 m

Top assembly includes the following consumables:

120573 Electrode 1

120576 Swirl Ring 1

120600 Retaining Cap 1

120826 Nozzle 1

120827 Shield 1

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powermax600 Service Manual

PARTS LIST - TORCH AND CONSUMABLES

M.04

PAC

123

* Included with replacement

lead assembly.

PAC123M Machine Torch Assembly and Leads - With Quick Disconnect

powermax600 Service Manual

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PARTS LIST - TORCH AND CONSUMABLES

Torch Consumables

Hand Cutting

Gouging

Machine Cutting

Shield

120828

120608

120827

120600

Nozzle

120826

120831

120826

Electrode Swirl RingRetaining Cap

120573

120576

Deflector

120303

120600

120574120606

Unshielded*

* In CE countries, unshielded consumables may only be used in machine-torch applications.

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PARTS LIST - TORCH AND CONSUMABLES

RECOMMENDED SPARE PARTS - PAC123 TORCH

Part Number Description

001288 ........ Handle, 2 Sides

020620 ........ Sleeve, Machine Torch Position

075339 ........ Screws, P/S, # 4 X 1/2, PH, RND, S/B

086001 ........ PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect)

086002 ........ PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)

086003 ........ PAC123T Hand Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect)

086004 ........ PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect)

086005 ........ PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)

086006 ........ PAC123M Machine Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect)

086023 ........ PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead (with Quick Disconnect)

086024 ........ PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead (with Quick Disconnect)

086025 ........ PAC123T Hand Torch Assembly with 50 ft / 15 m Lead (with Quick Disconnect)

086026 ........ PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead (with Quick Disconnect)

086027 ........ PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead (with Quick Disconnect)

086029 ........ PAC123M Machine Torch Assembly with 50 ft / 15 m Lead (with Quick Disconnect)

120570 ........ Hand Torch Main Body with Safety Switch

120583 ........ Machine Torch Main Body with Safety Switch

128374 ........ Replacement Machine Torch Lead, 15 ft / 4.5 m (No Quick Disconnect)

128375 ........ Replacement Machine Torch Lead, 25 ft / 7.5 m (No Quick Disconnect)

128376 ........ Replacement Machine Torch Lead, 50 ft / 15 m (No Quick Disconnect)

128377 ........ Replacement Hand Torch Start Switch (switch and wire splices)

128572 ........ Replacement Machine Torch Lead, 15 ft / 4.5 m (with Quick Disconnect)

128573 ........ Replacement Machine Torch Lead, 25 ft / 7.5 m (with Quick Disconnect)

128574 ........ Replacement Machine Torch Lead, 50 ft / 15 m (with Quick Disconnect)

129475 ........ Replacement Hand Torch Lead, 15 ft / 4.5 m (No Quick Disconnect)

129476 ........ Replacement Hand Torch Lead, 25 ft / 7.5 m (No Quick Disconnect)

129477 ........ Replacement Hand Torch Lead, 50 ft / 15 m (No Quick Disconnect)

129599 ........ Replacement Hand Torch Lead, 15 ft / 4.5 m (with Quick Disconnect)

129600 ........ Replacement Hand Torch Lead, 25 ft / 7.5 m (with Quick Disconnect)

129601 ........ Replacement Hand Torch Lead, 50 ft / 15 m (with Quick Disconnect)

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PARTS LIST - TORCH AND CONSUMABLES

Blank

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IRING DIAGRAMS

Section 7

WIRING DIAGRAMS

In this section:

Electrical Schematic: 230/400V ..................................................... 013335

Electrical Schematic: 208-240/480V .............................................. 013337

powermax600 Service Manual

7-1

10-99

18T

RT1

RT2

COMT

R26

RT6

15 14 13

/SSR

/PA

/GAS

11 10

.1UF 50V

C50

+24

/SPARE

009994

U11

1B 2B 3B 4B

2 3 4

5B 6B 7B

6 7

-V

1C 2C 3C 4C 5C 6C 7C

042188

ULN2003A

TP1

008924

+12

108071

OUTA

OUTB

/CAPON

/START

SPAREIN

HSTEMPOK

GASOK

R54

TFRI

TP2

IFB

IOCA

/VOK

008924

ELEC SCHEM: PMX600 230/400V

013-3-335 REV. B

REDBLK

R41

R42

(FRONT)

J17

POWER TRANSFORMER

SENSOR IN

TS2

2 1

PS1

TS1

+24

TB1

20 OHM

4.7 NF

TRANSFORMER

POWER

WHTWHT

RT5

VDC

EMI

PCB1

GRN/YEL

ON ON TORCH STUCK OPEN

(VISIBLE FOR 15 SEC. AFTER EVENT)

ON OFF INVERTER SAFETY INTERLOCK

(VISIBLE FOR 15 SEC. AFTER EVENT)

(BLINKING @ 1 SEC. RATE)

OFF ON SELF DIAGNOSTICS FAILURE

OFF OFF SYSTEM OKAY

STATUS

LED6LED7

FAULT CODES

CONTROL BOARD

PCB3

VDC 540 310

3 TURNS

109160

C24

C11

BRN

BLU

BLK

CURRENT

013333013333TIMING DIAGRAM

109061109079IGBT MODULE (Q2)

109118/2009999/2BULK CAPS ON POWER BD

014238014234POWER XFR (T2)

014241014231POWER FACTOR CHOKE (L1)

041607041568POWER BOARD (PCB2)

109134109090INPUT BRIDGE (D1)

041587041566EMI FILTER BOARD (PCB1)

003195003193CIRCUIT BREAKER (S1)

ON TORROID

23POWER CORD # TURNS

230vac, 3É”400vac, 3É”

086007086000

INPUT VOLTAGE

POWER SUPPLY PART #

POWER BOARD PCB2

VIO

ORG

BLU

BREAKER

CIRCUIT

LED8LED7LED6

START

041593

OVER TEMP

CAP OFF

LOW PRESSURE

LOW VOLTAGE

O.K.

POWER

CAP SWITCH

START

ELECTRODE

NOZZLE

WORK LEAD

014232

OUTPUT CHOKE

109088

OUTPUT BRIDGE

~ ~

129406

BRN

W18

009849/2

W19

W17

W16

5 TURNS

TRANSFER SENSOR

IGBT

ARC

PILOT

LEM

009849

MOV

J13

YEL

GND

CONTROL

MODULE

IGBT

CHOKE (L1)

POWER FACTOR

SOFT START

W14

REDBLK

RED

BLK

FAN

SOLENOID

GAS

SWITCH

THERMAL

HEATSINK

SWITCH

GAS

J16

J15

TRIP

VOLTAGE

OVER

J14

SENSE

VOLTAGE

LINE

J10

J11

J12

W15

26 POSITION RIBBON CABLE

W11

W12

W13

BRIDGE

INPUT

W10

230V UNIT ONLY

BOARD

FILTER

109070

X TURNS

FILTER

CORD

POWER

VOLTAGE

INPUT

3 PHASE

123

13 2134 21234

18REG

COMT

18T

COMINV

18INV

COMPA

18PA

+12

+24

SUPPLY

POWER

SYSTEM

FLYBACK

J18

18T

RT1

R12

RT2

COMT

RT4

15 14 13

/SSR

/PA

/GAS

11 10

.1UF 50V

+24

/SPARE

009994

1B 2B 3B 4B

2 3 4

5B 6B 7B

6 7

-V

1C 2C 3C 4C 5C 6C 7C

042188

ULN2003A

TP1

008924

+12

108071

OUTA

OUTB

/CAPON

/START

SPAREIN

HSTEMPOK

GASOK

R55

TFRI

TP2

IFB

IOCA

/VOK

008924

ELEC SCHEM: PMX600 208-240/480V

013-3-337 REV. B

CONT. PA

J18

OR WHT

ORG

5WHT

WHT

RED

208/240V (086021)

1É”

208/240

GRN

BLK

W2WHT

CIRCUIT

BREAKER

INPUT BRIDGE

D18

VDC

CIRCUIT

BREAKER

WHT

BLK

GRN

RED

480 3É”

480V (086022)

~ ~ ~

W14

W13

W12

REDBLK

R59

R58

R56

R57

(FRONT)

J17

POWER TRANSFORMER

SENSOR IN

TS2

2 1

PS1

TS1

+24

TB1

20 OHM

TRANSFORMER

POWER

RT3

VDC

D18

ON ON TORCH STUCK OPEN

(VISIBLE FOR 15 SEC. AFTER EVENT)

ON OFF INVERTER SAFETY INTERLOCK

(VISIBLE FOR 15 SEC. AFTER EVENT)

(BLINKING @ 1 SEC. RATE)

OFF ON SELF DIAGNOSTICS FAILURE

OFF OFF SYSTEM OKAY

STATUS

LED6LED7

FAULT CODES

CONTROL BOARD

PCB3

VDC 330 660

C50

C51

CURRENT

013333013333TIMING DIAGRAM

109079109183IGBT MODULE (Q2)

109179/2109187/2BULK CAPS

014252014251POWER XFR (T2)

041652041650POWER BOARD (PCB2)

109175109174INPUT BRIDGE (D18)

003193003202CIRCUIT BREAKER (S1)

023519129530CORD

480vac, 3É”208/240vac, 1É”

086022086021

INPUT VOLTAGE

POWER SUPPLY PART #

POWER BOARD PCB2

VIO

ORG

BLU

LED8LED7LED6

START

041654

OVER TEMP

CAP OFF

LOW PRESSURE

LOW VOLTAGE

O.K.

POWER

CAP SWITCH

START

ELECTRODE

NOZZLE

WORK LEAD

014232

OUTPUT CHOKE

109088

OUTPUT BRIDGE

~ ~

BRN

W18

009849/2

W19

W17

W16

5 TURNS

TRANSFER SENSOR

IGBT

ARC

PILOT

LEM

009849

MOV

J13

YEL

GND

CONTROL

MODULE

IGBT

SOFT START

K1,K2

REDBLK

RED

BLK

FAN

SOLENOID

GAS

SWITCH

THERMAL

HEATSINK

SWITCH

GAS

J16

J15

TRIP

VOLTAGE

OVER

J14

26 POSITION RIBBON CABLE

BRIDGE

INPUT

208/240V UNIT ONLY

123

13 2134 21234

18REG

COMT

18T

COMINV

18INV

COMPA

18PA

+12

+24

SUPPLY

POWER

SYSTEM

FLYBACK

Hypertherm Powermax600 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual