Hypertherm Powermax65 Service Manual

Plasma arc cutting systems

Service Manual – 807120 Revision 1

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powermax

Service Manual

English / English

Revision 1 – December 2012

Hypertherm, Inc.

Hanover, NH USA

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, Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)

return.materials@hypertherm.com (RMA email)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 301, South Building 495 ShangZhong Road Shanghai, 200231 PR China 86-21-60740003 Tel 86-21-60740393 Fax

Hypertherm Europe B.V.

Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax

07/18/12

ELECTROMAGNETIC COMPATIBILITY EMC

Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN60974-10 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 cutting equipment is designed for use only in an industrial 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 the workpiece. In other cases, 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, signaling and

telephone cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding

ofindustrial equipment.

e. Health of the people around, for example the use

ofpacemakers and hearing aids.

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 must 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.

Compliance Information EMC-1

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ELECTROMAGNETIC COMPATIBILITY

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 must 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 as set forth in and in accordance with the manufacturer’s written instructions. For example, 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 (nozzle for laser heads) at the same time.

Earthing of the workpiece

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

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

Screening and shielding

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

The operator should be insulated from all such bonded metallic components.

EMC-2 Compliance Information

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WARRANTY

Attention

Genuine Hypertherm parts are the factoryrecommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product.

You are solely responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you, and with respect to Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Pro and MicroEDGE Pro CNCs and ArcGlide THC, which shall be within a period of two (2) years from the date of delivery to you.

Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective 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, or to an authorized Hypertherm repair facility, all costs, insurance and freight pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph and with Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.

Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged.

Compliance Information W-1

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WARRANTY

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will have the right to defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement (and in any event no longer than fourteen (14) days after learning of any action or threat of action), and Hypertherm’s obligation to defend shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages.

Insurance

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

Transfer of rights

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

National and local codes

National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

Liability cap

In no event shall Hypertherm’s liability, if any, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

W-2 Compliance Information

9/10

Safety information

Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

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Table of ConTenTs

Section 1 Specifications

Safety information ................................................................................................................................................................................... 1-2

System description ................................................................................................................................................................................. 1-2

Where to find information .....................................................................................................................................................................1-3

Power supply dimensions ..................................................................................................................................................................... 1-4

Component weights ............................................................................................................................................................................... 1-5

Powermax65 power supply ratings ....................................................................................................................................................1-6

Powermax85 power supply ratings ....................................................................................................................................................1-8

Duramax 75° hand torch dimensions .............................................................................................................................................. 1-10

Duramax 15° hand torch dimensions .............................................................................................................................................. 1-10

Duramax 180° full-length machine torch dimensions .................................................................................................................. 1-11

Duramax 180° mini machine torch dimensions ............................................................................................................................. 1-11

Powermax65 cutting specifications ................................................................................................................................................. 1-12

Powermax85 cutting specifications ................................................................................................................................................. 1-13

Symbols and markings ........................................................................................................................................................................ 1-14

IEC symbols .......................................................................................................................................................................................... 1-15

Section 2 Power Supply Setup

Unpack the Powermax65 or Powermax85 system .........................................................................................................................2-2

Claims .............................................................................................................................................................................................2-2

Contents ......................................................................................................................................................................................... 2-3

Position the power supply.....................................................................................................................................................................2-4

Prepare the electrical power ................................................................................................................................................................2-4

Install a line-disconnect switch .................................................................................................................................................2-5

Requirements for grounding ...................................................................................................................................................... 2-5

Power connection for the Powermax65 ............................................................................................................................................2-6

Single-phase power cord (not for CE model) .................................................................................................................................. 2-7

Three-phase power cord – plug installation ..................................................................................................................................... 2-7

Power connection for the Powermax85 ............................................................................................................................................2-8

Single-phase power cord (not for CE model) .......................................................................................................................2-9

Single-phase power cord installation ................................................................................................................................... 2-10

Three-phase power cord – plug installation .................................................................................................................................. 2-11

Extension cord recommendations .................................................................................................................................................... 2-11

Extension cord specifications ................................................................................................................................................. 2-12

Engine-driven generator recommendations ........................................................................................................................ 2-13

Prepare the gas supply ....................................................................................................................................................................... 2-14

Additional gas filtration ............................................................................................................................................................. 2-14

Connect the gas supply ........................................................................................................................................................... 2-15

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Table of ConTenTs

Section 3 Torch Setup

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

Consumable life .......................................................................................................................................................................................3-2

CopperPlus™ electrode for Duramax torches........................................................................................................................3-2

Hand torch setup .................................................................................................................................................................................... 3-3

Choose the hand torch consumables .....................................................................................................................................3-4

Hand torch consumables ...........................................................................................................................................................3-5

Install the hand torch consumables ..........................................................................................................................................3-6

Machine torch setup...............................................................................................................................................................................3-7

Converting a full-length machine torch to a mini machine torch ....................................................................................... 3-8

Mount the torch .......................................................................................................................................................................... 3-10

Choose the machine torch consumables ............................................................................................................................ 3-12

Machine torch consumables ................................................................................................................................................... 3-12

Install the machine torch consumables ................................................................................................................................ 3-15

Aligning the torch ...................................................................................................................................................................... 3-15

Connecting an optional remote-start pendant ................................................................................................................... 3-16

Connecting an optional machine interface cable ............................................................................................................... 3-17

Connecting the torch lead ................................................................................................................................................................. 3-22

Using the cut charts ............................................................................................................................................................................ 3-23

Estimated kerf-width compensation ...................................................................................................................................... 3-24

85 A shielded consumables ................................................................................................................................................... 3-26

65 A shielded consumables ................................................................................................................................................... 3-30

45 A shielded consumables ................................................................................................................................................... 3-34

FineCut® consumables ............................................................................................................................................................ 3-38

85 A unshielded consumables ............................................................................................................................................... 3-43

65 A unshielded consumables ............................................................................................................................................... 3-47

45 A unshielded consumables ............................................................................................................................................... 3-51

Section 4 Operation

Controls and indicators ......................................................................................................................................................................... 4-2

Rear controls .................................................................................................................................................................................4-2

Front controls and LEDs ............................................................................................................................................................. 4-2

Status screen ................................................................................................................................................................................4-4

Operating the Powermax65 or Powermax85 ................................................................................................................................... 4-6

Connect the electrical power, gas supply, and torch lead .................................................................................................4-6

Attach the work lead to the power supply .............................................................................................................................. 4-7

Attach the work clamp to the workpiece ................................................................................................................................4-8

Turn ON the system ..................................................................................................................................................................... 4-9

Set the operating mode switch ................................................................................................................................................. 4-9

Check the indicators ................................................................................................................................................................. 4-10

Manually adjusting the gas pressure ..................................................................................................................................... 4-10

Adjusting the current (amperage) .......................................................................................................................................... 4-11

Understanding duty-cycle limitations .................................................................................................................................... 4-12

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Using the hand torch ........................................................................................................................................................................... 4-13

Operate the safety trigger ....................................................................................................................................................... 4-13

Hand torch cutting hints .......................................................................................................................................................... 4-14

Start a cut from the edge of the workpiece......................................................................................................................... 4-15

Pierce a workpiece .................................................................................................................................................................... 4-16

Gouge a workpiece .................................................................................................................................................................. 4-17

Common hand-cutting faults .................................................................................................................................................. 4-20

Using the machine torch .................................................................................................................................................................... 4-21

Ensure the torch and table are set up correctly ................................................................................................................. 4-21

Understand and optimize cut quality ..................................................................................................................................... 4-21

To pierce a workpiece using the machine torch ................................................................................................................ 4-23

Common machine-cutting faults ............................................................................................................................................ 4-24

Section 5 Troubleshooting and System Tests

Controls and indicators ......................................................................................................................................................................... 5-3

Theory of operation .................................................................................................................................................................................5-4

General ...........................................................................................................................................................................................5-4

200 – 600 V CSA 1- or 3-phase power supply functional description .......................................................................... 5-4

380/400 V CE 3-phase power supply functional description ........................................................................................... 5-5

Sequence of operation ................................................................................................................................................................ 5-6

Troubleshooting preparation ................................................................................................................................................................5-7

Test equipment .............................................................................................................................................................................5-7

Troubleshooting procedures and sequence .......................................................................................................................... 5-7

External inspection ....................................................................................................................................................................... 5-9

Internal inspection ........................................................................................................................................................................5-9

Initial resistance check ...........................................................................................................................................................................5-9

Check the power switch ............................................................................................................................................................. 5-9

Hypertherm IGBT tester .......................................................................................................................................................... 5-12

Indicator LEDs and device tests ............................................................................................................................................ 5-12

IGBT test preparation ............................................................................................................................................................... 5-13

IGBT device test using the Hypertherm tester ................................................................................................................... 5-14

Troubleshoot the Hypertherm IGBT tester .......................................................................................................................... 5-14

Schematic for building an IGBT tester ................................................................................................................................. 5-15

IGBT device test using a non-Hypertherm tester .............................................................................................................. 5-16

200 – 600 V CSA power supply overview .................................................................................................................................... 5-17

380/400 V CE power supply overview .......................................................................................................................................... 5-18

200 – 600 V CSA power supply overview (power board removed) ....................................................................................... 5-19

380/400 V CE power supply overview (power board removed) .............................................................................................. 5-20

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Fault codes ............................................................................................................................................................................................ 5-21

Displaying the service screen ................................................................................................................................................. 5-21

Important fault icons ................................................................................................................................................................. 5-22

Performing a cold restart ......................................................................................................................................................... 5-22

Fault codes and solutions ........................................................................................................................................................ 5-23

Troubleshooting guide ........................................................................................................................................................................ 5-32

System tests.......................................................................................................................................................................................... 5-38

Test 1 – Voltage input .............................................................................................................................................................. 5-39

Test 2 – DC Power Buss ........................................................................................................................................................ 5-40

Test 3 – Output diodes............................................................................................................................................................ 5-42

Test 4 – Inverter and PFC temperature sensor .................................................................................................................. 5-43

Test 5 – Flyback circuit (DC minor voltages) ..................................................................................................................... 5-46

Test 6 – Torch stuck open (TSO) ......................................................................................................................................... 5-48

Test 7 – Start signal ................................................................................................................................................................. 5-50

Test 8 – Torch cap switch ...................................................................................................................................................... 5-51

Test 9 – Electronic regulator .................................................................................................................................................. 5-52

Test 10 – Pressure sensor ...................................................................................................................................................... 5-53

Test 11 – Fan ............................................................................................................................................................................. 5-54

Test 12 – AUX switch .............................................................................................................................................................. 5-55

Section 6 Component Replacement

Remove and replace the power supply cover and Mylar® barrier ............................................................................................... 6-2

Remove the power supply cover and Mylar barrier .............................................................................................................. 6-2

Replace the Mylar barrier ............................................................................................................................................................6-3

Replace the power supply cover ..............................................................................................................................................6-4

Replace the power cord ........................................................................................................................................................................ 6-5

Replace the power cord (200 – 600 V 3-phase CSA, 400 V 3-phase CE) ................................................................. 6-5

Replace the power cord (200 – 480 V 1-phase CSA) ................................................................................................... 6-10

Replace the work lead ........................................................................................................................................................................ 6-11

Replace the fan .................................................................................................................................................................................... 6-12

Replace the air filter element ............................................................................................................................................................. 6-14

Replace the air filter subassembly ................................................................................................................................................... 6-15

Replace the power board .................................................................................................................................................................. 6-17

Remove the DSP board ........................................................................................................................................................... 6-17

Replace the power board (380/400V CE) ......................................................................................................................... 6-19

Replace the power board (200 – 600V CSA) ................................................................................................................... 6-22

Install the DSP board ............................................................................................................................................................... 6-25

Replace the Mylar barrier and power supply cover. .......................................................................................................... 6-26

Replace the control board ................................................................................................................................................................. 6-27

Replace the heat sink components ................................................................................................................................................. 6-29

65A CSA ..................................................................................................................................................................................... 6-30

65A CE ........................................................................................................................................................................................ 6-31

85A CSA ..................................................................................................................................................................................... 6-32

85A CE ........................................................................................................................................................................................ 6-33

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Section 7 Parts

Power supply parts ................................................................................................................................................................................. 7-2

Exterior front ..................................................................................................................................................................................7-2

Exterior rear .................................................................................................................................................................................... 7-3

Interior, power board side (200 – 600V CSA) .....................................................................................................................7-4

Interior, power board side (380/400V CE) ............................................................................................................................ 7-5

Interior, fan side ............................................................................................................................................................................7-6

Heat sink assembly ................................................................................................................................................................................. 7-8

65A CSA ........................................................................................................................................................................................ 7-8

65A CE ........................................................................................................................................................................................... 7-9

85A CSA ..................................................................................................................................................................................... 7-10

85A CE ........................................................................................................................................................................................ 7-11

Duramax 75° hand torch replacement parts .................................................................................................................................. 7-12

Duramax 15° hand torch replacement parts .................................................................................................................................. 7-13

Hand torch consumables ................................................................................................................................................................... 7-14

Duramax 180° full-length machine torch replacement parts ..................................................................................................... 7-15

Duramax 180° mini machine torch replacement parts ................................................................................................................ 7-17

Machine torch consumables ............................................................................................................................................................. 7-19

Accessory parts.................................................................................................................................................................................... 7-20

Powermax65 and Powermax85 labels ............................................................................................................................................ 7-21

Safety-critical parts.............................................................................................................................................................................. 7-22

Recommended spare parts ............................................................................................................................................................... 7-24

Section 8 Wiring Diagrams

Cutting timing diagram page 1 of 2....................................................................................................................................................8-3

Cutting timing diagram page 2 of 2....................................................................................................................................................8-4

Electrical schematic diagram (CSA) ..................................................................................................................................................8-5

Electrical schematic diagram (CE) .....................................................................................................................................................8-6

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Section 1 SPECIFICATIONS

In this section: