Hypertherm POWERMAX 800 Service Manual

Plasma Arc
Cutting System

Service Manual
802280 - Revision 4

®

EN50199
EN50192

Plasma Arc Cutting System

Service Manual

IM-228

(P/N 802280)

for systems beginning with serial number

800-010000

Revision 4 December, 1997

Hypertherm, Inc.

P.O. Box 5010

Hanover, New Hampshire 03755-5010

Tel.: [phone]
Fax: [phone]

© Copyright 1997 Hypertherm, Inc.

All Rights Reserved

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.: [phone] (Main Office)
Fax: [phone] (All Departments)
Tel.: [phone] (Technical Service)
Tel.: [phone] (Customer Service)

Hypertherm Plasmatechnik GmbH

Ohmstrasse 6
D–63477 Maintal, Germany
Tel.: [phone]
Fax: [phone]

European Technical Support Organization (ETSO)

Ohmstrasse 6
D–63477 Maintal, Germany
Tel.: [phone]
Fax: [phone]

Hypertherm Singapore Pte Ltd

No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
Tel.: [phone]
Fax: [phone]

:

Hypertherm U.K.

9 Berkeley Court • Manor Park
Runcorn, Cheshire, England WA7 1TQ
Tel.: [phone]
Fax: [phone]

Hypertherm France

10, Allée de I’lsara
F-95000 Cergy-Pontoise, France
Tel.: [phone]
Fax: [phone]

Hypertherm Italy

Via Stilicone 18
20154 Milan, Italy
Tel.: [phone]
Fax: [phone]

ELECTROMAGNETIC COMPATIBILITY

EMC INTRODUCTION

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

The limits required by EN50199 may not
be adequate to completely eliminate
interference when the affected equipment
is in close proximity or has a high degree
of sensitivity. In such cases it may be
necessary to use other measures to
further reduce interference.

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

INSTALLATION AND USE

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

Earthing of Workpiece

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

ASSESSMENT OF AREA

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

. In other cases

f. Equipment used for calibration or
measurement.
g. Immunity of other equipment in the
environment. User shall ensure that other
equipment being used in the environment
is compatible. This may require additional
protection measures.
h. Time of day that cutting or other
activities are to be carried out.

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

METHODS OF REDUCING
EMISSIONS

Mains Supply

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

Maintenance of Cutting Equipment

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

Cutting Cables

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

Equipotential Bonding

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

Earthing of Workpiece

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

Note. The cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorized by a person who is competent
to assess whether the changes will
increase the risk of injury, for example, by
allowing parallel cutting current return
paths which may damage the earth
circuits of other equipment. Further
guidance is given in IEC TC26 (sec)94
and IEC TC26/108A/CD Arc Welding
Equipment Installation and Use.

Screening and Shielding

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

Service Manual

i

WARRANTY

WARNING

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

GENERAL

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

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

PATENT INDEMNITY

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

DISCLAIMER OF OTHER WARRANTIES

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

ii

Service Manual

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Power Supply - 208/240/480V

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

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

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

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

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

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

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

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

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

Service Manual

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ILLUSTRATIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

iv

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Service Manual

Section 1 SAFETY

In this section:

SAFETY

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Before using this plasma arc system. . . .

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

About Notes, Cautions and Warnings

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

such as shown in this paragraph.

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

damage to the plasma system.

WARNINGS

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

WARNING — Instant-On

Torches

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

pushed.

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

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

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

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

WARNING — Electric Shock

HYPERTHERM Plasma Systems

1-1

10/24/96

SAFETY

Eye Protection

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

Lens Shade

Arc Current AWS (USA) ISO-4850

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

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

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

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

reduce reflection.

– Install protective screens or curtains to reduce

ultraviolet transmission.

Skin Protection

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

exposed areas.

– Cuffless trousers to prevent entry of sparks and

slag.

Toxic Fume Prevention

• Keep the cutting area well ventilated.

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

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

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

WARNING — Toxic Fumes

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

Fire Prevention

• Make fire extinguishers available in the
cutting area.

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

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

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

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

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

Electric Shock Prevention

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

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

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

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

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

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

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

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

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

1-2

01/97

HYPERTHERM Plasma Systems

SAFETY

Electric Shock Prevention (continued)

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

• Never bypass or shortcut the safety interlocks.

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

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

Explosion Prevention

WARNING — Compressed Gas

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

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

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

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

• Never lubricate cylinder valves with oil or grease.

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

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

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

Pressure Regulators

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

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

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

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

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

• Do not cut pressurized cylinders or any closed
container.

WARNING —

Hydrogen Explosion Hazard

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

Compressed Gas Cylinders

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

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

WARNING — Hydrogen Detonation

with Aluminum Cutting

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

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

Hoses

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

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

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

• Replace hose that is damaged in any way.

HYPERTHERM Plasma Systems

1-3

10/24/96

SAFETY

Hoses (continued)

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

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

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

Noise Protection

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

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

• Always wear proper ear protection when cutting or

gouging with the plasma system.

Grounding

Input Power

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

ground in the disconnect box.

• If installation of the plasma system involves

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

• Tighten all electrical connections to avoid excessive

heating.

Work Cable

• Attach the work cable securely to the workpiece or

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

Work Table

• Connect the work table to a high-quality earth

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

Safety Reminders

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

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

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

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

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

Electronic Health Support Equipment

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

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

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

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

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

1-4

10/24/96

HYPERTHERM Plasma Systems

Section 1a SÉCURITÉ

SÉCURITÉ

IDENTIFIER LES CONSIGNES
DE SÉCURITÉ

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

SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ

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

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

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

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

DANGER AVERTISSEMENT PRÉCAUTION

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

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

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

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

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

Prévention des incendies

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

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

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

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

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

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

Prévention des explosions

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

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

• Ne pas couper de récipients contenant des matières
combustibles.

AVERTISSEMENT

Risque d’explosion

Argon-hydrogène et méthane

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

AVERTISSEMENT

Détonation de l’hydrogène lors du

coupage de l’aluminium

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

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

HYPERTHERM Systèmes plasma 1a-1

10/6/98

SÉCURITÉ

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

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

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

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

Prévention des chocs électriques

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

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

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

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

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

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

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

• Inspecter fréquemment le cordon d’alimentation primaire

• Inspecter et remplacer les câbles de la torche qui sont

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

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

• Ne jamais contourner ou court-circuiter les verrouillages

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

• Ne jamais faire fonctionner le système plasma sans que

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

• Chaque système plasma Hypertherm est conçu pour être

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

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

usés ou endommagés.

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

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

de sécurité.

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

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

la prise de terre appropriée.

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

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

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

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

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

1a-2

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10/6/98

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

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

HYPERTHERM Systèmes plasma

SÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané

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

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

Protection des yeux Les rayons de l’arc plasma

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

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

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

Puissance des verres teintés

Courant de l’arc AWS (É.-U.) ISO 4850

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

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

o

11

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

• Rester éloigné de l’extrémité de la torche.

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

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

• Gants à crispin, chaussures et casque de sécurité.

• Vêtements ignifuges couvrant toutes les parties exposées
du corps.

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

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

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

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

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

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

MISE À LA MASSE ET À LA TERRE

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

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

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

Alimentation

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

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

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

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

HYPERTHERM Systèmes plasma 1a-3

4/9/99

10/6/98

SÉCURITÉ

SÉCURITÉ DES BOUTEILLES DE GAZ
COMPRIMÉ

• Ne jamais lubrifier les robinets des bouteilles ou les

régulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux et

accessoires appropriés et conçus pour chaque application
spécifique.

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

comprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux de

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

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES

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

• Manipuler et utiliser les bouteilles de gaz comprimé

conformément aux codes locaux ou nationaux.

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

verticale et bien assujettie.

• Le capuchon de protection doit être placé sur le robinet

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

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

une bouteille.

• Ne jamais exposer des bouteilles à une chaleur

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

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

outils pour débloquer le robinet des bouteilles.

PACEMAKERS ET
PROTHÈSES AUDITIVES

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

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

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

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

Pour réduire les risques associés aux champs
magnétiques :

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

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

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

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

1a-4

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10/16/98

HYPERTHERM Systèmes plasma

DESCRIPTION & SPECIFICATIONS

Section 2

DESCRIPTION & SPECIFICATIONS

In this section

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

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

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

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

Service Manual

2-1

9-96

DESCRIPTION & SPECIFICATIONS

INTRODUCTION

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

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

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

The Powermax800 operator manual provides setup and daily operating instructions.

2-2

7-97

Figure 2-1 Powermax800 Hand Plasma Cutting System*

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

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

Service Manual

SPECIFICATIONS

Power Supply

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

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

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

Duty Cycle (X) @ 40°C ....................................... 50% (I

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

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

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

Dimensions and Weight:

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

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

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

10.4"

DESCRIPTION & SPECIFICATIONS

=50A, U2=120V)

2

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

supply for more information on duty cycle

104° F (-10° and +40° C). Power supplies
operated in an ambient temperature above
86° F (30° C) may show some decrease in
duty cycle.

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

1

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

15.25" (390 mm) with wheels

23.7" (620 mm) with wheels

27.7" (700 mm) for 600V power supply

23.1"

Figure 2-2 Powermax800 Power Supply with Dimensions

Service Manual

19.6"

2-3

6-96

DESCRIPTION & SPECIFICATIONS

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

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

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

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

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

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

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

PAC121 50A TORCHES

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

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

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

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

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

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

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

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

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

6.2 bar) supplied to power supply
pressure regulator

4.8 bar)

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

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

PAC121TS Hand Torch Assembly

8.72"

8.50"

3.10"

1.00"

Figure 2-3 PAC121TS Torch with Dimensions

PAC121MS Machine Torch Assembly

1.58"

15.06"

1.38"1.00"

2-4

10-96

Figure 2-4 PAC121MS Torch with Dimensions

Service Manual

DESCRIPTION & SPECIFICATIONS

S MARK

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

WARNING

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

Consumable Parts - For CE Compliance

for a

120601

120602

120608

Figure 2-5 S Mark Label.

Service Manual

120438

120573

2-5

7-99

DESCRIPTION & SPECIFICATIONS

IEC SYMBOLS USED

Direct Current (DC)

Alternating current (AC)

Plasma cutting torch

AC input power connection

The terminal for the external protective (earth) conductor

An inverter-based power source

I

O

Anode (+) work clamp

Temperature switch

Pressure switch

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

Power is on

Power is off

Volt/amp curve, "drooping" characteristic

2-6

9-96

Service Manual

MAINTENANCE

Section 3 MAINTENANCE

In this section:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Service Manual

3-1

9-96

MAINTENANCE

INTRODUCTION

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

PAC121T trigger torch and PAC121M machine torch parts.

ROUTINE MAINTENANCE

Bowl Draining/Filter Element Cleaning

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

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

before proceeding.

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

release water from the bowl.

Gas supply hose
(disconnect)

Filter element

Filter Bowl

Cap

Figure 3-1 Filter Assembly

3. Unscrew the filter bowl.

4. Unscrew the filter element. See

Section 4 for part number information.

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

Clean the bowl with household soap only.

6. Replace the filter element and filter bowl.

7. Reconnect the gas supply hose.

Powermax800 Field Upgrade Kits and Optional Parts

in

3-2

Service Manual

MAINTENANCE

Cooling Air Filter Removal, Cleaning and Replacement

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

WARNING

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

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

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

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

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

Air Filter

Figure 3-2 Air Filter Removal

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

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

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

Service Manual

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3-96

MAINTENANCE

THEORY OF OPERATION

General

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

parallel

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

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

series

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

TB3

TB2 TB1

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

and

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

Figure 3-3 Inverter Links

TB2 TB1

480V Link on 208/240/480V units

and

400V Link on 200/230/400V units

TB3

Functional Description

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

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

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

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

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

3-4

3-96

Service Manual

MAINTENANCE

SEQUENCE OF OPERATION

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

System off

• Connect gas supply to filter-regulator on power unit

• Apply power at line voltage disconnect box.

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

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

• Push and hold GAS TEST switch to
check air pressure.

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

• Release GAS TEST switch.

Gas solenoid valve V1
closes. Gas flow stops.

• Connect work cable to workpiece and
position torch on workpiece.

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

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

• Move torch to make cut. Workpiece
falls away after cut.

Gas solenoid VI closes and gas
flow stops.

• Select cutting current with AMPS knob.

Power circuits ready.

3-6

Power circuits ready

Service Manual

TROUBLESHOOTING

MAINTENANCE

The troubleshooting procedures include the

Maintenance Checks.

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

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

These procedures are presented in a flow diagram format.

Initial Resistance Checks

and the

Corrective

Test Equipment

• Multimeter

Troubleshooting Procedures

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

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

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

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

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

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

Sequence of Operation

flow

Visual Inspection - External

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

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

Service Manual

3-7

MAINTENANCE

Visual Inspection - Internal

WARNING

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

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

WARNING

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

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

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

3-8

Service Manual

MAINTENANCE

WARNING

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

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

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

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

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

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

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

Initial Resistance Checks

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

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

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

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

Service Manual

Sequence of Operation

flow

3-9