Hypertherm Powermax900 Service Manual

Plasma Arc
Cutting System

Service Manual
803150 - Revision 3

®

EN50199
EN50192

Plasma Arc Cutting System

Service Manual

IM-315

(P/N 803150)

for systems beginning with serial number

900-010000

Revision 3 June, 2000

Hypertherm, Inc.

Hanover, NH

http://www.hypertherm.com

email:[e-mail]

© Copyright 2000 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 – toll-free in USA and Canada)
Tel.: [phone] (Customer Service – toll-free in USA and Canada)
email: [e-mail] (General Information)
email: [e-mail] (Technical/Customer Services)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau
Rodenbacher Chaussee 6
D–63457 Hanau-Wolfgang, Germany
Tel.: [phone]
Fax: [phone]

Hypertherm (S) Pte Ltd

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

Hypertherm UK Ltd

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

:

France

15 Impasse des Rosiers
95610 Eragny, France
Tel.: [phone]
Fax: [phone]

Hypertherm S.r.L.

Via Torino 2
20123 Milan, Italy
Tel.: [phone] (Customer Service)
Tel.: [phone] (Technical Service)
Fax: [phone] (All Departments)

Hypertherm B.V.

Burg, Haverkampstraat 13
7091 CN Dinxperlo, The Netherlands
Tel.: [phone] (Customer Service)
Fax: [phone]

European Technical Support Organization (ETSO)

Edisonstraat 12
3281 NC Numansdorp, The Netherlands
Tel.: [phone] (00 800 Hypertherm) – (toll-free Technical Service)
Tel.: [phone]
Fax: [phone]

Japan

Shinjuku Park Tower
30th Floor
3-7-1 Nishi-Shinjuku
Shinjuku-ku, Tokyo
163-1030, Japan
Tel.: [phone]
Fax: [phone]

5/00

ELECTROMAGNETIC COMPATIBILITY

EMC INTRODUCTION

Hypertherm's CE-marked equipment is
built in compliance with standard
EN50199. 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 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 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.
f. Equipment used for calibration or
measurement.

. In other cases

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.
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 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

W

ARRANTY

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.

WARNING

You are 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, 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, and (ii) with respect to the torch and leads within a
period of one (1) year from its date of delivery to you. This
warranty shall not apply to any Product which has been
incorrectly installed, modified, or otherwise damaged.
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
prepaid. Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph or
with Hypertherm’s prior written consent. The warranty

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.

formulae, or combinations not developed or purported to be
developed by Hypertherm, Hypertherm will 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 Hypertherm’s
obligation to indemnify 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, indirect, or
punitive damages (including but not limited to lost
profits) regardless of whether such liability is based on
breach of contract, tort, strict liability, breach of
warranties, failure of essential purpose or otherwise
and even if advised of the possibility of such damages.

LIABILITY CAP

In no event shall Hypertherm’s liability, 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 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.

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.

NATIONAL AND LOCAL CODES

National and Local codes governing plumbing and
electrical installation shall take precedent 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.

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,

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.

ii Hypertherm Warranty

5-00

TABLE OF CONTENTS

ELECTROMAGNETIC COMPATIBILITY ............................................................................................... i

WARRANTY...........................................................................................................................................ii

Section 1 Safety ................................................................................................ 1-1

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

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

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

ELECTRIC SHOCK CAN KILL........................................................................................................... 1-2

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

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

COMPRESSED GAS EQUIPMENT SAFETY.................................................................................... 1-4

ADDITIONAL SAFETY INFORMATION ............................................................................................. 1-4

NOISE CAN DAMAGE HEARING ..................................................................................................... 1-4

GAS CYLINDERS CAN EXPLODE IF DAMAGED ............................................................................1-4

GROUNDING SAFETY ...................................................................................................................... 1-5

PLASMA ARC CAN CAUSE INJURY AND BURNS .......................................................................... 1-5

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

Section 1a Sécurité .......................................................................................... 1a-1

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

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

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

DANGER AVERTISSEMENT PRÉCAUTION ................................................................................ 1a-2

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

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

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

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

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

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

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

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

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

Section 2 SPECIFICATIONS............................................................................. 2-1

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

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

Power Supply .............................................................................................................................. 2-3

PAC125 TORCHES ........................................................................................................................... 2-4

PAC125T Hand Torch Assembly.................................................................................................. 2-4

PAC125M Machine Torch Assembly ............................................................................................ 2-4

S MARK ........................................................................................................................................... 2-5

SETUP SPECIFICATIONS ................................................................................................................ 2-5

Power Cord Plugs........................................................................................................................ 2-5

Power Cords ................................................................................................................................ 2-5

208/240/480/600V Power Supplies ............................................................................................. 2-5

200/230/400V Power Supplies .................................................................................................... 2-5

Power Requirements ................................................................................................................... 2-6

Service Manual

iii

TABLE OF CONTENTS

Section 3 MAINTENANCE.................................................................................... 3-1

INTRODUCTION................................................................................................................................ 3-2

ROUTINE MAINTENANCE ................................................................................................................ 3-2

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

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

CONTROLS AND INDICATORS ........................................................................................................ 3-4

THEORY OF OPERATION ................................................................................................................ 3-5

General ........................................................................................................................................ 3-5

Functional Description ................................................................................................................. 3-6

SEQUENCE OF OPERATION ........................................................................................................... 3-7

TROUBLESHOOTING .......................................................................................................................3-8

Test Equipment ............................................................................................................................ 3-8

Troubleshooting Procedures........................................................................................................ 3-8

Visual Inspection - External ......................................................................................................... 3-8

Visual Inspection - Internal .......................................................................................................... 3-9

Resistance Checks .................................................................................................................... 3-10

POWERMAX900 TROUBLESHOOTING GUIDE ............................................................................ 3-13

Voltage Checks.......................................................................................................................... 3-18

Power Board Test Points ........................................................................................................... 3-22

POWER BOARD .............................................................................................................................. 3-22

CONTROL BOARD .......................................................................................................................... 3-24

Control Board LEDs................................................................................................................... 3-24

PAC125T TORCH PARTS REMOVAL AND REPLACEMENT ......................................................... 3-26

Torch Main Body Removal and Replacement ........................................................................... 3-26

Torch Switch Removal and Replacement .................................................................................. 3-27

PAC125M TORCH PARTS REMOVAL AND REPLACEMENT ........................................................ 3-28

Removal .................................................................................................................................... 3-28

Replacement ............................................................................................................................. 3-28

QUICK DISCONNECT O-RING REMOVAL AND REPLACEMENT ................................................ 3-30

Section 4 PARTS LIST – 208/240/480V ............................................................. 4-1

POWER SUPPLY - 208/240/480V ..................................................................................................... 4-2

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

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

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

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

Powermax900 Field Upgrade Kits and Optional Parts .............................................................. 4-10

POWER SUPPLIES - 208/240/480V, 1F/3F, 60 HZ ......................................................................... 4-10

RECOMMENDED SPARE PARTS - POWERMAX900- 208/240/480V ........................................... 4-11

Section 5 PARTS LIST - 200/230/400V .............................................................. 5-1

POWER SUPPLY - 200/230/400V ..................................................................................................... 5-2

Front ............................................................................................................................................ 5-2

Top and Right Side ...................................................................................................................... 5-4

Bottom and Left Side ................................................................................................................... 5-6

Rear ............................................................................................................................................. 5-8

Powermax900 Field Upgrade Kits and Optional Parts .............................................................. 5-10

POWER SUPPLIES - 200/230/400V, 1F/3F, 50/60 HZ .................................................................... 5-10

RECOMMENDED SPARE PARTS - POWERMAX900- 200/230/400V ........................................... 5-11

iv

Service Manual

TABLE OF CONTENTS

Section 6 PARTS LIST - 400V CE ...................................................................... 6-1

POWER SUPPLY - 400V CE ............................................................................................................. 6-2

Front ............................................................................................................................................ 6-2

Top and Right Side ...................................................................................................................... 6-4

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

Rear ............................................................................................................................................. 6-8

Powermax900 Field Upgrade Kits and Optional Parts .............................................................. 6-10

POWER SUPPLIES - 400V CE, 3F, 50 HZ...................................................................................... 6-10

RECOMMENDED SPARE PARTS - POWERMAX900 400V CE .................................................... 6-11

Section 7 PARTS LIST - TORCHES AND CONSUMABLES ........................... 7-1

PAC125T Torch Assembly and 25 ft (7.6 m) Lead - 083066........................................................ 7-2

PAC125T Torch Assembly and 50 ft (15.2 m) Lead - 083067...................................................... 7-2

PAC125M Torch Assembly and 14 ft (4.3 m) Lead - 083069 w/pigtail, 083073 no pigtail ........... 7-3

PAC125M Torch Assembly and 25 ft (7.6 m) Lead - 083068 w/pigtail, 083072 no pigtail ........... 7-3

PAC125M Torch Assembly and 35 ft (10.6 m) Lead - 083070 w/pigtail, 083074 no pigtail ......... 7-3

PAC125M Torch Assembly and 50 ft (15.2 m) Lead - 083071 w/pigtail, 083075 no pigtail ......... 7-3

Consumable Parts Kits ................................................................................................................ 7-4

Consumable Spare Parts Kit - CE (128289) ................................................................................ 7-4

Consumable Configurations ........................................................................................................ 7-5

Section 8 Wiring Diagrams................................................................................. 8-1

Appendix a ........................................................................................................... a-1

AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM ........................................................ a-1

Introduction .................................................................................................................................. a-1

Making an Aeration Manifold - Figure a-1.................................................................................... a-1

Appendix b ...........................................................................................................b-1

STANDARDS INDEX ......................................................................................................................... b-1

Appendix c ........................................................................................................... c-1

MACHINE INTERFACE SPECIFICATIONS....................................................................................... c-1

Service Manual

v

TABLE OF CONTENTS

vi

Service Manual

S

AFETY

Section 1

SAFETY

In this section:

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

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

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

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

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

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

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

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

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

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

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

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

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

Hypertherm Plasma Systems

1-1

8-99

S

AFETY

RECOGNIZE SAFETY INFORMATION

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

FOLLOW SAFETY INSTRUCTIONS

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

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

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

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

DANGER WARNING CAUTION

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

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

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

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

CUTTING CAN CAUSE FIRE OR EXPLOSION

Fire Prevention

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

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

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

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

• Ventilate potentially flammable atmospheres before
cutting.

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

Explosion Prevention

• Do not use the plasma system if explosive dust or

vapors may be present.

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

• Do not cut containers that have held combustible
materials.

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

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

WARNING

Hydrogen Detonation with Aluminum Cutting

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

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

1-2

8-99

Hypertherm Plasma Systems

ELECTRIC SHOCK CAN KILL

S

AFETY

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

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

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

Electric Shock Prevention

All Hypertherm plasma systems use high voltage in
the cutting process (200 to 400 VDC are common).
Take the following precautions when operating this
system:

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

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

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

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

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

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

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

• Inspect and replace any worn or damaged torch
leads.

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

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

• Never bypass or shortcut the safety interlocks.

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

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

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

• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.

CUTTING CAN PRODUCE TOXIC FUMES

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

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

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

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

Hypertherm Plasma Systems

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

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

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

1-3

8-99

S

AFETY

PLASMA ARC CAN CAUSE INJURY AND BURNS

Instant-On Torches

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

ARC RAYS CAN BURN EYES AND SKIN

Eye Protection Plasma arc rays produce intense

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

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

• Wear eye protection (safety glasses or goggles with
side shields, or a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s
ultraviolet and infrared rays.

Lens Shade

Arc Current AWS (USA) ISO 4850

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

The plasma arc will cut quickly through gloves and
skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

Skin Protection Wear protective clothing to protect
against burns caused by ultraviolet light, sparks and
hot metal.

• Gauntlet gloves, safety shoes and hat.

• Flame-retardant clothing to cover all exposed areas.

• Cuffless trousers to prevent entry of sparks and

slag.

• Remove any combustibles, such as a butane lighter

or matches, from your pockets before cutting.

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

• Paint walls and other surfaces with dark colors to

reduce reflection.

• Use protective screens or barriers to protect others

from flash and glare.

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

signs.

GROUNDING SAFETY

Work Cable Attach the work cable securely to the

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

Work Table Connect the work table to an earth
ground, in accordance with appropriate national or local
electrical codes.

1-4

8-99

Input Power

• Be sure to connect the power cord ground wire to
the ground in the disconnect box.

• If installation of the plasma system involves connect-

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

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

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

• Tighten all electrical connections to avoid excessive

heating.

Hypertherm Plasma Systems

S

AFETY

COMPRESSED GAS EQUIPMENT SAFETY

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

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

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

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

NOISE CAN DAMAGE HEARING

GAS CYLINDERS CAN EXPLODE
IF DAMAGED

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

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

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

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

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

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

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

PACEMAKER AND HEARING
AID OPERATION

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

• Use approved ear protection when using plasma
system.

• Warn others nearby about the noise hazard.

ADDITIONAL SAFETY INFORMATION

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

2. ANSI Standard Z49.2,

Welding Processes

1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1,

Educational Eye and Face Protection

Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1,

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

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

Recommended Safe Practices for the Preparation for

Safety in Welding and Cutting

Fire Prevention in the Use of Cutting and

, American National Standards Institute

Safe Practices for Occupation and

, American National

, American Welding Society

, American

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

To reduce magnetic field hazards:

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

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

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

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

5. AWS F5.2,

Cutting

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

6. CGA Pamphlet P-1,

Cylinders

1235 Jefferson Davis Highway, Arlington, VA 22202

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

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

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

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

Recommended Safe Practices for Plasma Arc

, American Welding Society

, Compressed Gas Association

Safety and Health Standards

Safe Handling of Compressed Gases in

Code for Safety in Welding and Cutting

Cutting and Welding Processes

National Electrical Code

, 29FR 1910

, National

, National Fire

,

Hypertherm Plasma Systems

1-5

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S

AFETY

1-6

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Hypertherm Plasma Systems

S

ÉCURITÉ

Section 1a

SÉCURITÉ

Cette section comprend:

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

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

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

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

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

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES

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

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

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

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

LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE

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

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

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

HYPERTHERM Systèmes plasma 1a-1

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S

ÉCURITÉ

IDENTIFIER LES CONSIGNES
DE SÉCURITÉ

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

SUIVRE LES INSTRUCTIONS
DE SÉCURITÉ

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

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

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

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

DANGER AVERTISSEMENT PRÉCAUTION

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

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

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

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

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

Prévention des incendies

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

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

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

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

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

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

Prévention des explosions

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

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

• Ne pas couper de récipients contenant des matières

combustibles.

AVERTISSEMENT

Risque d’explosion

Argon-hydrogène et méthane

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

AVERTISSEMENT

Détonation de l’hydrogène lors du

coupage de l’aluminium

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

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

1a-2

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HYPERTHERM Systèmes plasma

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

S

ÉCURITÉ

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

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

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

Prévention des chocs électriques

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

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

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

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

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

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

• Installer et mettre à la terre l’équipement selon les
instructions du présent manuel et conformément aux
codes électriques locaux et nationaux.

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

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

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

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

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

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

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

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

• Chaque système plasma Hypertherm est conçu pour être
utilisé uniquement avec des torches Hypertherm
spécifiques. Ne pas utiliser des torches inappropriées qui
pourraient surchauffer et présenter des risques pour la
sécurité.

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

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

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

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

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

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

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S

ÉCURITÉ

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

Torches à allumage instantané

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

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

Protection des yeux Les rayons de l’arc plasma

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

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

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

Puissance des verres teintés

Courant de l’arc AWS (É.-U.) ISO 4850

Jusqu’à 100 A 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.

1a-4

08/99

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

S

ÉCURITÉ

SÉCURITÉ DES BOUTEILLES DE GAZ
COMPRIMÉ

• Ne jamais lubrifier les robinets des bouteilles ou les

régulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux et

accessoires appropriés et conçus pour chaque application
spécifique.

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

comprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux de

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

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

LES BOUTEILLES DE GAZ
COMPRIMÉ PEUVENT EXPLOSER
EN CAS DE DOMMAGES

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

• Manipuler et utiliser les bouteilles de gaz comprimé

conformément aux codes locaux ou nationaux.

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

verticale et bien assujettie.

• Le capuchon de protection doit être placé sur le robinet

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

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

une bouteille.

• Ne jamais exposer des bouteilles à une chaleur

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

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

outils pour débloquer le robinet des bouteilles.

PACEMAKERS ET
PROTHÈSES AUDITIVES

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

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

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

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

Pour réduire les risques associés aux champs
magnétiques :

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

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

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

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

HYPERTHERM Systèmes plasma 1a-5

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ÉCURITÉ

1a-6

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HYPERTHERM Systèmes plasma

Section 2 SPECIFICATIONS

In this section:

SPECIFICATIONS

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

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

Power Supply .............................................................................................. 2-3

PAC125 Torches............................................................................................... 2-4

PAC125T Hand Torch Assembly.................................................................. 2-4

PAC125M Machine Torch Assembly............................................................2-4

S Mark ........................................................................................................ 2-5

Setup Specifications......................................................................................... 2-5

Power Cord Plugs........................................................................................ 2-5

Power Cords ................................................................................................ 2-5

208/240/480/600V Power Supplies ............................................................. 2-5

200/230/400V Power Supplies .................................................................... 2-5

Power Requirements ................................................................................... 2-6

Service Manual

2-1

SPECIFICATIONS

INTRODUCTION

The Powermax900 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
Powermax900 power supply provides constant-current output variable from 20 to 55 amps, for optimum
performance on all thicknesses of metal up to 5/8" (16 mm) thick. At 55 amps, the Powermax900 can also cut
metals up to 7/8" (22 mm) thick and will sever metals up to 1-1/8"
(29 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 Powermax900 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, 5 and 6 contain in-depth parts lists of the Powermax900 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 Powermax900 operator manual provides setup and daily operating instructions.

2-2

Figure 2-1 Powermax900 Hand Plasma Cutting System*

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

Service Manual

SPECIFICATIONS

Power Supply

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

Rated Output Current (I
Rated Output Voltage (U

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

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

Apparent Input Power (S1) ............................................ 12.5kVA (U1I1)

Input Voltage (U1)/Input Current (I1)

@ 6.6 kw Output ........................................................... 208V/55A; 240V/47A; 480V/28A - 1φ, 50/60 Hz

Dimensions and Weight:

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

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

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

) ..............................................20–55 amps

2

) ............................................ 120 VDC

2

100% (I2=39A, U2=120V for the 208/240/480V power
supplies) 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.

208V/32A; 240V/28A; 480V/15A - 3φ, 50/60 Hz
200V/57A; 230V/50A; 400V/33A - 1φ, 50/60 Hz
200V/33A; 230V/29A; 400V/18A - 3φ, 50/60 Hz
230V (CE)/29A; 400V (CE)/18A - 3φ, 50/60 Hz
600V/12A - 3φ, 60 Hz

15.3" (390 mm) with wheels

23.7" (620 mm) with wheels

27.7" (700 mm) for 600V power supply

SPECIFICATIONS

10.4"

Figure 2-2 Powermax900 Power Supply with Dimensions

23.1"

Service Manual

19.6"

2-3

10-98

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

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

PAC125 TORCHES

Maximum 55A Cutting Capacity (PAC125T) .................7/8" (22 mm) @ 50% duty cycle

Maximum 55A Cutting Capacity (PAC125M) ................1/2" (13 mm) @ 50% duty cycle

Maximum 39A Cutting Capacity (PAC125M) ................3/8" (9.5 mm) @ 100% duty cycle

Maximum current at 50% duty cycle .............................55 amps

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

Weight PAC125T ..........................................................4.5 pounds (2 kg) with 25 ft (7.6 m) lead

Weight PAC125M..........................................................7 pounds (3.2 kg) with 25 ft (7.6 m) lead

72 pounds (33 kg) with wheels
128 pounds (58 kg) for 600V and 230V-CE
power supplies

6.2 bar) supplied to power supply pressure
regulator

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

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

PAC125T Hand Torch Assembly

3.10"

1.00"

Figure 2-3 PAC125T Torch with Dimensions

PAC125M Machine Torch Assembly

8.72"

8.50"

PAC125T

1.58"

15.06"

1.38"1.00"

2-4

Figure 2-4 PAC125M Torch with Dimensions

Service Manual

SPECIFICATIONS

S MARK

The Powermax900 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 hand torches must have
shielded consumable parts to maintain S mark compliance.

SETUP SPECIFICATIONS

Power Cord Plugs

All 208/240/480V power supplies are shipped with a single-phase power cord and plug. To operate as a three-

phase unit, the user must obtain a power cord and plug that is certified by national or local electrical codes. The plug
should be connected to the power cord by a licensed electrician.

All 200/230/400V and 400V CE power supplies are shipped with a three-phase power cord and no plug. The
user must obtain a plug that is certified by national or local electrical codes. The plug should be connected to the
power cord by a licensed electrician.

Power Cords

If the power cord needs to be changed, use the tables below to choose the proper wire size for the appropriate length
cord. Note that the input current used to determine the cord size is I
for single-phase, and a 4-conductor SO type cord for three-phase power supplies. In other countries, use cords that
are certified by national or local codes. Prepare the power cord wires as shown in Fig. 2-5 for non-CE power
supplies, or Fig. 2-6 for CE power supplies. Note that all 4 wires must loop through the toroid in the CE power supply.
Cap or tin the conductor leads and use a #10 terminal on the ground wire. The cord should be installed only by a
licensed electrician.

. In the U.S., use a 3-conductor SO type cord

1eff

208/240/480/600V Power Supplies

Input Phase Input Recommended Power Cord Gauge Size (AWG) Voltage

Current (I

208 VAC 1 39A 8 8 6 4 4
240 VAC 1 33A 8 8 8 6 4

480 VAC 1 19A 12 12 12 10 8
208 VAC 3 23A 8 8 8 6 4
240 VAC 3 20A 10 10 10 8 6
480 VAC 3 10A 12 12 12 12 10
600 VAC 3 8A 12 12 12 12 10

) < 10 ft 10 – 25 ft 25 – 50 ft 50 – 100 ft 100 – 150 ft

1eff

200/230/400V Power Supplies

Input Phase Input Recommended Power Cord Gauge Size (mm2)
Voltage Current (I

200 VAC 1 40A 10 10 16 25 25
230 VAC 1 35A 6 6 10 16 25

400 VAC 1 23A 4 4 4 6 10
200 VAC 3 23A 4 4 6 16 25
230 VAC 3 21A 2.5 4 6 10 16
400 VAC 3 13A 2.5 2.5 2.5 4 6

) < 3 m 3 – 7.5 m 7.5 – 15 m 15 – 30 m 30 – 45 m

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Service Manual

2-5

SPECIFICATIONS

4.5" (114 mm)

3.5" (89 mm)

L1

L2

L3

Ground

Figure 2-5 Power Cord Preparation - Non-CE

0.5" (13 mm)

#10

All wires 1 turn
through 109068 toroid.

Figure 2-6 Power Cord Preparation - CE

4.75" (120 mm)

3.75" (95 mm)

L1

L2

L3

#10

Ground

Power Requirements

Line Voltage Disconnect Box

Use a line disconnect box for each power supply. This disconnect box allows the operator to turn the
power supply off quickly in an emergency situation. The switch should be located on a wall near the
power supply, and should be easily accessible to the operator. The interrupt level of the switch must be
equal to or exceed the continuous rating of the fuses. Use slow-blow fuses according to the power
requirements listed below.

Input Input Current Recommended

Voltage Phase @ 6.6 kw Output Slow-Blow Fuse Size

200 VAC 1 57 amps 70 amp
208 VAC 1 55 amps 70 amp
230 VAC 1 50 amps 70 amp
240 VAC 1 47 amps 60 amp
400 VAC 1 33 amps 40 amp
480 VAC 1 28 amps 35 amp

200 VAC 3 33 amps 40 amp
208 VAC 3 32 amps 40 amp
230 VAC 3 29 amps 35 amp
230 VAC (CE) 3 31 amps 40 amp
240 VAC 3 28 amps 35 amp
400 VAC 3 18 amps 25 amp
400 VAC (CE) 3 18 amps 25 amp
480 VAC 3 15 amps 20 amp
600 VAC 3 12 amps 20 amp

2-6

Service Manual

MAINTENANCE

Section 3 MAINTENANCE

In this section:

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

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

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

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

Controls and Indicators ........................................................................3-4

Theory of Operation .............................................................................3-5

Sequence of Operation ........................................................................3-7

Troubleshooting....................................................................................3-8

Test Equipment ................................................................................ 3-8

Troubleshooting Procedures............................................................3-8

Visual Inspection - External .............................................................3-8

Visual Inspection - Internal ..............................................................3-9

Resistance Checks ........................................................................ 3-10

Powermax900 Troubleshooting Guide ...............................................3-13

Voltage Checks.............................................................................. 3-18

Power Board ...................................................................................... 3-22

Control Board ..................................................................................... 3-24

Control Board LEDs....................................................................... 3-24

PAC125T Torch Parts Removal and Replacement ............................3-26

Torch Main Body Removal and Replacement ............................... 3-26

Torch Switch Removal and Replacement ...................................... 3-27

PAC125M Torch Parts Removal and Replacement............................ 3-28

Removal ........................................................................................ 3-28

Replacement ................................................................................. 3-28

Quick Disconnect O-Ring Removal and Replacement ...................... 3-30

Service Manual

3-1

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

PAC125T trigger torch and PAC125M 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
connection

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.

Powermax900 Field Upgrade Kits and Optional Parts

in

3-2

Service Manual

MAINTENANCE

Removal, Cleaning and Replacement of the Cooling Air Filter

Powermax900 systems are normally shipped without air filters. If your Powermax900 has the air filter
option, it will need periodic cleaning. 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 power supply cover. If power supply is directly con­nected to a line disconnect switch, 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 Powermax900 power switch to the OFF (0) position, unplug the power cable
from the wall receptacle and disconnect the gas supply.

2. Remove the 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. See
Section 4 for part number information.

Powermax900 Field Upgrade Kits and Optional Parts

in

Cooling 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

3-3