Hypertherm Powermax1000 Service Manual User Manual

145615-25ft4.5-7.5m35-50ft12-15m6.0BAR5.04.0PSI8070506080AMPS120926120925120978120927120928120928120929120977110378Rev.A6.0BAR5.04.0PSI807050606040AMP

Hypertherm Plasma Systems 1-1Section 1SAFETYIn this section:Recognize Safety Information...

SAFETY1-2 Hypertherm Plasma Systems11-98SAFETYRECOGNIZE SAFETY INFORMATIONThe symbols shown in this section are used toidentify potential hazards. Whe

Touching live electrical parts can cause a fatal shockor severe burn.• Operating the plasma system completes anelectrical circuit between the torch an

SAFETY1-4 Hypertherm Plasma Systems5/6/02SAFETYInstant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.A PLASMA ARC CAN CA

SAFETYHypertherm Plasma Systems 1-511-98SAFETY• Never lubricate cylinder valves or regulators with oilor grease.• Use only correct gas cylinders, regu

SAFETY1-6 Hypertherm Plasma Systems8-99SAFETYWARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and m

Hypertherm Systèmes plasma 1a-12/12/01Section 1aSÉCURITÉDans cette section :Identifier les consignes de sécurité...

SÉCURITÉ1a-2 Hypertherm Systèmes plasma2/12/01IDENTIFIER LES CONSIGNES DE SÉCURITÉLes symboles indiqués dans cette section sont utilisés pouridentifie

SÉCURITÉHypertherm Systèmes plasma 1a-32/12/01Toucher une pièce électrique sous tension peut provoquerun choc électrique fatal ou des brûlures graves.

SÉCURITÉ1a-4 Hypertherm Systèmes plasma5/6/02Torches à allumage instantanéL’arc plasma s’allume immédiatement après que la torchesoit mise en marche.L

powermax1000Service Manual(P/N 804300)Revision 1 – May, 2006© Copyright 2006 Hypertherm, Inc.All Rights ReservedHypertherm and Powermax are trademarks

SÉCURITÉHypertherm Systèmes plasma 1a-52/12/01• Ne jamais lubrifier les robinets des bouteilles ou lesrégulateurs avec de l’huile ou de la graisse.• U

SÉCURITÉ1a-6 Hypertherm Systèmes plasma2/12/01Étiquette de sécuritéCette étiquette est affichée sur la source de courant. Il est importantque l’utilis

HYPERTHERM Sistemas plasma 1b-12/12/01Seccíon 1bSEGURIDADEn esta sección:Reconocimiento de información de seguridad...

SEGURIDAD2/12/011b-2 HYPERTHERM Sistemas plasmaRECONOCIMIENTO DEINFORMACIÓN DE SEGURIDADLos símbolos que se muestran en esta sección se utilizanpara i

SEGURIDAD4/11/03HYPERTHERM Sistemas plasma 1b-3El contacto directo con piezas eléctricas conectadas puedeprovocar un electrochoque fatal o quemaduras

SEGURIDAD4/11/031b-4 HYPERTHERM Sistemas plasmaAntorchas de encendido instantáneoEl arco de plasma se enciende inmediatamente después deactivarse el i

SEGURIDAD2/12/01HYPERTHERM Sistemas plasma 1b-5• Nunca lubrique reguladores o válvulas de cilindros conaceite o grasa.• Utilice solamente cilindros, r

SEGURIDAD2/12/011b-6 HYPERTHERM Sistemas plasmaEtiqueta de advertenciaEsta etiqueta de advertencia se encuentra adherida a la fuente de energía.Es imp

powermax1000 Service Manual 2-11Section 2SPECIFICATIONSIn this section:Power supply ...

SPECIFICATIONS2-2 powermax1000 Service Manual1Power supplyRated open circuit voltage (U0)300 VDCOutput characteristic* Drooping*Defined as a plot of o

6/15/05Hypertherm, Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)[email protected]

SPECIFICATIONSpowermax1000 Service Manual 2-316.0BAR5.04.0PSI807050606040AMPS8025AC+_Dimensions and weightWeight of power supplywithout torch76 lb(34.

SPECIFICATIONS2-4 powermax1000 Service Manual1Handheld cutting capacity at 60 ampsRecommended capacity 3/4 inch (19 mm)Maximum capacity 1 inch (25 mm)

SPECIFICATIONS1powermax1000 Service Manual 2-5T60 hand torch dimensions 8.9" (226 mm)3.9"(99 mm)1.5"(38 mm)1.00"(25 mm)T60M machin

SPECIFICATIONS2-6 powermax1000 Service ManualSymbols and markingsS MARKThe S mark indicates that the power supply and torch are suitable for use in en

powermax1000 Service Manual 3-11Section 3MAINTENANCEIn this sectionControls and indicators ...

MAINTENANCE3-2 powermax1000 Service Manual1Test 14 – AUX switch ...

MAINTENANCE1Controls and indicators6.0BAR5.04.0PSI807050606040AMPS8025VAC+_Current(amps)adjustmentknobMode switchIndicatorLEDsPressuregaugePressurereg

MAINTENANCE3-4 powermax1000 Service Manual1Theory of operationGeneralRefer to the Functional descriptionand Sequence of operation sections below, and

MAINTENANCE1powermax1000 Service Manual 3-5Sequence of operationPower OFF• Connect the gas supply to the filter on the power unit.• Connect the torch

MAINTENANCE3-6 powermax1000 Service Manual1Troubleshooting preparationThe complexity of the circuits requires that service technicians have a working

ELECTROMAGNETIC COMPATIBILITY (EMC)EMC INTRODUCTIONHypertherm's CE-marked equipment is builtin compliance with standard EN50199. Theequipment sho

MAINTENANCE1powermax1000 Service Manual 3-7DANGERELECTRIC SHOCK CAN KILL• Turn off the power and remove the input power plug from its receptacle befor

MAINTENANCE3-8 powermax1000 Service Manual1Check power switch1. With the power disconnected, set the ON/OFF switch (S1) to ON (I).2. Check the resista

MAINTENANCE1powermax1000 Service Manual 3-9Hypertherm IGBT testerUse the Hypertherm IGBT tester (part number 128883) as described in the following sec

MAINTENANCE3-10 powermax1000 Service Manual1Caution: Failure to isolate the IGBT may result in false readings and/or damageto the IGBT tester.The illu

MAINTENANCE1powermax1000 Service Manual 3-11Schematic for building an IGBT testerTroubleshoot the Hypertherm IGBT tester1. Inspect the leads and the I

MAINTENANCE3-12 powermax1000 Service Manual1IGBT device test using non-Hypertherm testerThe device tester shown in Schematic for building an IGBT test

MAINTENANCE1powermax1000 Service Manual 3-13Control board (PCB3)Board common (TP1) PFC IGBT (Q7)Flyback circuitTorch (J18)Gas manifold Inverter circui

MAINTENANCE3-14 powermax1000 Service Manual1Problem This may mean Cause SolutionNo voltage, improper voltage applied tounit, defective power switch (S

MAINTENANCE1powermax1000 Service Manual 3-15Problem This may mean Cause SolutionConsumables not installed, installedimproperly, or damaged.Refer to th

MAINTENANCE3-16 powermax1000 Service Manual1Problem This may mean Cause SolutionArc lost contact with theworkpiece.Faulty work lead, work lead connect

WARRANTYii Hypertherm Plasma Systems9-01WARNINGGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system.

MAINTENANCE1powermax1000 Service Manual 3-17Problem This may mean Cause SolutionCurrent adjustment set too low.Verify that the current adjustment knob

MAINTENANCE3-18 powermax1000 Service Manual1Control board LEDsIf the red Fault LED illuminates, no yellow LEDs are illuminated, and the green AC and G

MAINTENANCE1powermax1000 Service Manual 3-19Test 1 – voltage input• Check the line voltage to the top of the power switch (S1).• Check the input volta

MAINTENANCE3-20 powermax1000 Service Manual1Test 2 – voltage balanceTest to check the balance of the bus voltage, the power-factor circuit, and the so

MAINTENANCE1powermax1000 Service Manual 3-21Test 3 – output diodes• Check each diode (connection 1 and 3) with an ohm meter in diode test mode.• For e

MAINTENANCE3-22 powermax1000 Service Manual180Test 4 – pilot arc IGBT (Q8)• Check the resistance of the gate drive circuit (R108, R110).• If the value

MAINTENANCE1powermax1000 Service Manual 3-23Test 5 – inverter IGBT (Q6) and PFC IGBT (Q7)• Check the resistance of the gate-drive circuit.• If the val

MAINTENANCE3-24 powermax1000 Service Manual1Test 6 – flyback circuitDC power supply circuit (+5 VDC, +10 VDC, +18 VDC, and +24 VDC)R20 = 0.75ΩVerify t

MAINTENANCE1powermax1000 Service Manual 3-25Test 7 – torch stuck open (TSO)• Check the resistance between the pilot arc IGBT (Q8) and J17. The value s

MAINTENANCE3-26 powermax1000 Service Manual1Test 8 – plasma start• After turning ON the power, put a jumper wire between red and white on the machine

TABLE OF CONTENTSpowermax1000 Service Manual iii1Electromagnetic Compatibility...

MAINTENANCE1powermax1000 Service Manual 3-27Test 11 – incoming line voltage (VACR)• Check the voltage on output of the input diode, whichshould equal

MAINTENANCE3-28 powermax1000 Service Manual1Test 14 – AUX switchIf the AUX switch on the I/O switch (S1) is open when the system is powered up, the IF

MAINTENANCEpowermax1000 Service Manual 3-291T60 hand torch connector pinouts and assemblyWHITEREDJ18VIOLETORANGEBLUEELECTRODENOZZLECAPSTARTKEYNOTE: PI

MAINTENANCE3-30 powermax1000 Service Manual1T60M machine torch connector pinouts and assemblyJ18WHITE123121011CAP896745REDORANGEORANGEBLUEWHITENOZZLEE

MAINTENANCEpowermax1000 Service Manual 3-311Power cord replacementDisconnect the electrical power and the gas supply before removing the old power cor

MAINTENANCE3-32 powermax1000 Service Manual1Torch replacementTurn OFF (O) the power switch.1Unplug the power cord from the power receptacle.2Open the

MAINTENANCE1powermax1000 Service Manual 3-33Align the mark on the strain relief with the mark on the end cap.4Pull back the quick-release collar and i

MAINTENANCE3-34 powermax1000 Service Manual1Filter element replacementABCDisconnect the electrical power and the gas supply.Remove the filter bowls fr

MAINTENANCE1powermax1000 Service Manual 3-35Work cable replacementDisconnect the electrical power, gas supply and torch lead before removing the old w

MAINTENANCE3-36 powermax1000 Service Manual1Capacitor replacementRemoval1. Disconnect the electrical power and the gas supply, then remove the power s

TABLE OF CONTENTSiv powermax1000 Service Manual1Seccíon 1b SeguridadReconocimiento de información de seguridad...

MAINTENANCE1powermax1000 Service Manual 3-37Heat sink component replacement1. Install the components to the heat sink as shown below.2. Use new therma

MAINTENANCE3-38 powermax1000 Service Manual4

powermax1000 Service Manual 4-11Section 4PARTS – POWER SUPPLYIn this section:Exterior ...

PARTS – POWER SUPPLY4-2 powermax1000 Service Manual1ExteriorPartItem number Description Qty.128686 Kit: Labels, domestic 1128685 Kit: Labels, CE 11 12

PARTS –_ POWER SUPPLYpowermax1000 Service Manual 4-31Interior right sidePartItem number Description Designator Qty.1128701 Kit: Control board, domesti

PARTS – POWER SUPPLY4-4 powermax1000 Service Manual1Back interior right sidePartItem number Description Designator Qty.1 128672 Kit: Power switch S1 1

PARTS –_ POWER SUPPLYpowermax1000 Service Manual 4-51Interior fan sidePartItem number Description Designator Qty.1 128627 Kit: Filter 1011093 Air filt

PARTS – POWER SUPPLY4-6 powermax1000 Service Manual1Heat sink assemblyPartItem number Description Designator Qty.127128 Thermal grease, 10 cc 11 12867

PARTS –_ POWER SUPPLY1Recommended spare partsPart number Description Pagereference008965...Current adjustment

PARTS – POWER SUPPLY4-8 powermax1000 Service Manual

TABLE OF CONTENTSpowermax1000 Service Manual v1Check power switch ...

powermax1000 Service Manual 5-11Section 5PARTS – TORCH AND CONSUMABLESIn this section:T60 hand torch assembly ...

PARTS – TORCH AND CONSUMABLES5-2 powermax1000 Service Manual1T60 hand torch assemblyItem Part number Description Quantity083172* T60 hand torch assemb

PARTS – TORCH AND CONSUMABLESpowermax1000 Service Manual 5-31871091211151421653413

PARTS – TORCH AND CONSUMABLES5-4 powermax1000 Service Manual1T60M machine torch assemblyItem Part number Description Quantity083175* T60M machine torc

PARTS – TORCH AND CONSUMABLESpowermax1000 Service Manual 5-5914101211131876235415

PARTS – TORCH AND CONSUMABLES5-6 powermax1000 Service Manual1Hand-held, shieldedGougingT60 consumable configurations12092912092512092612093212092840AO

PARTS – TORCH AND CONSUMABLESpowermax1000 Service Manual 5-71T60M consumable configurationsMechanized, shieldedUnshielded**120930 12093212092840AO-rin

PARTS – TORCH AND CONSUMABLES5-8 powermax1000 Service Manual1Recommended spare partsPart number Description058519 Torch o-ring027055 Silicone lubrican

powermax1000 Service Manual 6-11Section 6WIRING DIAGRAMSIn this section:Timing diagrams ...

6-2 powermax1000 Service Manual1

TABLE OF CONTENTSvi powermax1000 Service ManualT60 consumable configurations...

powermax1000 Service Manual 6-31

WIRING DIAGRAMS6-4 powermax1000 Service Manual1

6-53U22U23(VISIBLE FOR 10 SEC. AFTER EVENT)TORCH STUCK OPEN40 POSITION RIBBON CABLE(VISIBLE FOR 10 SEC. AFTER EVENT)129683WIRE GROUP 12360712360300320