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Hypertherm Powermax105 Operator Manual manuals

Owner’s manuals and user’s guides for Equipment Hypertherm Powermax105 Operator Manual.
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Hypertherm : Powermax105 Operator Manual User Manual (343 pages)


Brand: Hypertherm | Category: Equipment | Size: 31.86 MB |

 

Table of contents

Plasma arc cutting systems

1

Service Manual

3

(P/N 807580)

3

Introduction

5

Installation and use

5

Assessment of area

5

Methods of reducing emissions

5

Cutting cables

6

Equipotential bonding

6

Earthing of the workpiece

6

Screening and shielding

6

Attention

7

WARRANTY

7

W-2 Compliance Information

8

Service Manual

10

Section 1

19

SPECIFICATIONS

19

Safety information

20

System description

20

Where to find information

21

Power supply dimensions

22

SpecificationS

23

Service Manual 1-5

23

1-6 powermax

24

Service Manual 1-7

25

1-8 powermax

26

Service Manual 1-9

27

1-10 powermax

28

Symbols and markings

29

Noise levels

29

IEC symbols

30

Service Manual 2-1

31

Service Manual 2-3

33

Service Manual 2-5

35

Service Manual 2-7

37

Service Manual 2-9

39

Service Manual 2-11

41

Service Manual 2-13

43

Section 3

45

BASIC SYSTEM OPERATIONS

45

Basic system OperatiOns

47

Service Manual 3-3

47

Service Manual 3-5

49

Service Manual 3-7

51

Service Manual 3-9

53

Turn ON the system

53

Set the operating mode switch

53

Service Manual 3-11

55

Section 4

57

HAND TORCH SETUP

57

Hand torch components

59

Connecting the torch lead

63

Section 5

65

HAND CUTTING

65

Hand torch cutting hints

67

Pierce a workpiece

69

Hand Cutting

71

Service Manual 5-7

71

Gouge profile

71

Section 6

73

MACHINE TORCH SETUP

73

Consumable life

75

Service Manual 6-5

77

Mount the torch

79

Service Manual 6-11

83

Service Manual 6-15

87

Service Manual 6-17

89

105 A Shielded consumables

89

Service Manual 6-19

91

Service Manual 6-21

93

85 A Shielded consumables

93

Service Manual 6-23

95

Service Manual 6-25

97

65 A Shielded consumables

97

Service Manual 6-27

99

Service Manual

100

Machine Torch SeTup

101

Service Manual 6-29

101

45 A Shielded consumables

101

Service Manual 6-31

103

Service Manual 6-33

105

consumables

105

Service Manual 6-35

107

FineCut (Stainless Steel)

107

Service Manual 6-37

109

Service Manual 6-39

111

Service Manual 6-41

113

Service Manual 6-43

115

Service Manual 6-45

117

Service Manual 6-47

119

Service Manual 6-49

121

Service Manual 6-51

123

Service Manual 6-53

125

Section 7

127

MECHANIZED CUTTING

127

Mechanized cutting

129

Service Manual 7-3

129

Service Manual 7-5

131

Accessing raw arc voltage

133

Service Manual 7-9

135

Common machine-cutting faults

137

Section 8

139

Controls and indicators

141

Service Manual 8-5

143

Troubleshooting preparation

145

Initial resistance check

147

Service Manual 8-11

149

Service Manual 8-13

151

IGBT test preparation

151

Service Manual 8-15

153

Service Manual 8-17

155

Service Manual 8-19

157

Service Manual 8-21

159

Fault codes

161

Service Manual 8-25

163

Fault codes and solutions

163

Service Manual 8-27

165

Service Manual 8-29

167

Service Manual 8-31

169

Service Manual 8-33

171

Service Manual 8-35

173

Service Manual 8-37

175

Service Manual 8-39

177

Service Manual 8-41

179

Service Manual 8-43

181

Test 1 – Voltage input

181

Service Manual 8-47

185

J19J20J21J22

186

Service Manual 8-49

187

Service Manual 8-51

189

Install a test

191

Service Manual 8-55

193

Test 8 – Torch cap switch

193

Service Manual 8-57

195

Test 10 – Pressure sensor

195

Service Manual 8-59

197

Test 12 – AUX switch

197

Section 9

199

9-2 powermax

200

Replacing the power cord

203

Replacing the power switch

204

Replacing the control board

204

Replacing the DSP board

204

Replacing the power board

205

Replacing the pilot arc IGBT

206

Replacing the PFC IGBT module

207

Replacing the damper resistor

208

Replacing the thermal sensor

208

Replacing the fan shroud

208

Replacing the fan

209

Replacing the pressure switch

209

Replacing the solenoid valve

210

Replacing the gas tubing

210

Replacing the bulk capacitors

211

Replacing the output inductor

212

Replacing the transformer

212

Replacing the PFC inductor

212

Replacing the front end panel

213

Replacing the rear end panel

213

Power switch

214

Gas supply

214

Service Manual 9-17

215

9-18 powermax

216

Service Manual 9-19

217

9-20 powermax

218

Remove the component barrier

219

Remove the power supply cover

219

Remove the end panel bracket

220

Service Manual 9-23

221

9-24 powermax

222

Set the voltage divider board

224

Service Manual 9-27

225

9-28 powermax

226

Service Manual 9-29

227

9-30 powermax

228

Service Manual 9-31

229

Disconnect the gas tube

230

Connect the gas tube

230

Remove the power cord

231

9-34 powermax

232

Service Manual 9-35

233

Replace the power switch

234

Service Manual 9-37

235

9-38 powermax

236

Replace the control board

237

Remove the DSP board

238

Remove the power board

239

9-42 powermax

240

Service Manual 9-43

241

9-44 powermax

242

Service Manual 9-45

243

Replace the pilot arc IGBT

244

Replace the PFC IGBT module

245

Replace the damper resistor

246

Replace the snubber resistor

246

Replace the thermal sensor

247

Install the power board

251

Install the DSP board

252

Remove the fan shroud

253

Install the fan shroud

253

Replace the fan

254

Service Manual 9-57

255

Replace the pressure switch

256

Service Manual 9-59

257

9-60 powermax

258

Replace the solenoid valve

259

9-62 powermax

260

Replace the gas tubing

261

Replace the bulk capacitors

262

Service Manual 9-65

263

9-66 powermax

264

Service Manual 9-67

265

9-68 powermax

266

Service Manual 9-69

267

Replace the output inductor

268

Service Manual 9-71

269

9-72 powermax

270

Service Manual 9-73

271

Replace the transformer

272

Service Manual 9-75

273

9-76 powermax

274

Replace the PFC inductor

275

9-78 powermax

276

Service Manual 9-79

277

Replace the front end panel

278

Service Manual 9-81

279

9-82 powermax

280

Service Manual 9-83

281

Replace the rear end panel

282

Service Manual 9-85

283

9-86 powermax

284

Service Manual 9-87

285

Install the power cord

286

Service Manual 9-89

287

Install the end panel bracket

288

Install the component barrier

289

9-92 powermax

290

Section 10

291

TORCH COMPONENT REPLACEMENT

291

Torch componenT replacemenT

293

Service Manual 10-3

293



293



293



293

Service Manual 10-5

295



295



295



295

Torch componenT replacemenT

296

10-6 powermax

296



296

Service Manual 10-7

297

WARNING

297



297

Remove the left handle

298

Install the left handle

298

Remove the trigger and spring

299

Remove the start switch

300

Replace the start switch

300

Remove the right handle

301

Replace the cap-sensor switch

301

Replace the torch body

302

Replace the torch lead

303

Install the right handle

304

Service Manual 10-15

305

Remove the mounting sleeve

306

Remove the cap-sensor switch

306

Remove the torch body

306

Separate the torch components

306

Service Manual 10-17

307

Replace the gear rack

308

Replace the coupler

308

Install the torch body

309

Install the cap-sensor switch

309

Install the mounting sleeve

309

Connect the torch components

309

10-20 powermax

310

Section 11

311

Power supply parts

312

11-4 powermax

314

Service Manual 11-9

319

Heat sink assembly

320

Hand torch consumables

325

Service Manual 11-17

327

Service Manual 11-19

329

Machine torch consumables

330

Accessory parts

331

Powermax105 labels

331

Safety-critical parts

332

Item Part number Description

333

Recommended spare parts

336

Service Manual 11-27

337

11-28 powermax

338

Section 12

339

WIRING DIAGRAMS

339

Wiring Diagrams

340

12-2 powermax

340

Powermax Generic Timing Chart

341

PMX105 CSA

342

PMX105 230-400V CE

342

PMX105 380V CCC/230-400V CE

342

PMX105 380V CCC

343

PMX105 400V CE

343
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