Hypertherm Powermax1650 Service Manual User Manual

SERIES™G3_+4.05.05060AC7080VBAR6.0PSIAMPS30401008060Plasma ArcCutting SystemService Manual804470 Revision 2

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

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

Service Manual(P/N 804470)Revision 2 June, 2003Hypertherm, Inc.Hanover, NH USAwww.hypertherm.com© Copyright 2003 Hypertherm, Inc.All Rights Reserved

powermax1650 Service Manual2-10Section 2SPECIFICATIONSIn this section:Specifications – Power Supply ...

Rated Open Circuit Voltage (U0) 300 VDCOutput Characteristic* Drooping*Defined as a plot of output voltage versus output currentRated Output Current (

SPECIFICATIONSpowermax1650 Service Manual2-30Standard ModelInput Voltage200-208 230-240 400 480 600Input Current at 16kw Output53 46 27 22 21Input Cur

2-4 powermax1650 Service ManualSPECIFICATIONS0_+4.05.05060AC70 80VBAR6.0PSIAMPS30401008060Power Supply – Dimensions and WeightWeight of power supplywi

SPECIFICATIONSpowermax1650 Service Manual2-50Cutting Capacity At 100 AmpsRecommended capacity 1-1/4 inch (32 mm)Maximum capacity 1-1/2 inch (38 mm)Sev

2-6 powermax1650 Service ManualSPECIFICATIONS0Torch DimensionsT100 Hand Torch Dimensions 8.9" (226 mm)4.2"(107 mm)1.5"(38 mm)1.00"

SPECIFICATIONSpowermax1650 Service Manual2-70Symbols and MarkingsS MARKThe S mark indicates that the power supply and torch are suitable for use in en

2-8 powermax1650 Service ManualSPECIFICATIONS0

powermax1650 Service Manual3-10Section 3MAINTENANCEIn this section:Controls and Indicators...

MAINTENANCE3-2 powermax1650 Service Manual0Controls and Indicators_+4.0 5.050 60AC70 80VBAR6.0PSIAMPS30401008060Current(Amps)Adjustment /Gas TestKnobM

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

Theory of OperationGeneralRefer to Functional Description, Sequence of Operation and the system wiring diagram in Section 6.Functional DescriptionAC p

MAINTENANCE3-4 powermax1650 Service Manual0Sequence of OperationSystem OFF• Connect gas supply to filter on power unit.• Connect work lead to work pie

MAINTENANCEpowermax1650 Service Manual3-50TROUBLESHOOTINGThe complexity of the circuits requires that service technicians have a working knowledge of

MAINTENANCE3-6 powermax1650 Service Manual0WARNINGELECTRIC SHOCK CAN KILL• Turn off the power and remove the input power plug from its receptacle befo

MAINTENANCEpowermax1650 Service Manual3-70Resistance ChecksAll resistance values must be taken with the power cord disconnected and all internal power

MAINTENANCE3-8 powermax1650 Service Manual1Resistance Check #2• Remove the linkage bar as shown below.• Check each diode (connection 1 and 3) with an

MAINTENANCEpowermax1650 Service Manual3-90WARNINGELECTRIC SHOCK CAN KILL• Use extreme caution when working near live electrical circuits. Dangerous vo

MAINTENANCE3-10 powermax1650 Service Manual0Problem This May Mean Cause SolutionNo voltage or improper voltage applied to unitVerify incoming voltage

MAINTENANCEpowermax1650 Service Manual3-110Consumables not installed, installed improperly, or damagedRefer to consumable diagram for proper installat

MAINTENANCE3-12 powermax1650 Service Manual0Worn consumables Worn-out consumables Replace consumablesImproper air pressure setting or low flowInsuffic

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

This May Mean Cause SolutionStart LED on control board (PCB3) and Fault lamp are illuminatedContinuous start signal Shorted start wires or depressed s

MAINTENANCE3-14 powermax1650 Service Manual0Voltage ChecksVoltage Check #1• Check input voltage to the input diode bridge.• The AC voltage between a

MAINTENANCEpowermax1650 Service Manual3-150Voltage Check #2• Check output voltage of the input diode bridge.• Output VDC = Line Voltage * 1.414Note:

MAINTENANCE3-16 powermax1650 Service Manual0Voltage Check #3• Check voltage across IGBT module (Q14).Note: All values are ±15%.750 VDC

MAINTENANCEpowermax1650 Service Manual3-170Voltage Check #4• Check voltage across IGBT module (Q13).Note: All values are ±15%.750 VDC375 VDC375 VDC

MAINTENANCE3-18 powermax1650 Service Manual0Voltage Check #5• Check voltage across power supply capacitors.Note: All values are ±15%.375 VDC

MAINTENANCEpowermax1650 Service Manual3-190Resistance Check #3• Troubleshoot illuminated Torch Stuck Open LED on control board PCB3.1. Check resistan

MAINTENANCE3-20 powermax1650 Service Manual0WARNINGELECTRIC SHOCK CAN KILL• Use extreme caution when working near live electrical circuits. Dangerous

MAINTENANCEpowermax1650 Service Manual3-210Torch InstallationTurn OFF power.Remove power cord from power receptacle.Open Easy Torch Removal (ETR) d

MAINTENANCE3-22 powermax1650 Service Manual0Align marks on strain relief.Pull back quick-release collar and insert the lead’s gas fitting.Slide qui

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

MAINTENANCEpowermax1650 Service Manual3-230Filter Element ReplacementABCDisconnect electrical power and gas supply.Remove filter bowl on new and old f

MAINTENANCE3-24 powermax1650 Service Manual0Work Cable ReplacementDisconnect electrical power, gas supply, torch lead, and remove ETR barrier before r

MAINTENANCEpowermax1650 Service Manual3-250Capacitor ReplacementRemoval – Refer to figure below.Disconnect electrical power and gas supply before remo

MAINTENANCE3-26 powermax1650 Service Manual2Heat Sink Component ReplacementInstallation• Install components to the heat sink as shown below.• Use new

powermax1650 Service Manual4-10Section 4PARTS - POWER SUPPLYIn this section:Exterior ...

PARTS - POWER SUPPLY4-2 powermax1650 Service Manual0Power Supply – ExteriorPartItem Number Description Designator Qty.128750 Label Kit, Domestic 1128

PARTS - POWER SUPPLYpowermax1650 Service Manual4-30Power Supply – Interior Right SidePartItem Number Description Designator Qty.1 128736 Control PCB a

POWER SUPPLY PARTS4-4 powermax1650 Service Manual3Power Supply – Back interior right sidePartItem number Description Designator Quantity1 128757 Fron

PARTS - POWER SUPPLYpowermax1650 Service Manual4-50Power Supply – Interior Fan SidePartItem Number Description Designator Qty.1 128627 Filter bowl 101

PARTS - POWER SUPPLY4-6 powermax1650 Service Manual2Power Supply – Heat Sink AssemblyPartItem Number Description Designator Qty.027662 Thermal grease,

TABLE OF CONTENTSpowermax1650 Service Manualiii0Electromagnetic Compatibility...

Recommended Spare PartsPart Number ...Description...

PARTS - POWER SUPPLY4-8 powermax1650 Service Manual0

powermax1650 Service Manual5-10Section 5PARTS LIST - TORCH AND CONSUMABLESIn this section:T100 Hand Torch Assembly...

PARTS – TORCH AND CONSUMABLES5-2 powermax1650 Service Manual0T100 Hand Torch AssemblyItem Part Number Description Quantity059264* T100 Hand Torch Asse

PARTS – TORCH AND CONSUMABLESpowermax1650 Service Manual5-30

PARTS – TORCH AND CONSUMABLES5-4 powermax1650 Service Manual0T100M Machine Torch AssemblyItem Part Number Description Quantity059265* T100M Machine To

PARTS – TORCH AND CONSUMABLESpowermax1650 Service Manual5-50 

PARTS – TORCH AND CONSUMABLES5-6 powermax1650 Service Manual0Hand-Held, ShieldedGougingTorch Consumable Configurations12092912092512092612093212092822

PARTS – TORCH AND CONSUMABLESpowermax1650 Service Manual5-70Torch Consumable ConfigurationsMechanized, ShieldedUnshielded**120930 120932120928*220047

PARTS – TORCH AND CONSUMABLES5-8 powermax1650 Service Manual0Recommended Spare PartsPart Number Description058519 Torch O-Ring027055 Silicone Lubrican

TABLE OF CONTENTSiv powermax1650 Service Manual0Section 2 SpecificationsSpecifications – Power Supply ...

powermax1650 Service Manual6-10Section 6WIRING DIAGRAMSIn this section:Timing Diagrams...

6-2 powermax1650 Service Manual0Torch LeadLength(feet)5050tdelay(msec)Time Constant(msec)2501. 200ms DELAY IS FOR TORCH LEAD PRESSURIZATION.2. CURREN

powermax1650 Service Manual6-30EA~3FFh~01SetpointPA0CPA timeoutIcommand0121.5AReattachtransfercausesCPA OPERATION40A1.6AI SETPOINT0.4A30A 30ANOTE: UNI

U20U22(VISIBLE FOR 10 SEC. AFTER EVENT)TORCH STUCK OPEN40 POSITION RIBBON CABLE(VISIBLE FOR 10 SEC. AFTER EVENT)7050STATUSGAS45 6055 65 75 80 85TSOSP

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