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1. agi T oe see I pe 9 Ju afl TOL C 8 Tus b s NA fe e e Lower bar spanning D2 amp D3 12918 er el o gt gt E 5 s 2 es i 7 Location of Bars Spanning 02 D3 powermaxa800 Service Manual 3 13 MAINTENANCE 3 14 Measure resistance between the power supply chassis and the conductors on the plug of the power cord Do not use the ground conductor on the plug as a measuring point Meter indicates an open There is an internal short in the power supply Visually and with a meter inspect the unit for pinched broken and loose wires and wires with damaged insulation contacting the chassis Also check for loose hardware such as screws nuts and bolts Problem found and repaired To page 3 15 Check 4 Continue checking out unit until problem is found Then repeat check powermax800 Service Manual MAINTENANCE Measure resistance between the power supply chassis and the work cable clamp Fig 4 1 Meter indicates an open
2. Torch Lead w pigtail 25 ft 7 6 m 028926 eee tee Torch Lead w pigtail 35 ft 10 6 m 028919 iine Torch Lead w pigtail 50 ft 15 2 m 128123 rete Torch Lead no pigtail 14 ft 4 3 m 12812555 cte tene Torch Lead no pigtail 25 ft 7 6 m 128126 unten Torch Lead no pigtail 35 ft 10 6 m 12812 TR mes Torch Lead no pigtail 50 ft 15 2 m 044009 nr rre Quick Disconnect O Ring not shown 075321 Socket Cap 4 40 X 1 2 HX SS 075322 username M S 4 40 X 1 4 SL SZ 120282 mme Nozzle PAC121 50A Shield 120326 ies Shield PAC121M Machine Torch T2030 cierre t ites teeta cette Cap Retaining 120558 A Torch Main Body w Switch PAC121M O Ring BUNA 90 Duro 614X 070 Note See page 5 12 for detail of consumable parts Torch Main Torch Lead 028923 with pigtail 14 ft 4 3 m 028918 with pigtail 25 ft 7 6 m Torch Position 028926 with pigtail 35 ft 10 6 m Sleeve 028919 with pigtail 50 ft 15 2 m DS 020620 128123 no pigtail 14 ft 4 3 m wise ry 128125 no pigtail 25 ft 7 6 m 82 128126 no pigtail 35 ft 10 6 m 128127 no pigtail 50 ft 15 2 m 044016 On Off Pendant not part of machine torch assembly See Powermax800 Field Upgrade Kits and Optional Parts later in this section for part numbers Pigtail Figure 5 8 PAC121MS Torch Assembly and Leads powermax800 Service Manual 5 11 PARTS LIST CE CO
3. aia Socket Cap 4 40 X 1 2 HX SS 075322 ine aes b M S 4 40 X 1 4 SL SZ 120282 Nozzle PAC121 50A Shield 120326 i ae aes Shield PAC121M Machine Torch 120301 eem Cap Retaining 120558 isa Torch Main Body w Switch PAC121M 044016 eie O Ring BUNA 90 Duro 614X 070 Note See page 4 12 for detail of consumable parts Torch Main Torch Lead Body 028923 with pigtail 14 ft 4 3 m 120558 028918 with pigtail 25 ft 7 6 m Sleeve 028919 with pigtail 50 ft 15 2 m CNN AN 020620 128123 no pigtail 14 ft 4 3 m yx ry 128125 no pigtail 25 ft 7 6 m 572 128126 no pigtail 35 ft 10 6 m 128127 no pigtail 50 ft 15 2 m 044016 On Off Pendant not part of machine torch assembly See Powermax800 Field Upgrade Kits and Optional Parts later in this section for part numbers Pigtail Figure 5 8 PAC121MS Torch Assembly and Leads powermax800 Service Manual 4 11 Parts List CONSUMABLE PARTS Note See Section 5 Parts List 400V CE for parts and Shields components of the 400V CE Retaining Cap Powermax800 system 120301 Nozzles 120282 2 Shielded 120602 oe e Figure 4 7 Consumable Parts ey Deflector 120303 120301 708 Swirl Electrodes Ring PAC121 0 E 120573 Air Torch 020480 N 020361 Deflector 020395 lt Gouging Shield Wn 120608 120301 6 2 Gouging x O Ring 044016 120304 120303 120301 J 120
4. 003078 e Relay 30A NO Mag Blwt QDisc Term 4 5 129068 Circuit Breaker SA 4Pole 480V W TC 4 9 129151 Contactor SA Powermax800 4 9 008809 Fuse 1A 600V 13 32X1 1 2Slo 2 4 4 014207 Xfmr Powermax800 208 240 480 Control 4 7 014210 Xfmr Powermax800 208 240 480 Power 4 7 014186 Inductor Powermax800 2MH 50A 4 7 023922 Cable w Clamp PMX800 Work 20 4 3 027080 Fan 225CFM 120VAC 50 60HZ 4 7 Pressure Switch 39 Psi 013 Orifice 005112 s Sol Valve 100 1 8FPT 24VAC NC 006054 011072 Filter 20 Micron 1 8FPT 4 9 011079 Filter Element for 011072 Filter 4 9 011073 Regulator 0 125 Psig 1 8FPT 4 3 022027 Press Gauge 160 1 5 1 8CBM Panel 4 3 029957 Heatsink SA Powermax800 Power 4 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 4 5 Diode 1600V 100A 3PH Module Thermal Pad AL 340 180 4 5 109019 008904 005178 Temp Switch Opens 85 Closes 75 4 5 009849 008908 Resistor 20 Ohm 50W 5 NON IND 4
5. 5A see Parts List for part number and specifications Figure 3 6 Control Board Test Points and LED Locations powermaxa800 Service Manual 3 29 9 96 MAINTENANCE TORCH CHECK A failure of the torch cap sensor circuit will cause the Powermax800 power supply to shut down and a failure of the torch start circuit will prevent the torch from firing If your Powermax800 has either of these problems and you have followed the Corrective Maintenance Checks beginning on page 3 17 proceed with the following checks Cap Sensor Circuit Check If the torch retaining cap is screwed down tightly and the ON OFF power switch shuts off there could be a problem with the torch cap sensor circuit A WARNING Set the Powermax800 power switch to off unplug the power cable and disconnect the gas supply Always wait 5 minutes before removing any cover of the power supply 1 Disconnect power and gas See warning above 2 Remove the power supply cover 3 Locate fuses F1 and F2 on the control board See Fig 3 6 4 Checkto see if the fuses are open If the fuses are open replace the torch the torch leads and the control board fuse s See Section 4 Parts List or Section 5 Parts List CE to order new components If the fuses are OK the retaining cap microswitch is working the line voltage is OK and the power supply continues to shut off replace the control board 3 30 powermax800 Ser
6. sensor Q CONNECT 029962 ef 2 14 amp 8 POWER PCB 041532 IN PWR XFMR 135 C gt 152 91 TN 1 F 250 OHMS CURRENT SETPOINT 125 8 i23456789 10 11 12 15 14 12345678910 amp 12345678 tal Eu PMX800 CE ELEC SCH 400V 015 5 290 1 1 W49 9 CONTROL PCB 041517 Control Board Test Points Transtersignal Alogichigh I2Y indicates that the ercistranstemed 9 temperatures ars A logic high 12V indicates that unit is in transferred mode w38 39 E at os rer SES TS2 8 2 Pl n v 52s a m a 6 Ot 2 EE dp d e 95 722 6 A Et 11215 4 516 ES 24V 27V 120 Fe 12 12V Ki E 2 8 9 AVS CONTROL 5 NM m An Denon 0 jon zac i88 00 07 000 103 90000000 2 gt d Faga 1 T Ber e iei DIE K M RA 700 rn DC 0 0000 Fe De 035 0 00000000 ol oo lt OUTPUT VOLTAGE SNUBBER NJ bel
7. 8 8 7 818 8 OPTION 2 c2 ____ eee VOLTS MACHINE INTERFACE START XFER BIBT PS 8 5 TO JPB 6 12V FER LED FUNCTIONS D8 POWER ON D15 LINE VOLTAGE D24 OVERCURRENT D25 PILOT ARC RELAY D26 GAS SOL D27 MAIN CONTACTOR PRE D29 OVER TEMP D35 PRESSURE OK D38 ARC XFER D42 PLASMA START PMX800 TROUBLE SHOOTING SCH 015 2 292 1 OF 2 6 5 A WARNING A SHOCK HAZARD The E terminals and J1 are accessible from the back side of the power PCB Use extreme caution when taking these readings Voltages up to 300 VDC are present at the rear of the power PCB Power Board Test Points rest Point Descipion E1 to gh voltage powe E14 to E3 One half of High voltage po Left inverter E4 to ES inverter Soft start signal from control After incoming voltage is accepted by control board control board sends 12VDC to relay RL1 on power board LINE VOLTAGE LED will remain lit until soft start signal is complete about 5 seconds after 51 is thrown J1 5 to J1 4 12VDC 5 sec after 51 The large electrolytic capacitors blue cased cylinders located on the front side of the power PC board store large amounts of energy in the form of electrical voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the PC board and on certai
8. 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 9 Immunity of other equipment in the environment User shall ensurethat other equipment being usedinthe environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises METHODS OF REDUCING EMISSIONS Mains Supply Cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cut
9. Yes No Isolate and check control transformer T1 power switch S1 input filter MOV1 capacitors C1 C2 and C3 contactor CR1 and all associated wiring for shorts Repair problem and repeat check Indicates high ohms or infinity Indicates low ohms or short 2 Isolate and check control transformer T1 E MO power switch S1 d i fuses F1 and F2 et and associated wiring for opens and associated wiring for shorts Repair problem and repeat check Repair problem and repeat check To page 3 11 Three Phase Check 1 3 12 powerrmax800 Service Manual MAINTENANCE Disconnect torch lead Place lead of ohm meter to upper bar spanning output diodes D2 and D3 Place lead of ohm meter to lower bar spanning output diodes D2 and D3 Meter indicates infinity or high Kohms Replace diodes D2 and D3 Place lead of ohm meter to upper bar spanning output diodes D2 and D3 Place lead of ohm meter to lower bar spanning output diodes D2 and D3 Meter indicates 1 7K ohms Replace diodes D2 and D3 Yes To page 3 14 Check 3 Upper bar spanning D2 amp D3 II LL 2I IT o e e P 95 e D
10. The Powermax800 conforms to C standard EN50192 The mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The torches must have shielded consumable parts to maintain S mark compliance See warning below and Figure 2 5 7 UN A WARNING A The voltage between the tip of the torch and the workpiece will exceed 113VDC if shielded consumable parts are not installed in the torch If using the 400V CE power supply the PAC121TS torch must be operated with shielded parts to main tain the mark and CE low voltage compliance for hand held applications See Figure 2 5 below and also Section 5 Consumable Parts For CE Compliance for a list of CE consumable parts This requirement does not apply to machine torch Ke applications Consumable Parts Shield 5 Cutting Retaining Nozzles Standard 121 120601 Hand EUM t 2 120282 Swirl iElectrode Ring 120301 120602 Machine 120438 120573 020361 Gouging Shield 9 120608 120801 Figure 2 5 5 Mark Label powermax800 Service Manual 2 5 7 99 DESCRIPTION amp SPECIFICATIONS IEC SYMBOLS USED E Liaw i 7 9 96 Direct Current DC Alternating current AC Plasma cutting torch AC input power connection The terminal for the external protective earth conductor An inverter based power source Anode w
11. la et 1a 2 Pr vention des vapeurs toxiques sisi 1a 2 Pr vention des incendies is 1a 2 Pr vention des chocs lectriques siens 1a 2 Pr vention des explosions C 1a 3 Protection contre le 1a 4 Mise la masse et la terre iii 1a 4 Rappels de s curit 1a 4 Proth ses 6lectroniques mE 1a 4 SECTION 2 DESCRIPTION 4 SPECIFICATIONS 2 1 INtrODUCHON cM E E 2 2 2 3 121 50 TOCNE 2 4 IEC Symbols Used MEE 2 6 SECTION 3 gis rilg E 3 1 Lite fe ERES ERE 8 2 nie miii duEMSrdc MR 3 2 Theon of Operation sossen 3 4 Sequence of Operation 3 6 Troubleshooting 4223 22828800 avons erie eee ed na tie een ee 3 7 Power Boardi gocis 3 26 COMMON BOATA 3 28 MOPCH GHECK nee 3 30 PAC121TS Torch Parts Removal and Replacement ss 3 32 PAC121MS Torch Parts Removal and Replacement 3 34 Quick
12. starr 2 sensor Lucx connect 029962 i od 15 jd 88 gI 5 109 041532 041496 PILOT ARC PCB PCB 041486 P1 LE INTERFACE 250 OHMS 5 041494 He 123 23456 78 9 10 11 12 13 14 24v 27 120 49 123456789 10 11 12 13 14 12345678910 8 12545678 PMX800 ELEC SCH 208 240 480 o 013 3 285 CONTROL PCB 041472 1 1 HEATSINK 029957 200 230 400 200 230 400 18 o fee de EE 39 ON CONTROL a INPUT 1 5 H WORK BUSS BAR PELLEM 4 gt NOZZLE 014208 PWR XFMR T2 XFMR 014211 ror staat 2 sensor 029962 work L1 8 ELECTRODE E 19 w109 POWER PCB 041532 PILOT ARC ICBT Q3 029961 de GATE DRIVE P1 250 OHMS CURRI SETPOINT 5 afise iiswr us to INESE o PMX800 ELEC SCH 200 250 400 e CONTROL PCB 041517 015 3 291 1 OF 1 QUICK CONNECT NOT USEO HEATSINK 029957 W35 W41 W42 W44 W45 20 5007 SLOW BLOW 400v 30 INPUT wef bes 3139 te 7 014186 NOZZLE PWR XFMR T2 014211 014209 CNIL XFMR qu start
13. Filter Bowl Cap Figure 3 1 Filter Assembly Unscrew the filter bowl Unscrew the filter element See Powermax800 Field Upgrade Kits and Optional Parts in Section 4 for part number information Clean filter element with alcohol then blow out with air from the inside of the filter element Clean the bowl with household soap only Replace the filter element and filter bowl Reconnect the gas supply hose powermax800 Service Manual MAINTENANCE Cooling Air Filter Removal Cleaning and Replacement Powermax800 systems are normally shipped without air filters If your Powermax800 has the air filter option it will need cleaning periodically Excessively dirty or dusty environments can block the cooling air filter if installed and cause the power supply to overheat and shut down WARNING SHOCK HAZARD Always turn off power and unplug cord from wall and wait 5 minutes before removing any cover of the power supply If power supply is directly connected to a line disconnect box place line disconnect switch to OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures 1 Turn the Powermax800 power switch to the OFF 0 position unplug the power cable from the wall receptacle and disconnect the gas supply See warning above 2 Remove the 22 screws that secure the power supply cover to the
14. Warn other people in the area not to look directly at the arc unless they are wearing glasses goggles or a helmet Prepare the cutting area in a manner that reduces the reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Install protective screens or curtains to reduce ultraviolet transmission Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing which covers all exposed areas Ouffless trousers to prevent entry of sparks and slag Toxic Fume Prevention Keep the cutting area well ventilated Remove all chlorinated solvents from the cutting area before cutting Certain chlorinated solvents decompose when exposed to ultraviolet radiation to form phosgene gas Wear proper breathing mask and use proper ventilation when cutting galvanized metal Do not cut containers with toxic materials inside Clean containers that have held toxic materials thoroughly before cutting WARNING Toxic Fumes Do not cut metal or painted metals containing zinc lead cadmium or beryllium unless the operator or anyone else subjected to the fumes wears respiratory equipment or an air supplied helmet Fire Prevention Make fire extinguishers available in the cutting area Remove all combustible materials from th
15. correct No Yes Yes Replace control board Check connectors amp wires between fuses and T1 Repair as needed 3 20 powermax800 Service Manual 3 96 MAINTENANCE From page 3 20 Yes LINE VOLTAGE LED Off No Check for low input voltage at TB1 Is line voltage for 200V lt 170V 208V lt 178V 230V lt 195V 240V lt 204V 400V lt 340V 480V lt 408V 600V lt 510V No Check to see if D27 is illuminated D27 illuminated Yes Replace control board To age 3 22 Yes Yes Correct supply voltage Check connectors amp wires between Meter indicates 0 ohms Yes fuses and T1 Repair as needed Replace F1 and or F2 Unplug power cord Measure resistances of fuses F1 amp F2 No Check control board JP2 24VAC at pins 1 amp 2 voltages 27VAC at pins 6 amp 7 correct Yes Replace control board powermax800 Service Manual 3 21 9 96 MAINTENANCE From page 3 21 Yes To page 3 23 GAS PRESSURE LED On Yes No Yes Check pressure regulator gauge for 70 psi Adjust pressure Pressure No regulator for 70 psi corrected Yes Check inlet gas supply pressure to pressure regulator It should be a minimum of 90 psi 6 2 bar Disconnect wires W92 amp W93 on pressure switch PS1 Measure voltage Adjust inlet Inlet Pressure pres
16. 2 005112 Pressure Switch 39 Psi 013 Orifice 006054 Sol Valve 100 1 8FPT 24VAC NC 4 3 011072 Filter 20 Micron 1 GEPT eet npe cp de vene deett 011079 Filter Element for 011072 Filter 011073 Regulator 0 125 Psig 1 8FPT ss 022027 Press Gauge 160 1 5 1 8CBM 4 3 029957 Heatsink SA Powermax800 Power Unit 4 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 4 5 109019 008904 Diode 1600V 100A 3PH Module Thermal Pad AL 340 180 4 5 005178 Temp Switch Opens 85 Closes 75 4 5 009849 008903 Resistor 20 Ohm 50W 5 NON IND 4 Thermal Pad AL 197 114 4 4 5 009850 008902 Resistor 20 Ohm 25W 596 NON IND 4 Thermal Pad AL 103 108 4 4 5 Capacitor 012UF 1000WV 10 Poly 4 Capacitor 6800PF 1000WV 10 Poly 4 IGBT Gate Drive SA Powermax800 2 Thermal Pad AL 370 134 2 PCB Assy Powermax800 Control Assy Powermax800 ZB Power Cord 2 bmm HD21 22 iei ent aere Rave e Eae MOV Cap
17. Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only T Order corresponding thermal pads when ordering these items A Available only on power supplies with the pilot arc control option Available only on power supplies with the machine interface option Used only on 208 240 480V power supplies Used only on 200 230 400V power supplies For power supplies with serial numbers before 800 010000 order 128108 power board kit to replace power board 4 4 powermax800 Service Manual 9 96 Parts List POWER SUPPLY 208 240 480V 200 230 400V Figure 4 2 Powermax800 Top and Right Side powermax800 Service Manual 4 5 9 96 Parts List POWER SUPPLY 208 240 480V 200 230 400V Note See Section 5 Parts List 400V CE for parts and components of the 400V CE Bottom and Left Side owermax800 system Index No Part No Description Ref Desig Quantity 1 001521 Panel Powermax800 Pwr Unit Center 1 2 001522 Chassis Powermax800 Pwr Unit 1 3 004667 Bracket Powermax800 Pwr Unit Fan 1 4 014207 Xfmr Powermax800 208 240 480 Control T1 1 4 014208 Xfmr Powermax800 200 230 400 Control T1 1 5 014210 Xfmr Powermax800 208 240 480 Power T2 w TS2 1 5 014211 Xfmr Powermax800 200 230 400 Power T2 W TS2 1 6 014186 Inductor Powermax800 2MH 50A L1 1 7 027080 F
18. Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only T Order corresponding thermal pads when ordering these items Available only on power supplies with the pilot arc control option Available only on power supplies with the machine interface option For power supplies with serial numbers before 800 010000 order 128108 power board kit to replace power board 5 4 powermax800 Service Manual Panrs Lisr CE Figure 5 2 Powermax800 CE Top and Right Side POWER SUPPLY 400V CE 25 26 5 5 powermax800 Service Manual 9 96 Panrs Lisr CE POWER SUPPLY 400V CE Note See Section 4 Parts List for parts and components of the non CE Powermax800 Bottom and Left Side Index No 5 6 9 96 10 12 Notes systems Part No Description Ref Desig Quantity 001521 Panel Powermax800 Pwr Unit Center 1 001522 Chassis Powermax800 Pwr Unit 1 004667 Bracket Powermax800 Pwr Unit Fan 1 014209 Xfmr Powermax800 CE 400V Control T1 1 014211 Xfmr Powermax800 200 230 400 Power T2 w TS2 1 014186 Inductor Powermax800 2MH 50A L1 1 027443 Fan 260CDM 120VAC 50 60HZ M1 1 129046 Heatsink SA Powermax800 CE Power Unit 1 004721 Heatsink Powermax800 Power Unit 1 041532 PCB Assy Powermax800 ZB Power 1 029978 Heatsink SA Pwrmx800 PA Cont PCB Q3 004673 Heatsink Powermax800
19. There is an internal short in the power supply Visually and with a meter inspect the unit for pinched broken and loose wires and wires with damaged insulation contacting the chassis Also check for loose hardware Such as screws nuts and bolts Problem found and repaired To page 3 16 Check 5 Continue checking out unit until problem is found Then repeat check powermaxa800 Service Manual 3 15 MAINTENANCE Measure resistance between the conductors on the plug of the power cord and the work cable clamp Do not use the ground conductor on the plug as a measuring point Meter indicates an open There is an internal short in the power supply Visually and with a meter inspect the unit for pinched broken and loose wires and wires with damaged insulation contacting the chassis Also check for loose hardware such as Screws nuts and bolts Problem found and repaired End of resistance checks To page 3 17 Continue checking out unit until problem is found Then repeat check 3 16 powerrmax800 Service Manual MAINTENANCE Corrective Maintenance Checks A WARNING A SHOCK HAZARD Always turn off power and unplug cord from wall and wait 5 minutes before removing any cover of the power supply If power supply is directly connected to a line disconnect box place line discon nect switch to OFF position In the U S use a lock out tag out proce dure until the service or ma
20. Thermal Pad AL 197 114 4 4 5 009850 008902 Resistor 20 Ohm 25W 5 NON IND 4 Thermal Pad AL 103 108 4 4 5 009918 Capacitor 012UF 1000WV 10 Poly 4 4 5 009968 Capacitor 6800PF 1000WV 10 Poly 4 4 5 029998 008905 IGBT Gate Drive SA Powermax800 2 Thermal Pad AL 370 134 2 4 5 041472 PCB Assy Powermax800 Control 4 5 041532 PCB Assy Powermax800 ZB Power 4 5 4 7 129114 Cord Plug 42 1Phase 8 380 3Prong 7 3 4 9 029674 MOV Cap Assy MAX42 43 70 3PH 4 5 0289085 Kit Powermax800 Cooling Fan Filter 4 7 RECOMMENDED SPARE PARTS POWERMAX800 200 230 400V Part Number Description Page Reference 003078 einen Relay 30A NO Mag Blwt QDisc Term 129068 orent ree Circuit Breaker SA 4Pole 480V W TC 129151 nantes Contactor SA Powermax800 008958 Fuse 1A 500V 10mmX38mm SLO 2 014208 Xfmr Powermax800 200 230 400 4 7 014211 Lett Xfmr Powermax800 200 230 400 Power 4 7 014186 Inductor Powermax800 2MH 50A 023922 Cable w Clamp PMX800 Work 20 027443 Fan 260CDM 120VAC 50 60
21. control board sends 12VDC to relay throwing power switch RL1 on power board LINE VOLTAGE LED will remain lit until soft 51 start signal is complete about 5 seconds after S1 is thrown J1 6 to J1 4 Shut down signal from power board Protection circuit on power 12 VDC normally board will go low 0 VDC to control board to shut down power 0 VDC if voltage too 9 96 supply if it detects over voltage high 3 26 powermaxa800 Service Manual MAINTENANCE A WARNING A SHOCK HAZARD Do not attempt repairs on the power board or control board Do not in any way cut away or remove the protective conformal coating from either board To do so will risk a short between the AC input circuit to the output circuit and may cause serious injury or death The power supply and PC boards are subjected to dielectric and insula tion resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty If questions or problems arise during servicing call the Hypertherm Technical Services department at 1 800 643 9878 1 E15 BLKWHT Figure 3 5 Back Side of Power Board Test Points powermaxa800 Service Manual 3 27 9 96 MAINTENANCE CONTROL BOARD Control Board LEDs There are 4 control board LEDs visible from the Powermax800 front panel There are 6
22. 3 4NPT 375 500 1 10 047180 Cord 2 5mm PVC HD21 22 7 3 1 129049 Electric Line Filter SA Powermax800 CE 1 11 041505 PCB Assy Powermax800 CE Line Filter 1 12 004692 Bracket Powermax800 CE EMI 1 13 008949 Terminal Board 3 Term 1 14 008279 Strain Relief PG9 5X 187 312 Nylon 15 123099 Cable Powermax800 Machine Interface 008201 Receptacle Shell 17 14 Reverse Sex 008186 Socket 24 20 AWG Type III Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Use 129136 to replace power cord rear panel if you have the machine interface option Available only with the machine interface option 5 8 powermax800 Service Manual 11 96 Panrs Lisr CE POWER SUPPLY 400V CE Figure 5 4 Powermax800 CE Rear 5 9 powermax800 Service Manual 9 96 Parts List CE PAC121TS Torch Assembly and 25 7 6 m Lead 083003 PAC121TS Torch Assembly and 50 15 2 m Lead 083004 Part Number Description 001288 Handle PAC121T 002244 adc eR Safety Trigger PAC121T 005094 eri es Switch Torch Pushbutton Electrode Air 020361 rette eet eret Ring Swirl 027254 de nna Trigger Spring PAC 121T 027460 2 11 nes Ring Gutcha 075340 e aT aa Screws P S 4 x 5 8 PH RND S B 120282 icti een Nozzle PAC121 50A Shield 1202
23. 5 029998 008905 IGBT Gate Drive SA Powermax800 2 Thermal Pad AL 370 134 2 5 5 041517 eene Assy Powermax800 Control 5 5 041532 PCB Assy Powermax800 ZB Power 5 5 5 7 129049 Electric Line Filter SA Powermax800 CE esee 5 9 047180 eem Cord 2 5mm PVC 21 22 73 5 9 028908 rame Kit Powermax800 Cooling Fan 5 7 See Section 4 Parts List for parts and components of non CE Powermax800 systems 5 14 powermax800 Service Manual 9 96 Section 6 WIRING DIAGRAMS In this section Powermax800 Electrical Schematic 208 240 480V 6 2 Powermax800 Electrical Schematic 200 230 400V 6 3 Powermax800 Electrical Schematic 400 6 4 Powermax800 Troubleshooting Schematic 1 012 6 5 Powermax800 Troubleshooting Schematic 2 of 2 6 6 Powermax800 CE Troubleshooting Schematic 1 of 2 6 7 Powermax800 CE Troubleshooting Schematic 2 of 2 6 8 powermaxa800 Service Manual 6 1 HEATSINK 029957 Ts Fab de ea tot ee EC ET aaa A 1 5 ut E lw WORK CONTACTOR 53 DORES EARTH GNO i gt NOZZLE PWR XFMR T2 1014210
24. 5 008904 Thermal Pad AL 340 180 1 6 008905 Thermal Pad AL 370 134 2 7 008906 Thermal Pad AL 380 100 2 8 009849 Resistor 20 Ohm 50W 596 NON IND 4 9 009850 Resistor 20 Ohm 25W 596 NON IND 4 10 009918 Capacitor 012UF 1000WV 1096 Poly 4 10A 009968 Capacitor 6800PF 1000WV 1096 Poly 4 11 005178 Temp Switch Opens 85 Closes 75 C TS1 1 12 0299981 IGBT Gate Drive SA Powermax800 Q1 1 13 0299981 IGBT Gate Drive SA Powermax800 Q2 1 14 109018T Diode 600V 100A UFast Recovery Dual D2 1 15 109018T Diode 600V 100A UFast Recovery Dual D3 1 16 1090191 Diode 1600V 100A 3PH Module D1 1 17 041472 PCB Assy Pwrmx800 Control 208 240 480V 1 008989 Fuse 500ma 250V IEC 127 3 Fast F1 F4 pcb fuse 4 17 041517 PCB Assy Pwrmx800 Control 200 230 400V 1 008989 Fuse 500ma 250V IEC 127 3 Fast F1 F4 pcb fuse 4 18 041532 PCB Assy Powermax800 ZB Power 1 19 014137 Current Sense Transformer 40A CS1 1 20 014137 Current Sense Transformer 40A CS2 1 21 008301 Fuse Holder 2P 30A 13 32 X 1 1 2 1 22 008809 Fuse 1A 600V 13 32 X 1 1 2 Slo F1 F2 2 22 008958 Fuse 1A 500V 10mmX38mm Slo F1 F2 2 029978 Heatsink SA Powermax800 PA Cont PCB Q3 23 004673 Heatsink Powermax800 PA Cont 24 008905 Thermal Pad AL 370 134 25 1090201 Diode 600V 100A Fast IGBT Module 26 041486 PCB Assy Powermax800 PA Cont 028905 Kit Powermax800 Machine Interface 208 240 480V 128035 Kit Powermax800 Machine Interface 200 230 400V 27 041494 PCB Assy Powermax800 Machine Interface Notes
25. ELECTROMAGNETIC COMPATIBILITY EMC INTRODUCTION The 400V CE power supply has been built in compliance with standard EN50199 To ensure that the equipment works in a compatible manner with other radio and electronic systems the equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity In such cases it may be necessary to use other measures to further reduce interference This plasma equipment should be used only in an industrial environment It may be difficult to ensure electromagnetic compatibility in a domestic environment INSTALLATION AND USE The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility ofthe 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 In other cases 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
26. PA Cont 028908 Kit Powermax800 Cooling Fan Filter 129100 Capacitor SA Powermax800 CE 1 Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Available only on power supplies with the pilot arc control option Available only as an option For power supplies with serial numbers before 800 010000 order 128108 power board kit to replace power board powermax800 Service Manual CE Parts Lisr POWER SUPPLY 400V CE NN PD ate S 8 2 4 TN NX d Figure 5 3 Powermax800 CE Bottom and Left Side 5 7 powermax800 Service Manual Panrs Lisr CE POWER SUPPLY 400V CE Note See Section 4 Parts List for parts and components of the non CE Powermax800 systems Rear Index No Part No Description Ref Desig Quantity 1 001503 Pnl Powermax800 Pwr Unit Plastic Rear 1 2 001522 Chassis Powermax800 Pwr Unit 1 3 129068 Circuit Breaker SA 4Pole 480V W TC S1 1 4 129151 Contactor SA Powermax800 CR1 1 029955 Manifold SA Powermax800 Pwr Unit 1 5 011072 Filter 20 Micron 1 8FPT 1 6 015285 Male Connector 1 8NPTX1 4Push in Tube 1 7 011079 Filter Element for 011072 Filter 1 129048 Linecord Panel SA Powermax800 CE Pwr Unit 1 8 001571 Panel Powermax800 Power Cord amp EMI 1 9 008782 Strain Relief
27. Sil Flat washer 257 500 062 Black Nylon Label PMX800 Pwr Unit Control Panel Cable w Clamp PMX800 Work 20 Strain Relief PG9 X 187 312 Nylon Manifold SA PMX800 Pwr Unit Pressure Switch 39 Psi 013 Orifice PS1 Sol Valve 100 1 8FPT 24VAC NC V1 Regulator 0 125 Psig 1 8FPT Nut Regulator Panel Mounting Female Elbow 1 8NPTX1 4Push in tube Male Elbow 1 8NPX1 4Push in tube Male Conn 1 8NPTX1 4Push in tube Nip 1 8 X CL Hex Brass Tee 1 8 Brass Nip 1 8 X 2 L Brass Press Gauge 160 1 5 1 8CBM Panel Tubing 1 4 OD 04W Blue Nylon Harness PMX800 Power Unit Pot 250 Ohm 1W 1096 1T Cerm P1 Recept SA PMX800 Pwr Unit Quick Disc Locknut 42 43 Quick Disc Recept Socket MS Cont Female Elbow 1 8NPTX1 4Push in tube Flat Washer 1 2 500 1 50 125 Nylon VND mm nn nm nm nm Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only powermax800 Service Manual Panrs Lisr CE POWER SUPPLY 400V CE Figure 5 1 Powermax800 CE Front 5 3 powermax800 Service Manual 7 97 Panrs Lisr CE POWER SUPPLY 400V CE Note See Section 4 Parts List for parts and components of the non CE Powermax800 Top and Right Side Index No Part No Description Ref Desig Quantity 1 001521 Pnl Powermax800 Pwr Unit Center 1 2 003078 Relay 30A NO Mag B
28. bon contact m tal m tal Ne pas fixer le c ble de retour la partie de la pi ce qui doit se d tacher Table de travail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s Alimentation S assurer que le fil de terre du cordon d alimentation est connect la terre dans le coffret du sectionneur S il est n cessaire de brancher le cordon d alimentation la source de courant lors de l installation du syst me s assurer que le fil de terre est correctement branch Placer tout d abord le fil de terre du cordon d alimentation sur le plot de mise la terre puis placer les autres fils de terre par dessus Bien serrer l crou de retenue S assurer que toutes les connexions sont bien serr es pour viter la surchauffe HYPERTHERM Syst mes plasma 1a 3 4 9 99 S CURIT S CURIT DES BOUTEILLES DE GAZ COMPRIM Ne jamais lubrifier les robinets des bouteilles ou les r gulateurs avec de l huile ou de la graisse Utiliser uniquement les bouteilles r gulateurs tuyaux et accessoires appropri s et con us pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz contenu dans chaque tuyau Se r f rer aux codes locaux ou nationaux en vigueur LES BOUTEIL
29. 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 XX 2 5000 0 550 Air Filter 50 202040 5555 0000 10 E 5 gt E 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 powermaxa800 Service Manual 3 3 3 96 MAINTENANCE THEORY OF OPERATION General The Powermax800 is a multi voltage multi phase power supply The two inverter inputs are linked in parallel for 208 or 240V on the 208 240 480V units and for 200 or 230V on the 200 230 400V units The inverters are linked in series for 480V on the 208 240 480V units and for 400V on the 200 230 400V units The inverter links are located in the link box behind the rear panel at TB3 See Fig 3 3 The 400V CE power supply does not have a link box 2 S D EN 208 or 240V Links 208 240 480V units 480V Link on 208 240 480V
30. ees Inductor Powermax800 2MH 0 5 7 023922 Cable w Clamp PMX800 Work 20 5 3 027443 ree ao dessen Fan 260CDM 120 50 60HZ 5 7 005112 nn se Pressure Switch 39 Psi 013 Orifice 5 3 006054 Sol Valve 100 1 8FPT 24VAC sise 5 3 011072 1 2 Filter 20 Micron 5 9 Filter Element for 011072 Filter 2 5 9 Regulator 0 125 1 8FPT iii 5 3 022027 a eos Press Gauge 160 1 5 1 8CBM 5 3 129046 eate Heatsink SA Powermax800 CE Power Unit 5 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 5 5 109043 008947 Diode 1600V 30A 3PH Bridge Thermal 315 114 5 5 005178 sedens Temp Switch Opens 85 Closes 75 C sse 5 5 009849 008903 Resistor 20 Ohm 50W 5 NON IND 4 Thermal Pad AL 197 114 4 5 5 009850 008902 Resistor 20 Ohm 25W 5 NON IND 4 Theral Pad AL 103 108 4 5 5 009018 nene Capacitor 012UF 1000WV 10 Poly 4 5 5 009968 Capacitor 6800pF 1000MV 10 Poly 4 5
31. for damage or cracking of the cover Bare wiring can kill Do not use a system with a damaged power cord Replace a damaged power cord immediately Inspect the torch leads Replace if frayed or damaged Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process 01 97 HYPERTHERM Plasma Systems Electric Shock Prevention continued Before changing the torch parts disconnect the main power or unplug the power supply After changing torch parts and replacing the retaining cap plug in the power supply again Never bypass or shortcut the safety interlocks Before removing a power supply cover for maintenance disconnect the main power at the wall disconnect switch or unplug the power supply To avoid exposure to severe electrical hazard wait five minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply unit covers are in place Exposed power supply connections present a severe electrical hazard Explosion Prevention A WARNING Compressed Gas The plasma system uses compressed gas Observe proper precautions when handling and using compressed gas equipment and cylinders Do not use the plasma system if explosive dust or vapors may be present Do not cut pressurized cylinders or any closed container Ww z
32. les yeux des rayons ultraviolets et infrarouges de l arc Puissance des verres teint s Courant de l arc AWS U ISO 4850 Jusqu 100 A 8 11 100 200 10 11 12 200 400 12 13 Plus de 400 A N 14 N 14 Protection de la peau Porter des v tements de s curit pour se prot ger contre les br lures que peuvent causer les rayons ultraviolets les tincelles et le m tal br lant LES RAYONS DE L ARC PEUVENT BR LER LES YEUX ET LA PEAU Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles 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 Pr parer la zone de coupage afin de r duire la r verb ration et la transmission de la lumi re ultraviolette Peindre les murs et autres surfaces de couleur sombre pour r duire la r flexion de la lumi re Utiliser des crans et autres dispositifs de protection afin de prot ger les autres personnes de la lumi re et de la r verb ration Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux MISE LA MASSE ET LA TERRE Cable de retour Bien fixer le cable de retour ou de masse la pi ce couper ou la table de travail de facon assurer un
33. more LEDs that are visible only when the cover is removed See Figure 3 6 for location of LEDs 08 POWER Illuminates when power is applied 015 LINE VOLTAGE when the input voltage is out of limits This LED will remain on if the line voltage is too low and go on briefly before the power supply shuts down if the line voltage is too high Note LINE VOLTAGE LED always remains on for about 5 seconds after the power supply is turned on and before a soft start signal is sent from the control board to the power board The upper and lower range for line voltages are as follows Lower Limit Line Voltage Upper Limit 170VAC 200VAC 235VAC 178VAC 208VAC 239VAC Note To avoid performance 195VAC 230VAC 270VAC deterioration of the 204VAC 240VAC 276VAC Powermax800 input voltage 340VAC 400VAC 470VAC e 2 should be within 10 of the 408VAC 480VAC SS2VAC specified system line voltage 510VAC 600VAC 690VAC P y 9 setting D24 OVERCURRENT when CS1 or CS2 senses current above 70 amps 025 PILOT ARC RELAY Illuminates when pilot arc relay CR2 is energized 026 GAS SOLENOID Illuminates when gas solenoid is energized when GAS TEST switch is pressed or when plasma start is pressed 027 MAIN CONTACTOR Illuminates when contactor is energized following soft start 029 TEMP LED Remains off when temperature is within operating limits It llluminates when the thermostat in the power transformer opens
34. o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques Garder loin de soi et du m me c t du corps le c ble de retour et le faisceau de la torche Faire passer le faisceau de la torche le plus pr s possible du c ble de retour Ne pas s enrouler le faisceau de la torche ou le c ble de retour autour du corps e Se tenir le plus loin possible de la source de courant 1a 4 10 16 98 HYPERTHERM Syst mes plasma Section 2 DESCRIPTION amp SPECIFICATIONS In this section INTRODUCTION ERE SPECIFICATIONS vi ne SYMBOLS powerrmax800 Service Manual 2 1 9 96 DESCRIPTION amp SPECIFICATIONS INTRODUCTION The Powermax800 plasma cutting system uses an inverter power supply to provide a smooth DC output voltage producing excellent cut and gouge quality on mild steel stainless steel aluminum and other metals The Powermax800 power supply provides constant current output variable from 20 to 50 amps for optimum performance on all thicknesses of metal up to 1 2 inch 12 mm thick At 50 amps the Powermax800 can cut metals up to 3 4 inch 20 mm thick and will sever metals up to 1 inch 25 mm thick Air is the primary plasma gas providing low operating cost c
35. power supply is directly connected to a line disconnect box place line discon nect switch to OFF position In the U S use a lock out tag out proce dure until the service or maintenance work is complete In other coun tries follow appropriate local or national safety procedures If power is required for servicing be aware that dangerous voltages exist within the power supply which could cause serious injury or death If questions or problems arise during servicing call the Hypertherm Techni cal Services department at 1 800 643 9878 A WARNING A The aluminum heatsink on the power PC board is electrically live when the plasma is on In case of an electrical failure of the inverter circuit the heatsink may be live when the power is off SHOCK HAZARD The large electrolytic capacitors blue cased cylinders located on the power PC board store large amounts of energy in the form of electrical voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the PC board and on certain areas of the PC board Never discharge the capacitors with a screwdriver or other implement explosion property damage and or personal injury will result Wait at least 5 minutes after turning the power supply off before touching the PC board or capacitors If questions or problems arise during servicing call Hypertherm Technical Services at 1 800 643 9878 powermax800 Service Manual MAINTENANCE A WARNING A SHO
36. t Side ecc 4 4 Bottom and Lett Side dpt rud 4 6 212 E E A O 4 8 TS Torem ASsembly siiis aaa 4 10 PAC121MS Torch Assembly 4 11 Gonsutmable Parts fo Hate 4 12 Powermax800 Field Upgrade Kits and Optional Parts 4 13 Power Supplies 208 240 480 4 13 Power Supplies 200 230 400 4 13 Recommended Spare Parts Powermax800 208 240 480V 4 14 Recommended Spare Parts Powermax800 200 230 400V 4 14 powermaxa800 Service Manual 4 1 6 96 Parts List POWER SUPPLY 208 240 480V Note See Section 5 Parts List Front Index No 4 2 7 97 Notes Part No 001502 001522 004675 008965 075498 010917 023922 008279 029955 005112 006054 011073 011074 015282 015283 015285 015517 015540 015588 022027 046077 029956 009480 029962 004532 008606 015282 075362 400V CE for parts and 200 230 400V components of the 400V CE Powermax800 system Description Ref Desig Quantity 800 Pwr Unit Plastic Front Chassis PMX800 Pwr Unit Spacer PMX800 Pressure Gauge Knob 850 Dia 1 4 SFT BIk Sil Flat washer 257 500 062 Black Nylon Label PMX800 Pwr Unit Control Panel Cable w Clamp PMX800 Work 20 Strain Relief PG9 X 187 312 Nylon Manifold SA PMX800 Pwr Unit Pressure Switch 39 P
37. units and and 200 or 230V Links on 200 230 400V units 400V Link on 200 230 400V units Figure 3 3 Inverter Links Functional Description Refer to block diagram 3 4 Figure 3 3 and the system wiring diagram See Section 4 Parts List to identify system components referenced in this description AC power enters power switch S1 from terminal block TB1 The MOV and filter capacitor block provides spike and noise suppression A soft start is implemented via power board resistors R1 and R2 and relay RL1 and the main contactor CR1 Once the capacitors on the power board are charged up and incoming power is within limits the control board turns on the main contactor Diode bridge D1 rectifies the AC to DC The DC voltage is then supplied to the inverters Each inverter consists of several components an isolated gate bipolar transistor IGBT Q1 or Q2 a coil of the power transformer T2 a current sense transformer CS1 or CS2 and sections of the power board The inverters operate as a pulse width modulator controlled half bridge circuit The inverters are capacitor fed and transformer coupled switching at 20 KHZ The inverter outputs are connected in series and are rectified by output diodes D2 and D3 The output circuitry consists of a current sensor CS4 and transfer sensor CS3 located on the control board pilot arc relay CR2 and output inductor L1 The feedback loop operates as follows The amp adjust pot P1 is first set to the
38. up to 300 VDC are present at the rear of the power PCB The large electrolytic capacitors blue cased cylinders located on the front side of the power PC board store large amounts of energy in the form of electrical voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the PC board and on certain areas of the PC board Never discharge the capacitors with a screwdriver or other implement explosion property damage and or personal injury will result Wait at least 5 minutes after turning the power supply off before handling the PC board or capacitors If questions or problems arise during servicing call Hypertherm Technical Services at 1 800 643 9878 Use extreme caution when taking the voltage readings on the back of the power PCB see warning above Use an isolated or floating digital volt meter since high voltages are present The following table lists the test points their descriptions and values Refer also to Figure 3 5 to locate test points Power Board Test Points Test Point Description Value E1 to High voltage power Left Inverter 300VDC E14 to One half of High voltage power Left Inverter 150VDC E4 to E5 High voltage power Right Inverter 300VDC E15 to E5 One half of High voltage power Right Inverter 150VDC J1 5 to J1 4 Soft start signal from control PCB After incoming voltage is 12VDC 5 sec after accepted by control board
39. 574 Extended 9 _ 120305 op Consumable Spare Parts Kit 028904 Mach Consumable Spare Parts Kit 128030 Part Number Description Qty Part Number Description Qty Box Consumable Parts 1 Box Consumable Parts 1 Electrode 3 Electrode 4 Electrode Extended 1 Electrode Extended 2 Nozzle 50A Shielded 3 Nozzle 50A Shielded 2 Nozzle 50A Gouging 1 Nozzle 40A Shielded 2 Nozzle Pipe Saddle Extended 1 Nozzle Pipe Saddle Extended 2 Shield T torch 1 Shield M torch 1 Shield Gouging 1 Deflector 1 Deflector 1 O Ring 3 O Ring 3 Nipple 1 8 NPT QDisc Steel 1 Nipple 1 8 NPT QDisc Steel 1 Bushing Reducer 1 4 X 1 8 Brass 1 Bushing Reducer 1 4 X 1 8 Brass 1 Reducer 1 4 FPT X 1 8 NPT Brass 1 Reducer 1 4 FPT X 1 8 NPT Brass 1 Lubricant Silicone 1 4 Oz Tube 1 Lubricant Silicone 1 4 Oz Tube 1 4 12 powermax800 Service Manual 7 99 Parts List POWERMAX800 FIELD UPGRADE KITS AND OPTIONAL PARTS Part Number Description 028714 ete On Off Pendant w Lead 25 ft 7 6 m Also comes standard with most machine torch system configurations See note below 128061 nene ee On Off Pendant w Lead 50 ft 15 2 m 128062 On Off Pendant w Lead 75 ft 23 028864 2 ETT Kit Powermax800 Pwr Unit Wheels 028898 eats Pilot Arc Controller Kit 028905 Machine Interface Ki
40. 83 nen Shield PAC121 50A 120301 re Cap Retaining 120556 Torch Main Body w Switch PAC121T 044019 items O Ring BUNA 90Duro 614X 070 12900 1 S rm ne Torch Lead 25 ft 7 6 m T290027 Torch Lead 50 ft 15 2 m 044009 2 2 4 1 Quick Disconnect O Ring not shown i Used only in 083003 Used only in 083004 Note See page 5 12 for detail of consumable parts Torch Torch Lead Handle Pushbutton 129001 25 7 63 m 001288 t Switch 005094 Ring 027466 Trigger Spring 027254 Safety Trigger 002244 001288 Torch Main Body w Switch 120556 Screw 5 044016 075340 Figure 5 5 PAC121TS Torch Assembly and Leads 5 10 powermax800 Service Manual Panrs Lisr CE PAC121MS Torch Assembly and 14 ft 4 3 m Lead 083049 w pigtail 083054 no pigtail PAC121MS Torch Assembly and 25 ft 7 6 m Lead 083011 w pigtail 083056 no pigtail PAC121MS Torch Assembly and 35 ft 10 6 m Lead 083044 w pigtail 083057 no pigtail PAC121MS Torch Assembly and 50 ft 15 2 m Lead 083012 w pigtail 083058 no pigtail Part Number Description 020351 cereis Electrode 020361 Ring Swirl 020559 2 manettes Sleeve Machine Torch PAC121M 020620 Sleeve Torch Position PAC121M 028923200000 Seven Torch Lead w pigtail 14 ft 4 3 m 028918
41. A logic high 12V indicates that the inverter is on TP8 Transfer latch sig nal A logic high 12V indicates that unit is in transferred mode TP9 Temp OK signal A logic high 12V indicates that all temperatures are OK TP10 Continuous PA threshold voltage Set to 3 55V by P3 TP11 7 0V TP15 Error amplifier reference voltage During inverter operation this signal is 1 915V at 50A current setting and 75V at 20A current setting TP16 Error amplifier output voltage TP17 Reference voltage 2 50V TP18 Output current value signal 38 3mv amp TP19 Wiper voltage 2 5V at 50A current setting and 1 00V at 20A current setting TP20 GND TP21 Buffered inverted capacitor feed version of pulse width modulator B signal TP22 Buffered inverted version of pulse width modulator A signal Fuses F1 F2 Cap sensor circuit protection 5A see Parts List for part number and specifications F3 F4 0 0 biki Ig 3790030009000 3 93 0000 015 ep ENTE E mg D zum 1 000 000008 0 hern paol m USO Em D35 ot E 001 see 111 Deog og 00000075 Sme 02 VIT 1 0000 henson 0 om occi ee Start circuit protection
42. Assy MAX42 43 70 3PH 029674 028908 4 14 powermax800 Service Manual 9 96 Note See Section 5 Parts List 400V CE for parts and components of the 400V CE Powermax800 system Section5 PARTS LIST CE In this section Power Supply 400V rrt etn Dope 5 2 5 2 MOP ANG SIC ee 5 4 Bottom and Left Side usce siae Ld ui nn 5 6 eL a a attente 5 8 PAGCT21TTS TOPEHASSOMDIY dues paies chers eer MEER nes 5 10 PAC121MS Torch Assembly diu nan sn oven 5 11 Consumable Parts CE 5 12 Powermax800 Field Upgrade Kits and Optional 5 5 13 Power Supplies 400V CE 5 13 Recommended Spare Parts Powermax800 400V CE 5 14 powermaxa800 Service Manual 5 1 6 96 Panrs Lisr CE POWER SUPPLY 400V CE Note See Section 4 Parts List Front Index No 5 2 7 97 Notes Part No 001502 001522 004675 008965 075498 010917 023922 008279 029955 005112 006054 011073 011074 015282 015283 015285 015517 015540 015588 022027 046077 029956 009480 029962 004532 008606 015282 075362 for parts and components of the non CE Powermax800 systems Description Ref Desig Quantity 800 Pwr Unit Plastic Front Chassis PMX800 Pwr Unit Spacer PMX800 Pressure Gauge Knob 850 Dia 1 4 SFT BIk
43. CK HAZARD Do not attempt repairs on the power board or control board Do not in any way cut away or remove the protective conformal coating from either board To do so will risk a short between the AC input circuit to the output circuit and may cause serious injury or death The power supply and PC boards are subjected to dielectric and insula tion resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty If questions or problems arise during servicing call the Hypertherm Tech nical Services department at 1 800 643 9878 1 Set the Powermax800 power switch to off unplug the power cord and disconnect the gas supply see warnings 2 Remove the cover of the power supply by removing 22 securing screws 3 Visually inspect the inside of the power supply especially on the side with the power board see Figures 4 2 and 4 3 Look for broken or loose wiring connections burn and char marks damaged components etc Repair or replace as necessary Initial Resistance Checks 1 After visually inspecting the exterior and interior of the power supply always perform the initial resistance checks before applying power to the power supply If these checks are not performed prior to power up further damage to the power supply could result 2 Perform the initial resistanc
44. Cap Sensor Circuit later in this section Check connectors wires W94 and W95 and solder joints Repair as needed See also Torch Check Cap Sensor Circuit later in this section powermaxa800 Service Manual 3 19 9 96 MAINTENANCE From page 3 19 Unplug power cord Measure resistance of fan M1 Resistance Yes 208 240 480V units approx 190 ohms correct 200 230 400V units approx 130 ohms Check connectors amp No No wires between fan and No Replace M1 control board connector JP2 pins 12 To amp 14 page POWER ON Yes Yes 3 21 LED On Wires and Ke Yes connectors OK At control board connector JP2 check No Yes terminals 1 amp 2 for 24VAC and terminals 6 amp 7 for 27VAC Repair or replace as needed No Voltages Measure input line voltage at correct power switch S1 Single phase units between P1 amp P2 Three phase units between P1 amp P2 P2 amp P3 and P1 amp P3 Yes Replace control board Check main Voltage power coming Check wiring between T1 and correct into power control board If wiring is OK supply replace T1 Yes Measure input line voltage at control board connector JP2 pins 1 amp 2 for 24VAC JP2 pins 6 amp 7 for 27VAC JP2 pins 9 amp 11 for 120VAC Unplug power cord Measure resistances of fuses F1 amp F2 Meter indicates 0 ohms No Replace F1 and or F2 Voltages
45. Disconnect O Ring Removal and Replacement 3 36 SECTION 4 PARTS LIST vna idv E v v vu 4 1 Power Supply 208 240 480V 20 2 UAUT 4 2 2 5 Torch ASsembly 4 10 PAC121MS 2 Reese ata ster 4 11 Consumable Parts 4 12 Powermax800 Field Upgrade Kits and Optional Parts 4 13 Power Supplies 209 240 480V iiit ctus been tee terere bs cie bes 4 13 Power Supplies 200 230 400V retenir rien manner inner c Exe HE RAE use couse FEE RAE zo 4 13 Recommended Spare Parts Powermax800 208 240 480 4 14 Recommended Spare Parts Powermax800 200 230 400 4 14 powermax800 Service Manual iii TABLE OF CONTENTS SECTIONS PARTS LIST sooo corso od cc erasa gua aD corso cba ue M PSU 5 1 Power SUPDIV ipe EE 5 2 12115 22 RP Em 5 10 PAC121MS Torch Assembly M 5 11 Consumabl Parts CE Fete rie der em re en tue 5 12 Powermax800 Field Upgrade Kits and Optional Parts 5 13 Power Supplies 00 ED 5 13 Recommended Spare P
46. FER ALI I D42 PLASMA START ate imc rami lt 20000000 PMX800 CE TROUBLE SHOOTING SCH 6 7 oo 013 2 296 10F 2 Power Board Test Points E15 to E5 J1 5 to J1 4 J1 6 to J1 4 Soft start signal from control PCB After incoming voltage is accepted by control board contro board sends 12 VDC to relay on power board LINE VOLTAGE LED will remain lit until soft start signal is complete about 5 seconds after S1 is thrown Shut down signal from power board Protection circuit on power board will go low 0 VDC to control board to shut down power supply if it detects over voltage cocoon 1 6 an et E2 POWER PCB A WARNING A SHOCK HAZARD The terminals and J1 are accessible from the back side of the power PCB Use extreme caution when taking these readings Voltages up to 300 VDC are present at the rear of the power PCB The large electrolytic capacitors blue cased cylinders located on the front side of the power PC board store large amounts of energy in the form of electrical voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the PC board and on certain areas of the PC board Never discharge the capacitors with a screwdriver or other implement explosion property damage and or personal injury will result Wait at least 5 minutes af
47. LES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES 6 2 Les bouteilles de gaz contiennent du gaz haute pression Si une bouteille est endommag e elle peut exploser Manipuler et utiliser les bouteilles de gaz comprim conform ment aux codes locaux ou nationaux Ne jamais utiliser une bouteille qui n est pas plac e la verticale et bien assujettie Le capuchon de protection doit tre plac sur le robinet sauf si la bouteille est en cours d utilisation ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des cl s ou d autres outils pour d bloquer le robinet des bouteilles LE BRUIT PEUT PROVOQUER DES PROBLEMES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs Utiliser un casque de protection homologu lors de l utilisation du syst me plasma Pr venir les personnes aux alentours des risques encourus en cas d exposition au bruit e PACEMAKERS ET PROTHESES AUDITIVES x Les champs magn tiques produits par les courants a haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un m decin avant de s approcher d un lieu
48. Manual MAINTENANCE Three Phase Check 1 Set power switch S1 of OFF 0 Measure resistance between the conductors connected to link box terminal TB1 1 amp TB1 2 TB1 1 amp TB1 3 and TB1 2 amp TB1 3 on the plug of the power cord Do not use the ground pin on the plug as a measuring point Note On the 400V CE power supply there is no link box U U U U J elololo Tes Naan TB1 Meter Check power cord and indicates an power switch S1 Replace TB2 3A 20 faulty component Fig 4 4 TB1 2 4 1 1 10 Yes 4 Set power switch 51 to ON 1 Measure resistance Link Box Behind Rear Panel between the conductors on the plug of the power cord Do not use the ground pin on the plug as a measuring point The reading between TB1 1 amp TB1 2 is the resistance across the control transformer primary for the selected input voltage To page 3 12 Meter indicates open between L No TB1 1 amp TB1 3 and open between TB1 2 amp TB1 3 Yes Between To To TB1 1 amp TB1 2 does meter indicate page 3 13 page 3 12 18 ohms 200V Check 2 R No 20 ohms 208V Yes 22 ohms 230V 22 ohms 240V 56 ohms 400V 65 ohms 480V powermaxa800 Service Manual 3 11 3 97 MAINTENANCE From From page 3 11 page 3 11 L R No To page 3 13 Check 2 Indicates low ohms or short No
49. NSUMABLE PARTS CE Note See Section 4 Parts List Shielded for parts and components of the non CE Powermax800 systems Shields 120601 Retaining Cap amp 120301 Nozzles gt 120282 120602 Dh Swirl PAC121 120573 Torch 020361 lt D 620 94 Gouging Shield m 120608 120281 0 HO O Ring 044016 Figure 5 7 Consumable Parts CE Consumable Spare Parts Kit CE 128033 Part Number Description Quantity Box Consumable Parts 1 Electrode 3 Swirl Ring 1 Nozzle 50A Shielded 3 Nozzle 50A Gouging 1 Shield T torch 1 Shield M torch 1 Shield Gouging 1 Nipple 1 8 NPT QDisc Steel 1 Bushing Reducer 1 4 X 1 8 Brass 1 Reducer 1 4 FPT X 1 8 NPT Brass 1 Lubricant Silicone 1 4 Oz Tube 1 powermax800 Service Manual Panrs Lisr CE POWERMAX800 FIELD UPGRADE KITS AND OPTIONAL PARTS Part Number Description 028714 ees On Off Pendant w Lead 25 ft 7 6 m Also comes standard with most machine torch system configurations See note below 128061 nene ee On Off Pendant w Lead 50 ft 15 2 m 128062 wie ent On Off Pendant w Lead 75 ft 23 m 028864 ETT Kit Powermax800 Pwr Unit Wheels 028898 etm Pilot Arc Controller Kit 128036 Machine Interface Kit 400V 028907 Work Cable 50 15 2 m 028908 Cooling Fan Filter Ki
50. PAC121TS Torch Main Body Removal 3 32 Figure 3 8 121 5 Torch Switch Removal 3 33 Figure 3 9 PAC121MS Torch Assembly 3 35 Figure 3 10 Quick Disconnect O Ring Removal and 3 36 Figure 4 1 1 1 1 1 d kate tas 4 3 Figure 4 2 Powermax800 and Right Side iii 4 5 Figure 4 3 Powermax800 Bottom and Left Side 4 7 Figure 4 4 Powermax800 Rear 2 4 9 Figure 4 5 PAC121TS Torch Assembly and 4 10 Figure 4 6 PAC121MS Torch Assembly and nennen nre nnns 4 11 Figure 4 7 Consumable Parts 4 12 Figure 5 1 Powermax800 CE 5 3 Figure 5 2 Powermax800 CE Top and Right Side 5 5 Figure 5 3 Powermax800 Bottom and Left 5 7 Figure 5 4 Powermax800 CE Rear iii 5 9 Figure 5 5 PAC121TS Torch Assembly Leads 5 10 Figure 5 6 PAC121MS Torch Assembly and 5 11 Figure 5 7 Consumable Parts CE elite teen ed eeu eb ane eiae 5 12 Figure a 1 Aeration Manifold eire usine den creta de a do dee X VE ask a 1 iv powermax800 Service Manual 9 96 Section 1 SAFET
51. PCB 4 ALL TERMINALS PREFIXED WITH E ARE LOCATED ON POWER PCB PMX800 TROUBLE SHOOTING SCH 6 6 013 2 292 2 OF 2 dE WES DS ES Dh ESL Ld DE i oS do PE d ty tem Control Board Test Points egulated DC voltage pproximately 30VDC at nomi put voltage Peo OE CEE INV ON signal ______________ high 12V indicates that the inverter is on Transfer latch signal A logic high 12V indicates that unit is in transferred mode 2 OK sig hig d aa OUTPUT VOLTAGE SNUBBER 109 ELECTRODE WORK WHO NOZZLE MACHINE INTERFACE 8 START es 5 400v P 11 v FER o FAN 5 EE g3 aa d dj ins TIBIA 5 CORAN A 2 DEEE INA 4 CHEB PS TST see TEREE 120v TO 28 5 24V 27 120 45 Rees 12v SEXFER 5 KI 95 AVS 4579 Ave CONTROL 5 E LED FUNCTIONS ma bleh er lt 855 6 D8 POWER ON 08 00000000000 30 20 0000 LES D ES TE i D LINE VOLTAGE O Y ipn 7 D25 PILOT ARC RELAY Bi 200000 e 200000 pos gl i D27 MAIN CONTACTOR PRE 700 oe ia DS PRESSURE OK 000000000000 D38 ARC X
52. SHALL CONSTITUTE THE SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF ITS WARRANTY PATENT INDEMNITY Except only in cases of Products not manufactured by HYPERTHERM or manufactured by a person other than HYPERTHERM not in strict conformity with HYPERTHERM s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by HYPERTHERM HYPERTHERM agrees to indemnify protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because of the use in or about the construction or operation of Equipment or any design system formula combination article or material which infringes or alleges to infringe on any patent or other right Distributors shall notify HYPERTHERM promptly upon learning of any action or threatened action in connection with any such alleged infringement and each party may appoint its own counsel for any such action or threatened action DISCLAIMER OF OTHER WARRANTIES HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR OTHERS INCLUDING WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE EITHER EXPRESS OR IMPLIED EXCEPT AS PROVIDED HEREIN This warranty is in lieu of any and all warranties express or implied by law or otherwise and Distributors are not authorized
53. Torch Parts Removal and Replacement 3 32 Torch Main Body Removal and Replacement 3 32 Torch Switch Removal and 3 33 PAC121MS Torch Parts Removal and Replacement 3 34 ESS TIEREN MOINES 3 34 tS 3 34 Quick Disconnect O Ring Removal and Replacement 3 36 powermax800 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 121 trigger torch and PAC121M machine torch parts ROUTINE MAINTENANCE Bowl Draining Filter Element Cleaning Moisture coming out of the torch can cause the torch to sputter and hiss If there is moisture purge the lines If moisture builds up in the bowl of the filter at the rear of the power supply drain the bowl and clean the filter element 1 3 2 Shut the gas supply off and disconnect the gas supply hose from the filter assembly before proceeding Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl Gas supply hose disconnect Filter element
54. Y In this section About Notes lt Cautions and Warnings 1 1 Pressure 1 3 1 2 mei 1 3 Eye Protection sereia 1 2 Noise Protection 4 1 4 Skin Protection 1 2 Grounding 1 4 Toxic Fume Prevention 1 2 Input Power 1 4 Fire Prevention eee 1 2 Work Gans quid Orsi 1 4 Electric Shock Prevention 1 2 Work Table 1 4 Explosion Prevention 1 3 Safety Reminders 1 4 Compressed Gas Cylinders 1 3 Electronic Health Support Equipment 1 4 Before using this plasma arc system Each person who will operate this equipment perform service or maintenance or supervise its use must read the safety instructions and warnings in this manual and the labels on the equipment About Notes Cautions and Warnings Notes Throughout this manual useful information for operating the plasma system is presented in notes such as shown in this paragraph Cautions Information in bold type and surrounded by a box describes a situation that may cause damage to the plasma
55. al being cut acoustics and size of the cutting room distance from the torch and other factors acceptable noise levels as defined by national or local codes may be exceeded by your plasma system Always wear proper ear protection when cutting or gouging with the plasma system Grounding Input Power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply be sure to properly connect the power cord ground wire Conform to Canadian Standards Association CSA standards by placing the power cord ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating Work Cable Attach the work cable securely to the workpiece or the work table by making good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to a high quality earth ground in accordance with the U S National Electrical Code Article 250 Section H Grounding Electrode System or other appropriate national or local codes Safety Reminders Never bypass or shortcut the safety interlocks on any of the plasma system units Except in Hypertherm s largest mechanized systems all Hypertherm torches are designed with a safety interlock
56. amaged in any way Never attempt to lubricate a regulator with oil or grease A WARNING Hydrogen Detonation with Aluminum Cutting When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Installing an aeration manifold on the floor of the water table is an effective way to eliminate the possibility of hydrogen detonation when cutting aluminum Refer to the Appendix section of this manual for instructions on how to fabricate an aeration manifold Hoses Label and color code all gas hoses in order to clearly identify the type of gas in each hose Consult applicable national or local codes Never use the oxygen hose for any gas other than oxygen Examine hoses at regular intervals for leaks wear loose connections or other hazard Replace hose that is damaged in any way HYPERTHERM Plasma Systems 1 3 10 24 96 SAFETY Hoses continued Keep hose lengths to a minimum to prevent damage reduce pressure drop and to prevent possible flow restrictions Prevent kinking by laying out hoses as straight as possible between termination points Coil any excess hose and place it out of the way to prevent damage and to eliminate the danger of tripping Noise Protection The plasma cutting process can generate high levels of noise Depending on the arc current materi
57. an 225CFM 120VAC 50 60HZ M1 1 7 027443 Fan 260CDM 120VAC 50 60HZ M1 1 029957 Heatsink SA Powermax800 Power Unit 1 8 004721 Heatsink Powermax800 Power Unit 1 9 041532 PCB Assy Powermax800 ZB Power 1 029978 Heatsink SA Pwrmx800 PA Cont PCB Q3 10 004673 Heatsink Powermax800 PA Cont 11 028908 Kit Powermax800 Cooling Fan Filter Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Available only on power supplies with the pilot arc control option Available only as an option Used only on 208 240 480V power supplies Used only on 200 230 400V power supplies For power supplies with serial numbers before 800 010000 order 128108 power board kit to replace power board 4 6 powermax800 Service Manual 9 96 Parts List 200 230 400V POWER SUPPLY 208 240 480V PT e 5 WA AE 47 83 CCT Figure 4 3 Powermax800 Bottom and Left Side 4 7 powermax800 Service Manual 9 96 Parts List POWER SUPPLY 208 240 480V Note See Section 5 Parts List 400V CE for parts and 200 230 400V components of the 400V CE Powermax800 system Rear Index No Part No Description Ref Desig Quantity 1 001503 Pnl Powermax800 Pwr Unit Plastic Rear 1 2 001522 Chassis Powermax800 Pwr Unit 1 3 129068 Circuit Break
58. anifold to a shop air line Set a pressure regulator to obtain a steady stream of bubbles Aeration Manifold 5 e o o e o o o Distribution Lines e o o o o o e o o o e o o e oe o o o o Regulated air in Figure a 1 Aeration Manifold powermax800 Service Manual a 1 APPENDIX STANDARDS INDEX For further information concerning safety practices to be exercised with plasma arc cutting equipment please refer to the following publications 1 ANSI Standard Z49 1 Safety in Welding and Cutting obtainable from the American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 NIOSH Safety and Health in Arc Welding and Gas Welding and Cutting obtainable from the Superinten dent of Documents U S Government Printing Office Washington D C 20402 3 OSHA Safety and Health Standards 29FR 1910 obtainable from the U S Government Printing Office Washington D C 20402 4 ANSI Standard 287 1 Safe Practices for Occupation and Educational Eye and Face Protection obtain able from the American National Standards Institute 1430 Broadway New York NY 10018 5 ANSI Standard 241 1 Standard for Men s Safety Toe Footwear obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard 249 2 Fire Prevention the Use of Cutti
59. anual 3 23 MAINTENANCE From page 3 23 Yes Press amp hold GAS TEST switch S2 Adjust pressure regulator for 70 psi 4 8 bar indication dynamic on gauge Check JP4 sockets and control board pins 5 amp 6 Check wires W65 amp W66 Check gas 70 psi 4 8 bar d ipd Indicates 0 psi ynamic Yes solenoid V1 amp pressure regulator If no problems are found replace control PCB No Yes Ensure GAS TEST switch S2 has Check regulator amp been released Press torch start hoses for leaks Switch to fire pilot arc Unplug power supply Disconnect control board connector JP8 Measure resistance between JP8 Sockets 5 amp 6 while pressing torch start switch Pilot arc fires Check regulator amp hoses for leaks Yes Air coming See Torch To page 3 25 out of torch No Yes Check Start Circuit later in this section Check control board TP2 for 12V when torch start switch is pressed Disconnect torch lead and check pins 6 amp 7 of torch lead plug when torch start button is pressed See Torch Check Start Circuit later in this section Check wiring from power Check JP4 sockets supply quick disconnect and control board to control board JP8 pins 1 amp 2 Check wires W61 amp Relay CR2 W62 closes when Check pilot arc relay torch start CR2 Switch is pressed See Torch Check Start Circuit later in this section C
60. arts Powermax800 400V CE iii 5 14 SECTION6 WIRING DIAGRAMS 42 2 6 1 Powermax800 Electrical Schematic 208 240 480V is 6 2 Powermax800 Electrical Schematic 200 230 400V ii 6 3 Powermax800 Electrical Schematic 400V CE iii 6 4 Powermax800 Troubleshooting Schematic 1 of 2 6 5 Powermax800 Troubleshooting Schematic 2 of 2 in 6 6 Powermax800 CE Troubleshooting Schematic 1 of 2 6 7 Powermax800 CE Troubleshooting Schematic 2 of 2 nennen 6 8 APPENDIX A AERATION MANIFOLD FOR CUTTING ALUMINUM eee a 1 APPENDIX B STANDARDS 2 44 0 a 2 ILLUSTRATIONS Figure 2 1 Powermax800 Hand Plasma Cutting System nennen 2 2 Figure 2 2 Powermax800 Power Supply with Dimensions sese 2 3 Figure 2 3 121 5 Torch with Dimensions ss 2 4 Figure 2 4 121 5 Torch with Dimensions 2 4 Figure 2 5 S Mark Label 2 5 Figure 3 1 Filter ASSOMDIY iua cuneo eaaet esae LB erase Eod 3 2 Figure 3 2 Air Filter Removal 3 3 Figure 3 3 Inverter Links 3 4 Figure 3 4 Single Phase 240 or 208V Block 3 5 Figure 3 5 Back Side of Power Board Test Points 3 27 Figure 3 6 Control Board Test Points sisi 3 29 Figure 3 7
61. ation on duty cycle Ambient temperature duty Power supplies will operate between 14 and 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 Apparent Input Power S 10 4kVA U I Input Voltage U Input Current l 6 kw Output 208V 50A 240V 43A 480V 25A 16 60 Hz 208V 29A 240V 25A 480V 13A 3 60 Hz 200V 52A 230V 45A 400V 30A 1 50 60 Hz 200V 30A 230V 26A 400V 16A 3 50 60 Hz 400V CE 16A 36 50 60 Hz 600V 11A 36 60 Hz Dimensions and Weight Dept sine 23 1 590 WICH 10 4 260 mm without wheels 15 25 390 mm with wheels Height Mrs te times 19 6 500 mm without wheels 23 7 620 mm with wheels 27 7 700 mm for 600V power supply 23 1 Figure 2 2 Powermax800 Power Supply with Dimensions powermax800 Service Manual 2 3 6 96 DESCRIPTION amp SPECIFICATIONS Gas ees Gas Quality Ail einer aede Gas Quality Nitrogen Gas Inlet Pressure Gas ROW aene eee each tie cede Power Supply pressure regulator setting PAC121 50A TORCHES Maximum 50A Cutting Capacity PAC121TS M
62. aximum 50 Cutting Capacity PAC121MS Maximum 35A Cutting Capacity PAC121MS Maximum current at 50 duty cycle Gas BOW cose ei RE tette hi Gouging Capability metal removal rate Weight PAC121TS 2 Weight PAC121MS PAC121TS Hand Torch Assembly 65 pounds 30 kg without wheels 72 pounds 33 kg with wheels 128 pounds 58 kg for 600V power supply Air or Nitrogen Clean dry oil free xu 99 995 pure NUT 90 psi 6 2 bar 320 scfh 5 3 scfm at 90 psi 150 l min at 6 2 bar supplied to power supply pressure regulator am 70 psi 4 8 bar flowing TEN 3 4 20 mm 50 duty cycle E 3 8 10 mm 50 duty cycle Eus 1 4 6 mm 100 duty cycle i veia res 50 amps 320 scfh 5 3 scfm at 70 psi 150 l min at 4 8 bar ERIS 6 3 pounds 2 9 kg hr Weis 4 5 pounds 2 kg with 25 ft 7 6 m lead 7 pounds 3 2 kg with 50 ft 15 m lead po 7 pounds 3 2 kg with 25 ft 7 6 m lead 9 5 pounds 4 3 kg with 50 ft 15 m lead 8 72 i 8 50 9007000000000 nn Im 1 58 3 10 95 Figure 2 3 PAC121TS Torch with Dimensions PAC121MS Machine Torch Assembly 15 06 1 00 E 1 38 Figure 2 4 PAC121MS Torch with Dimensions 2 4 powermax800 Service Manual 10 96 DESCRIPTION amp SPECIFICATIONS MARK
63. btain able from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 15 ANSI Standard 788 2 Practices for Respiratory Protection obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 16 Canadian Electrical Code Part 1 Safety Standards for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Rexdale Ontario Canada M9W1R3 b 1 powermax800 Service Manual
64. desired value Current sensor CS4 measures the actual output current and compares it at the error amplifier with the user set current setting The error amplifier output is an analog indication of how wide the pulse width should be to maintain the current setting The error amplifier output is then fed to the pulse width modulator chip PWM The pulse width modulator sends the signal to the gate drive board transformers and the gate drive boards in turn drive the inverter IGBTs Q1 and Q2 3 4 powerrmax800 Service Manual 3 96 MAINTENANCE SEQUENCE OF OPERATION Shaded boxes represent operator action Clear boxes represent results from operator action System off After five seconds LINE VOLTAGE and TEMP LEDs turn off indicating line voltage and transformer temperatures are within operating limits Fan M1 operates and POWER and GAS PRESSURE LEDs light indicating system is ready for operation Gas solenoid valve V1 opens and gas flows Pilot arc relay CR1 closes and pilot arc starts Cutting arc transfers to workpiece Pilot arc relay CR1 opens and pilot arc stops Gas solenoid valve V1 opens to purge system and to allow setting of pressure Gas solenoid valve V1 closes Gas flow stops Gas solenoid VI closes and gas flow stops Power circuits ready Power circuits ready 3 6 powerrmax800 Service Manual MAINTENANCE TROUBLESHOOTING The troubleshooting procedures include th
65. drog ne et le m thane sont des gaz inflammables et potentiellement explosifs Conserver l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de m thane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasma d argon hydrog ne ou de m thane AVERTISSEMENT D tonation de l hydrog ne lors du coupage de l aluminium Lors du coupage de l aluminium sous l eau ou si l eau touche la partie inf rieure de la pi ce d aluminium de l hydrog ne libre peut s accumuler sous la pi ce couper et d tonner lors du coupage plasma Installer un collecteur d a ration au fond de la table eau afin d liminer les risques de d tonation de l hydrog ne Se r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration HYPERTHERM Syst mes plasma 1a 1 10 6 98 S CURIT Y e LES CHOCS ELECTRIQUES PEUVENT FATALS Toucher une pi ce lectrique sous tension peut provoquer Installer et mettre la terre l quipement selon les un choc lectrique fatal ou des br lures graves instructions du pr sent manuel et conform ment aux La mise en fonctionnement du syst me plasma ferme un codes lectriques locaux et nationaux circuit lectrique entre la torche et la pi ce couper La Inspecter fr quemment le cordon d alimentation primaire pi ce couper et tout autre l ment en contact a
66. e nitial Resistance Checks and the Corrective Maintenance Checks These procedures are presented in a flow diagram format The complexity of the circuits require that service technicians have a working knowledge of inverter power supply theory In addition to being technically qualified technicians must perform all testing with safety in mind If questions or problems arise during servicing call the Hypertherm Technical Services Department at 1 800 643 9878 Test Equipment Multimeter Troubleshooting Procedures Maintenance of the Powermax800 power supply consists of performing visual inspection and trouble shooting procedures Refer to the system wiring diagram when performing the checkout procedures e To locate power supply and torch components refer to Section 4 for 208 240 480V 200 230 400V power supplies and Section 5 for 400V CE power supplies After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power unit for proper operation Visual Inspection External 1 Inspect the outside of the power supply for damage to the cover and external components 2 Inspect the torch and the torch lead for damage powermaxa800 Service Manual 3 7 MAINTENANCE Vis 3 8 ual Inspection Internal A WARNING A SHOCK HAZARD Always turn off power and unplug cord from wall and wait 5 minutes before removing any cover of the power supply If
67. e checks beginning on the following page 3 After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power unit for proper operation powermaxa800 Service Manual 3 9 MAINTENANCE Single Phase Check 1 Set power switch S1 to OFF 0 Measure resistance between the conductors line and neutral on the plug of the power cord Do not use the ground conductor on the plug as a measuring point Check power cord and power Meter indicates an open No Switch S1 Replace faulty component Fig 4 4 Yes Set power switch S1 to ON 1 Measure resistance between the conductors line and neutral on the plug of the power cord This reading is the resistance across the control transformer primary for the selected input voltage 18 ohms 200V Yes 22 ohms 22 ohms 56 ohms 65 ohms To page 3 13 Check 2 Indicates low ohms or short Yes Isolate and check control transformer T1 power switch S1 input filter MOV1 capacitor C1 and associated wiring for shorts Repair problem and repeat check 3 10 3 97 Meter indicates 20 ohms 208V 230V 240V 400V 480V Indicates high ohms or infinity Isolate and check control transformer T1 power switch S1 fuses F1 and F2 and associated wiring for opens Repair problem and repeat check powermax800 Service
68. e immediate cutting area to a distance of at least 35 feet 10 m Quench freshly cut metal or allow metal to cool before handling it or bringing it into contact with combustible materials Never use a plasma system to cut containers with potentially flammable materials inside Such containers must be thoroughly cleaned prior to cutting Ventilate potentially flammable atmospheres before cutting with a plasma system When cutting with oxygen as the plasma gas an exhaust ventilation System is required Never operate the plasma system in an atmosphere which contains heavy concentrations of dust flammable gas or combustible liquid vapors unless properly vented Electric Shock Prevention A All Hypertherm plasma systems use high voltage up to 280 VDC to initiate the plasma arc Take the following precautions when operating the plasma system Wear insulated gloves and boots and keep body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Maintain proper insulation against electrical shock If you must work in or near a damp area use extreme caution Provide a wall mounted disconnect switch with properly sized fuses close to the power supply This switch allows the operator to turn the power supply off quickly in an emergency situation Conform to all local electrical codes for primary wiring sizes and types Inspect the primary power cord frequently
69. e key slot on power supply and push it in until the pins seat 11 Turn the connector securing ring 1 4 turn counterclockwise to ensure that the securing ring threads and the connector receptacle threads are aligned prior to tightening Turn the connector securing ring clockwise to tighten powermaxa800 Service Manual 3 35 9 96 MAINTENANCE QUICK DISCONNECT O RING REMOVAL AND REPLACEMENT The quick disconnect O ring on the PAC121 torch leads provides a tight seal between the quick disconnect plug and the power supply receptacle This O ring prevents plasma gas from leaking during cutting To remove and replace the O ring in the event of damage or wear proceed as follows and refer to Figure 3 10 1 2 3 36 9 96 Turn the Powermax800 power switch OFF 0 Unplug the power cable or set line disconnect switch to off and disconnect gas supply Unscrew and remove the torch lead quick disconnect plug from the receptacle on the power supply Remove the O ring from the quick disconnect as shown in Figure 3 10 using needle nose pliers tweezers etc Replace O ring Ensure it seats properly Quick Disconnect Power Gas Gland O Ring 044009 Figure 3 10 Quick Disconnect O Ring Removal and Replacement powermaxa800 Service Manual Section 4 PARTS LIST In this section Power Supply 208 240 480V 200 230 400 V aber Ope 4 2 ROME 4 2 Top and Rig
70. ended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty GENERAL Inc warrants that Products shall be free from defects in materials and workmanship under proper and normal use for which such Equipment is recommended for a period of two 2 years except only with respect to the Torch for which the warranty period shall be one 1 year from the date of its delivery to you HYPERTHERM at its sole option shall repair replace or adjust free of charge any Products covered by this warranty which shall be returned with HYPERTHERM s prior authorization which shall not be unreasonably withheld properly packed to HYPERTHERM s place of business Hanover New Hampshire all costs insurance and freight prepaid and which examination proves not to be free from defects in materials and workmanship HYPERTHERM shall not be liable for any repairs replacements or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with HYPERTHERM s written consent This warranty shall not apply to any Product which has been mishandled incorrectly installed modified or assembled by you or any other person HYPERTHERM shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable warranty period specified herein above THE FOREGO ING
71. er SA 4Pole 480V W TC S1 1 4 129151 Contactor SA Powermax800 CR1 1 029955 Manifold SA Powermax800 Pwr Unit 1 5 011072 Filter 20 Micron 1 8FPT 1 6 015285 Male Connector 1 8NPTX1 4Push in Tube 1 7 011079 Filter Element for 011072 Filter 1 029964 Linecord Panel SA Powermax800 208 240 480V 1 8 001506 Panel Powermax800 Power Cord 1 9 008228 Cord Grip 1NPT 690 990 2Screws 1 10 129114 Power Cord SA Powermax800 1 129055 Linecord Panel SA Powermax800 200 230 400V 1 8 001506 Panel Powermax800 Power Cord 1 9 008228 Cord Grip 1NPT 690 990 2Screws 1 10 129115 Power Cord SA Powermax800 200V 1 029982 Link Box SA Powermax800 208 240 480V 1 129058 Link Box SA Powermax800 200 230 400V 11 001500 Box Powermax800 Pwr Cord 1 12 008900 Terminal Board 4 Terminal with protector 1 13 008926 Terminal Board 4 Terminal with protector 2 1 14 008933 Terminal Board 3 Terminal with protector TB1 1 15 008279 Strain Relief PG9 5X 187 312 Nylon 16 123099 Cable Powermax800 Machine Interface 008201 Receptacle Shell 17 14 Reverse Sex 008186 Socket 24 20 AWG Type III Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Use 129134 to order power cord rear panel for 208 240 480V power supplies if you have the machine interface option Use 129135 to order power cord rear panel for 200 230 400V po
72. f unplug the power cable and disconnect the gas supply Disconnect the torch lead quick disconnect from the power supply 2 Remove the five screws that secure the handle halves together and remove handles from torch main body torch switch and safety trigger Fig 3 8 3 Remove the red wires attached to the pilot arc tab Fig 3 7 Note for step 4 Disconnect wires by pulling on terminals Do not pull on wires 4 Disconnect the two lead terminals blue wire in each terminal from the two white wires of the cap sensor microswitch Fig 3 7 5 Disconnect the plunger wire from the torch main body by holding the plunger nut with a 1 4 6mm wrench or nut driver and removing the plunger screw Fig 3 7 6 Disconnect the torch main body and torch lead gas fittings using 5 16 8mm and 7 16 11mm open end wrenches 7 Replace with the new torch main body by reversing these instructions Note When connecting the plunger wire be certain to keep the plunger wire terminal at the proper angle as shown in Fig 3 7 inset Tighten the plunger screw with 8 Ib in 9 kg cm of torque 8 Install the torch main body and torch switch back into handle Fig 3 8 Be certain that torch switch slides into position above safety trigger and that trigger movement activates the switch pushbutton and then releases While positioning the handle halves together be careful not to pinch any wires 9 Replace the five screws to secure the handle halves t
73. 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 notall 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 notbe 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 powermaxa800 Service Manual WARRANTY A WARNING A Genuine Hypertherm parts are the factory recomm
74. heck consumables and Repair or replace as replace nozzle if needed necessary No Repair wiring as needed 3 24 powerrmax800 Service Manual 9 96 MAINTENANCE From page 3 24 Yes Connect work clamp to workpiece Set AMPS control P1 to minimum 20 amps Depress torch start switch to transfer arc to workpiece Check TP1 of control board for 12V Arc transfers Yes Check that work clamp is making good metal to metal contact Replace consumables If arc does not Set AMPS control to maximum 50 2 Yes transfer after amps Depress torch start switch OK changing to transfer arc to workpiece to see consumables if cutting current is adjustable replace No control board Repair or replace work cable and clamp Replace AMPS control pot P1 If new pot Cutting current does not fix problem adjustable replace control board Yes Corrective maintenance checks complete powermaxa800 Service Manual 3 25 MAINTENANCE POWER BOARD The power board contains part of a soft start or in rush circuit an over voltage shut down circuit and the high voltage power circuits for left and right inverters Voltages can be taken at the rear of the power PCB to check these functions A WARNING A SHOCK HAZARD The E terminals and J1 are accessible from the back side of the power PCB Use extreme caution when taking these readings Voltages
75. intenance work is complete In other coun tries follow appropriate local or national safety procedures If power is required for servicing be aware that dangerous voltages exist within the power supply which could cause serious injury or death If questions or problems arise during servicing call the Hypertherm Techni cal Services department at 1 800 643 9878 A WARNING A The aluminum heatsink on the power PC board is electrically live when the plasma is on In case of an electrical failure of the inverter circuit the heatsink may be live when the power is off SHOCK HAZARD The large electrolytic capacitors blue cased cylinders located on the power PC board store large amounts of energy in the form of electrical voltage Even if the power is off dangerous voltages exist at the capacitor terminals on the PC board and on certain areas of the PC board Never discharge the capacitors with a screwdriver or other implement explosion property damage and or personal injury will result Wait at least 5 minutes after turning the power supply off before touching the PC board or capacitors If questions or problems arise during servicing call Hypertherm Technical Services at 1 800 643 9878 powermax800 Service Manual 3 17 MAINTENANCE A WARNING A SHOCK HAZARD Do not attempt repairs on the power board or control board Do not in any way cut away or remove the protective conformal coating from either board To do so will risk a
76. ion of the power supply from power up to cutting 3 18 powermax800 Service Manual MAINTENANCE Set power switch S1 to ON 1 Correct voltage links See label in linkbox and Powermax800 Operator Manual IM227 Section 3 Note 400V CE power supplies have no link box To age 3 20 pag No No Yes Power supply linked for proper line voltage LINE VOLTAGE LED lights briefly before shutdown 2 Yes At torch check that retaining cap is on tightly and that consumables are properly installed Loosen retaining cap and listen for cap sense microswitch to open click Tighten retaining cap and listen for switch to close Replace Power Board Is line voltage for 200V 235V Microswitch opens amp closes 208V gt 239V 230V gt 270V 240V gt 276V Control board 400V gt 470V 480V gt 552V replacement fix problem 600V gt 690V With retaining cap tightened disconnect connector JP8 at Control PCB Fig 4 2 Measure resistance between JP8 Sockets 9 amp 10 Ensure cap To sense microswitch is closed page 3 20 Yes Replace Control Board and repeat test Meter Disconnect torch lead Measure resistance indicates 0 ohms between pins 2 amp 8 of torch lead plug Yes Replace torch main body and switch or torch lead See also Torch Check Cap Sensor Circuit later in this section See Torch Check
77. lwt QDisc Term CR2 1 129046 Heatsink SA Powermax800 CE Power Unit 1 3 004721 Heatsink Powermax800 Pwr Unit 1 4 008947 Thermal Pad AL 315 114 1 5 008905 Thermal Pad AL 370 134 2 6 008906 Thermal Pad AL 380 100 2 7 009849 Resistor 20 Ohm 50W 596 NON IND 4 8 009850 Resistor 20 Ohm 25W 596 NON IND 4 9 009918 Capacitor 012uF 1000WV 10 Poly 4 9A 009968 Capacitor 6800pF 1000MV 10 Poly 4 10 005178 Temp Switch Opens 85 Closes 75 C TS1 1 11 0299981 IGBT Gate Drive SA Powermax800 Q1 1 12 0299981 IGBT Gate Drive SA Powermax800 Q2 1 13 1090181 Diode 600V 100A UFast Recovery Dual D2 1 14 109018T Diode 600V 100A UFast Recovery Dual D3 1 15 109043T Diode 1600V 30A 3PH Bridge Isol Bplr D1 1 16 041517 PCB Assy Powermax800 Control 1 008989 Fuse 500ma 250V IEC 127 3 Fast F1 F4 pcb fuse 4 17 041532 PCB Assy Powermax800 ZB Power 1 18 014137 Current Sense Transformer 40A CS1 1 19 014137 Current Sense Transformer 40A CS2 1 20 008301 Fuse Holder 2P 30A 13 32 X 1 1 2 1 21 008752 Fuse Block 3P 30A 600V 13 32X1 1 2 1 22 008958 Fuse 1A 500V 10mmX38mm Slo F1 F2 2 23 008959 Fuse 20A 500V 10mmX38mm Slo 3 029978 Heatsink SA Pwrmx800 PA Cont PCB Q3 24 004673 Heatsink Powermax800 PA Cont 25 008905 Thermal Pad AL 370 134 26 1090201 Diode 600V 100A Fast IGBT Module 27 041486 PCB Assy Pwermax800 PA Cont 128036 Kit Powermax800 Machine Interface 28 041494 PCB Assy Powermax800 Machine Interface Notes Bold part numbers and descriptions are subassemblies
78. n areas of J1 6 to 1 4 Shut down signal from power board Protection circuit on power 12 VOC normally the PC board Never discharge the capacitors with a screwdriver or other S Tk dct Mai Vn am 79029 cs implement explosion property damage and or personal injury will result Wait at least 5 minutes after turning the power supply off before handling the PC board or capacitors If questions or problems arise during ics servicing call Hypertherm Technical Services at 1 800 643 9878 1 35 INPUT FILTER MOV BLOCK M P 1 w32 ME v V y go 5 Py 19 5 ge ws wo m 8 7 15 E T ED wo lo 7 i V VV s SAFETY GND wo m wae ERU enr GND bn yum 4 EN 2 NOTES 1 THIS IS A TROUBLE SHOOTING REFERENCE SCHEMATIC WHICH MIC vas PERTAINS TO BOTH DOMESTIC AND MULTI VOLT INT L UNITS DIFFERENCES IN MULTI VOLT INT L UNITS VOLTAGES ARE IN meee SQUARE BRACKETS lt 2 VOLTAGE LINKING 208 200 208 200 TB3 1 TO TB3 2 AND TB3 3 TO TB3 4 240 250 2401250 TB3 1 TO TB3 2 AND TB3 3 TO TB3 4 gt cocoon 6 1 lt wis e ED eo 9 400 _ 480 400 85 2 TO 783 3 3 TRANSFORMER T2 IS SINGLE CORE DUAL SECTION TEX SHOWN SEPERATED FOR CLARITY POWER
79. n end wrenches Replacement 1 Remove the O ring from the replacement torch main body Caution Use caution when removing the O ring it can easily be damaged 2 Connect the torch main body to the torch lead gas fitting using open end wrenches 3 Connect the two lead terminals blue wire in each terminal to the two white wires of the cap sensor microswitch 4 Connectthe two lead terminals four white wires in each terminal to the two black plunger wires of the torch main body 3 34 powerrmax800 Service Manual 9 96 MAINTENANCE Cap Sensor Torch Red Microswitch Main Body Wires 2 Screw SEA SWR White Blue Torch Position Shield O Ring Screw 3 VS E Wires 2 Wires 2 Sleeve Torch Lead Retaining Sleeve Figure 3 9 PAC121MS Torch Assembly 5 Secure the red wires from the torch lead to the torch main body with screw 6 Position the torch sleeve onto the torch main body and secure it with the three screws 7 Use caution when installing the O ring onto the torch main body it can be easily damaged Lightly coat with silicone 8 Screw the torch position sleeve and the torch sleeve together 9 When the nozzle electrode and swirl ring are properly in place replace the retaining cap with shield When the retaining cap is tightened the microswitch will click indicating that the torch main body has been replaced correctly 10 Align the connector plug key on torch lead with the connector receptacl
80. ng and Welding Processes obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 Welding and Cutting Containers Which Have Held Combustibles obtainable from the American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 8 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 Standard 70 1978 National Electrical Code obtainable from the National Fire Protection Associa tion 470 Atlantic Avenue Boston MA 02210 10 Standard 518 Cutting and Welding Processes obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 11 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 12 CSA Standard W117 2 Code for Safety in Welding and Cutting obtainable from the Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada 13 NWSA booklet Welding Safety Bibliography obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWS F4 1 Recommended Safe Practices for Prepa ration for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances o
81. ogether Red White Wires 8 Wires 2 Pilot Arc Blue Torch Lead Tab Wires 2 Cap Sensor Microswitch White Wires 2 Plunger Terminal Plunger GEL Wire a EY Proper plunger Nut 0542 Screw terminal mounting T angle Torch Cap Sensor Main Body Microswitch Figure 3 7 PAC121TS Torch Main Body Removal 3 32 powermax800 Service Manual 12 97 MAINTENANCE Torch Switch Removal and Replacement To remove and replace the torch switch order the torch switch and two splices 074069 and refer to the following procedure and Figure 3 8 See page 4 10 for a complete torch parts list 1 Ensure the Powermax800 power switch is set to O off unplug the power cable and disconnect the gas supply Remove the five screws that secure the handle halves together Remove the torch switch from the handle Remove the torch switch by cutting the two splices at the torch lead violet wires Replace the torch switch by crimping the switch wires and the violet wires from the torch lead together with the splices Install the torch switch back into handle Be certain that torch switch slides into position above safety trigger and that trigger movement activates the switch pushbutton and then releases While positioning the handle halves together be careful not to pinch any wires Replace the five screws to secure the handle halves together Torch Switch Violet Trigge
82. oit tr s bien ventil e et que l op rateur porte un masque masque respiratoire homologu respiratoire Les rev tements et m taux contenant ces Ne pas proc der au coupage pr s d endroits o mati res peuvent produire des vapeurs toxiques lors du s effectuent le d graissage le nettoyage ou la coupage vaporisation Certains solvants chlor s se d composent Ne jamais couper de r cipients pouvant contenir des sous l effet des rayons ultraviolets et forment du mati res inflammables avant de les avoir vid s et phosg ne nettoy s correctement 1a 2 HYPERTHERM Systemes plasma 5 27 99 S CURIT Torches allumage instantan L arc plasma s allume imm diatement apr s que la torche Soit mise en marche L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de m tal pr s de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes Protection des yeux Les rayons de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d crans lat raux ou encore masque de soudure avec des verres teint s appropri s pour prot ger
83. om the power supply as possible 1 4 10 24 96 HYPERTHERM Plasma Systems Section 1a S CURIT IDENTIFIER LES CONSIGNES A DE SECURITE Les symboles indiqu s dans cette section sont utilis s pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce soit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et Suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE SECURITE Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non autoris es sur la machine peuvent engendrer des probl mes de s curit et raccourcir la dur e d utilisation de l quipement DANGER AVERTISSEMENT PR CAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSE MENT sont situ es sur la machine pour signaler certains dangers sp cifiques Les messages d AVERTISSEMENT pr c dent les ins
84. ombined with high speed performance Cylinder air or shop air can be used as long as it is clean dry and oil free When properly set and maintained the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality The Powermax800 can also cut with nitrogen when extended electrode life is a priority This service manual provides information for qualified service technicians to troubleshoot and repair the power supply and torch Sections 4 and 5 contain in depth parts lists of the Powermax800 systems This manual also provides a detailed list of safety practices so that the system can be safely tested and maintained READ THE SAFETY SECTION Section 1 FIRST The Powermax800 operator manual provides setup and daily operating instructions Figure 2 1 Powermax800 Hand Plasma Cutting System Single phase 208 240 480V power supply shown See Section 5 for part numbers and descriptions of other Powermax800 power supplies 2 2 powermax800 Service Manual DESCRIPTION amp SPECIFICATIONS SPECIFICATIONS Power Supply Rated Open Circuit Voltage U 300VDC Rated Output Current lp sise 20 50 amps Rated Output Voltage U 120VDC Duty Cycle X 40 50 1 50 U 120V 100 1 44 U 97V See data tag on power supply for more inform
85. ork clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle Power is on Power is off Volt amp curve drooping characteristic powermaxa00 Service Manual Section 3 MAINTENANCE In this section m 3 2 Routine Maintenance do dede ad Te Rr baee 3 2 Bowl Draining Filter Element Cleaning 3 2 Cooling Air Filter Removal Cleaning and Replacement 3 3 Theory or een 3 4 Sequence of Operation 3 6 TrOBDISSDOOU FG bota Mete 3 7 a 3 7 Troubleshooting 5 3 7 Visual Inspection External is Deere eterni 3 7 Visual Inspection Internal M ts 3 8 Initial Resistance Checks 3 9 Corrective Maintenance 3 17 Power ia a a 3 26 is Re 3 28 Control Board LEDS o Tirer 3 28 Control Board Test Points 3 29 TONE CMG CK cerca TTE 3 30 Cap Sensor Circuit Check 3 30 Start s trente nent es due 3 31 PAC121TS
86. ouvertures assez grandes Ne jamais faire fonctionner le syst me plasma sans que pour viter tout contact physique avec le travail ou le sol les capots de la source de courant ne soient en place S il s av re n cessaire de travailler dans ou pr s d un Les raccords expos s de la source de courant sont endroit humide proc der avec une extr me prudence extr mement dangereux Installer un sectionneur avec fusibles appropri s Lors de l installation des connexions attacher tout d abord proximit de la source de courant Ce dispositif permet la prise de terre appropri e l op rateur d arr ter rapidement la source de courant en Chaque syst me plasma Hypertherm est concu pour tre cas d urgence utilis uniquement avec des torches Hypertherm e En cas d utilisation d une table eau s assurer que cette sp cifiques Ne pas utiliser des torches inappropri es qui derni re est correctement mise la terre pourraient surchauffer et pr senter des risques pour la s curit LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES zb Le coupage peut produire des vapeurs et des gaz toxiques Ne pas couper des m taux peints ou contenant des qui r duisent le niveau d oxyg ne dans l air et peuvent mati res toxiques comme le zinc galvanis le plomb le provoquer des blessures voire la mort cadmium ou le b ryllum moins que la zone de travail Conserver le poste de coupage bien a r ou utiliser un S
87. over 110 C 230 F or if the heatsink becomes too hot over 85 C 185 F Overheating can be caused by exceeding the duty cycle rate D35 GAS PRESSURE Illuminates when incoming gas pressure sensed by PS1 is within operating limits over 39 psi 2 7 bar D38 ARC TRANSFER Illuminates when arc transfers to the workpiece 042 PLASMA START Illuminates when the torch start button is pushed or when start button is activated from the machine interface The control board also controls the sequence required to generate plasma 3 28 9 96 Turns on the inverter when the torch switch button is pressed After a short delay turns on the gas solenoid valve V1 to blow back the electrode Monitors the pilot arc for arc transfer Ramps the current control command from the pilot arc level 20 amps to the cut current selected by the operator Turns the inverter off if the arc transfer does not occur within 5 seconds Turns the power supply off when the retaining cap is loose or when line voltage is too high powermax800 Service Manual Control Board Test Points Test Point Description MAINTENANCE Value TP1 Transfer signal A logic high 12V indicates that the arc is transferred TP2 Start signal A logic high 12V indicates that the torch start switch is on TPS GND TP4 12V TP5 Unregulated DC voltage Approximately 30VDC at nominal input voltage TP6 18V TP7 INV ON signal
88. powermaxsoo Plasma Arc Cutting System Service Manual IM 228 P N 802280 for systems beginning with serial number 800 010000 Revision 4 December 1997 Hypertherm Inc P O Box 5010 Hanover New Hampshire 03755 5010 Tel 603 643 3441 Fax 603 643 5352 Copyright 1997 Hypertherm Inc All Rights Reserved HYPERTHERM and POWERMAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Offices Worldwide Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA Tel 603 643 3441 Main Office Fax 603 643 5352 All Departments Tel 800 643 9878 Technical Service Tel 800 737 2978 Customer Service Hypertherm Plasmatechnik GmbH Ohmstrasse 6 D 63477 Maintal Germany Tel 49 6181 94070 Fax 49 6181 940719 European Technical Support Organization ETSO Ohmstrasse 6 D 63477 Maintal Germany Tel 49 6181 94070 Fax 49 6181 940739 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm U K 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 Hypertherm France 10 All e de l Isara F 95000 Cergy Pontoise France Tel 33 1 34 24 03 05 Fax 33 1 34 25 09 64 Hypertherm Italy Via Stilicone 18 20154 Milan Italy Tel 39 2 34 53 22 11 Fax 39 2 34 53 20 18
89. r Handle gt Screw 5 Figure 3 8 PAC121TS Torch Switch Removal powermaxa800 Service Manual 3 33 12 97 MAINTENANCE PAC121MS TORCH PARTS REMOVAL AND REPLACEMENT Repair of the PAC121MS machine torch normally requires replacement of the torch main body and or the torch lead Order the torch main body with switch Refer to Figure 3 9 and perform the steps below See page 4 11 for a complete torch parts list Removal 1 Setthe Powermax800 power switch to O off unplug the power cable and disconnect the gas supply Disconnect the torch lead quick disconnect from the power supply 2 Unscrew the retaining cap and remove the remaining parts nozzle electrode and swirl ring 3 Remove the O ring from the torch main body 4 Remove the three screws securing the torch sleeve to the torch main body 5 Unscrew the torch position sleeve from the torch sleeve and slide it back out of the way 6 Remove the screw securing the red wires from the torch lead to the torch main body Note for steps 7 and 8 Disconnect wires by pulling on terminals Do not pull on wires 7 Disconnect the two lead terminals four white wires in each terminal from the two black plunger wire terminals of the torch main body 8 Disconnect the two lead terminals blue wire in each terminal from the two white wires of the cap sensor microswitch 9 Disconnect the torch main body and torch lead gas fitting using the 5 16 8 mm and 7 16 11 mm ope
90. r detail of consumable parts Torch Lead Torch Handle orc 129001 25 7 63 m Pushbutt 001288 22 129002 50 15 25 m 2 005094 Gutcha Ring CS 027466 Trigger Spring 027254 Safety Trigger 002244 001288 Torch Main S Body w Switch 120556 Screw 5 075340 Figure 4 5 PAC121TS Torch Assembly and Leads 4 10 powermax800 Service Manual Parts List PAC121MS Torch Assembly and 14 ft 4 3 m Lead 083049 w pigtail 083054 no pigtail PAC121MS Torch Assembly and 25 ft 7 6 m Lead 083011 w pigtail 083056 no pigtail PAC121MS Torch Assembly and 35 ft 10 6 m Lead 083044 w pigtail 083057 no pigtail PAC121MS Torch Assembly and 50 ft 15 2 m Lead 083012 w pigtail 083058 no pigtail Part Number Description 020351 Electrode 02036 ike rae etes Ring Swirl 020559 Sleeve Machine Torch PAC121M 020620 irte ME Sleeve Torch Position PAC121M 028923 ioni staat eit Torch Lead w pigtail 14 ft 4 3 m 028918 events Torch Lead w pigtail 25 ft 7 6 m 028926 Torch Lead w pigtail 35 ft 10 6 m 028919 nim Torch Lead w pigtail 50 ft 15 2 m 128123 ose aes Torch Lead no pigtail 14 ft 4 3 m 128125202 emnes Torch Lead no pigtail 25 ft 7 6 m 128126 iamen Torch Lead no pigtail 35 ft 10 6 m 128127 inis Torch Lead no pigtail 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown
91. short between the AC input circuit to the output circuit and may cause serious injury or death The power supply and PC boards are subjected to dielectric and insula tion resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty If questions or problems arise during servicing call the Hypertherm Tech nical Services department at 1 800 643 9878 If no problems were found during the initial resistance checks and the power supply still does not operate correctly perform the following corrective maintenance checks Note The corrective maintenance flow charts are best guess solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before purchasing a major replacement component check with Hypertherm s Technical Service group at 1 800 643 9878 or the nearest Hypertherm repair facility 1 Connect the torch lead to the power supply 2 Connect the power cord into the line voltage disconnect switch box or plug into a properly grounded outlet 3 Connectthe gas supply to the pressure regulator at the rear of the power supply 4 Perform the corrective maintenance checks starting on the following page 5 After the problem has been located and repaired refer to the Sequence of Operation in this section for the normal operat
92. si 013 Orifice PS1 Sol Valve 100 1 8FPT 24VAC NC V1 Regulator 0 125 Psig 1 8FPT Nut Regulator Panel Mounting Female Elbow 1 8NPTX1 4Push in tube Male Elbow 1 8NPX1 4Push in tube Male Conn 1 8NPTX1 4Push in tube Nip 1 8 X CL Hex Brass Tee 1 8 Brass Nip 1 8 X 2 L Brass Press Gauge 160 1 5 1 8CBM Panel Tubing 1 4 OD 04W Blue Nylon Harness PMX800 Power Unit Pot 250 Ohm 1W 1096 1T Cerm P1 Recept SA PMX800 Pwr Unit Quick Disc Locknut 42 43 Quick Disc Recept Socket MS Cont Female Elbow 1 8NPTX1 4Push in tube Flat Washer 1 2 500 1 50 125 Nylon VND mm nn nm nm Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only powermax800 Service Manual Parts List 200 230 400V POWER SUPPLY 208 240 480V Figure 4 1 Powermax800 Front 4 3 powermax800 Service Manual 7 97 Parts List POWER SUPPLY 208 240 480V Note See Section 5 Parts List 400V CE for parts and 200 230 400V components of the 400V CE Top and Right Side Powermax800 system Index No Part No Description Ref Desig Quantity 1 001521 Pnl Powermax800 Pwr Unit Center 1 2 003078 Relay 30A NO Mag Blwt QDisc Term CR2 1 3 029674 MOV Cap Assy MAX42 43 70 3PH MOV1 1 029957 Heatsink SA Powermax800 Power Unit 1 4 004721 Heatsink Powermax800 Pwr Unit 1
93. sure for 90 Ok psi 6 2bar Replace Yes Check hose from supply to regulator pressure regulator filter element and pressure regulator Replace as required Unplug power cord Reconnect wires W92 amp W93 to PS1 Check connections and Disconnect JP8 from control wiring between control board PCB Measure resistance JP8 and terminals on PS1 between JP8 sockets 7 amp 8 Replace control PCB 3 22 powermax800 Service Manual MAINTENANCE From page 3 22 Yes Replace temperature switch TS1 If TS1 opens again after replacement replace heat sink SA Unplug power cord Allow power supply to cool down to room temperature Plug in power cord and turn power supply on Disconnect temperature switch TS2 wires W88 amp W99 at power transformer T2 Measure resistance across wires coming TEMP from transformer LED remains Off Problem is either with transformer T2 heatsink SA control board or associated wiring Unplug power cord Allow power supply to cool down to room temperature Disconnect JP8 from control PCB Measure resistance between JP8 sockets 1 amp 2 and Replace transformer 3 amp 4 T2 Disconnect temperature Switch TS1 wires W86 amp W87 at heatsink SA Measure resistance across temperature switch Yes Temperature switches are functioning Problem is either with transformer T2 heatsink SA control board or associated wiring powermaxa800 Service M
94. system A A WARNINGS A Warnings describe situations that present a physical danger to the operator and advice to avoid or correct the situation Each type of warning includes applicable danger symbols such as a hand burn electrical shock fire explosion etc WARNING Instant On A WARNING Electric Shock Torches Instant on torches produce a plasma Never touch the torch body workpiece or the water in arc immediately after the torch switch a water table when operating the plasma system is pushed When using a water table be sure that it is correctly Always hold a hand torch away from connected to earth ground your body as a precaution against Operating the plasma system completes an electrical accidental torch firing Be aware of circuit between the torch and the workpiece and this hazard which has potential for anything touching the workpiece The workpiece is part serious bodily injury of the electrical circuit HYPERTHERM Plasma Systems 1 1 10 24 96 SAFETY Eye Protection Wear dark safety glasses or goggles with side shields or a welding helmet in accordance with applicable national or local codes to protect eyes against the plasma arc s ultraviolet and infrared rays Lens Shade Arc Current C AWS USA 150 4850 Up to 100 A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 13 Over 400 No 14 No 14 Replace the glasses goggles or helmet when the lens becomes pitted or broken
95. t 208 240 480V 128085 Machine Interface Kit 200 230 400V 028907 iine Work Cable 50 15 2 m 028908 mens Cooling Fan Filter Kit Powermax800 011079 Gas Filter Element 129019 Jumper Powermax800 Link Box 128092 ea Kit Powermax800 600V 008809 Fuse 1A 600V 13 32 X 1 1 2 Slo Used 208 240 480V power supplies 008958 Fuse 1A 500V 10mm X 38mm Slo Used on 200 230 400V and 400V CE power supplies 023206 Cable Machine Interface 25 7 6 m Comes standard with machine torch system configurations and with machine interface kits POWER SUPPLIES 208 240 480V 10 36 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 083002 Hand No No 083015 Hand Yes No 083016 Machine No Yes 083017 Machine Yes Yes POWER SUPPLIES 200 230 400V 10 30 50 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 083030 Hand No No 083033 Hand Yes No 083036 Machine No Yes 083039 Machine Yes Yes Notes Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations See Section 5 Parts List 400V CE for parts and components of the 400V CE Powermax800 system powermax800 Service Manual 4 13 9 96 Parts List RECOMMENDED SPARE PARTS POWERMAX800 208 240 480V Part Number Description Page Reference
96. t Powermax800 011079 rentes Gas Filter Element 12909 utto rtt at Jumper Powermax800 Link Box 008958 Fuse 1A 500V 10mm X 38mm Slo Used on 200 230 400V and 400V CE power supplies 023200 iiie Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits POWER SUPPLIES 400V CE 36 50 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 083018 Hand No No 083021 Hand Yes No 083024 Machine No Yes 083027 Machine Yes Yes Notes Contact your distributor or call the nearest Hypertherm office for hand and machine torch System configurations See Section 4 Parts List for parts and components of non CE Powermax800 systems powermaxa800 Service Manual 5 13 9 96 Panrs Lisr CE RECOMMENDED SPARE PARTS POWERMAX800 400V Page Part Number Description Reference 003078 rennes Relay 30A NO Mag Blwt QDisc 5 5 129068 oe ees Circuit Breaker SA 4Pole 480V 5 9 129151 Contactor 800 5 9 008958 Fuse 1A 500V 10mm X 38mm 2 5 5 008959 Fuse 20A 500V 10mm X 38mm 5003 5 5 014209 eem Xfmr Powermax800 CE 400V Control VU 5 7 014211 ones Xfmr Powermax800 200 230 400 5 7 014186
97. ter turning the power supply off before handling the PC board or capacitors If questions or problems arise during servicing call Hypertherm Technical Services at 1 800 643 9878 NOTES PERTAINS TO THE PMXBOO CE UNIT 2 TRANSFORMER T2 IS SINGLE CORE DUAL SECTION SHOWN SEPERATED FOR CLARITY 3 ALL TERMINALS PREFIXED WITH E ARE LOCATED ON POWER PCB PMX800 CE TROUBLE SHOOTING SCH 013 2 296 2 OF 2 1 THIS IS TROUBLE SHOOTING REFERENCE SCHEMATIC WHICH 6 8 APPENDIX A AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM Introduction When plasma arc cutting aluminum at the water table surface or below water free hydrogen gas may be generated by the cutting process The high temperature of the plasma process causes disassociation of oxygen and hydrogen from the water in the water table The hot aluminum which has a high affinity for oxygen then combines with the oxygen leaving free hydrogen An effective means of avoiding free hydrogen buildup is to install an aeration manifold on the floor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Figure c 1 Make an Aeration Manifold with two inch 50 mm PVC tubing with one inch 25 mm Distribution Lines connected to it Drill 1 8 inch 3 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distribution lines and install the lines so that oxygen is delivered to all parts of the cutting area Connect the m
98. that prevents firing of the plasma arc when the retaining cap is loosened Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a potentially dangerous situation to the operator and any personnel in the area Hypertherm s warranty does not cover problems caused by the use of torches not made by Hypertherm Use only consumable parts and replacement parts made by Hypertherm Hypertherm s warranty does not cover problems caused by the use of parts not made by Hypertherm Never operate the plasma system with any of its covers not in place This would be hazardous to the operator and other people in the area and prevents the proper cooling of the equipment Electronic Health Support Equipment Plasma arc cutting and gouging systems create electric and magnetic fields that may interfere with the correct operation of electronic health support equipment such as pacemakers or hearing aids Any person who wears a pacemaker or hearing aid should consult a doctor before operating or being near any plasma system when it is in use To minimize exposure to EMF Keep both the work cable and the torch lead on one side of your body Keep your body from coming in between the torch lead and the work cable Route torch leads as close as possible to work cable Do not wrap the torch lead or work cable around your body Stay as far away fr
99. ting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking andstabilizing 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
100. to give any other warranty purporting to be binding upon HYPERTHERM upon resale of Products to their customers IN NO EVENT shall HYPER THERM be liable for incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any Equipment sold hereunder ii powermax800 Service Manual TABLE OF CONTENTS SECTION 1 SAFETY ins 1 1 About Notes Cautions amp Warnings sienne 1 2 ive TEE 1 2 Eye Protection ii 1 2 idunt 1 2 Toxic FUME Prevention Tode ctr eee bru basen an Ee tnt Einen in ee exam 1 2 Fire Prevention 1 2 Electric Shock 1 2 p 1 3 Noise MIRI ME 1 4 Grounding E EE 1 4 Safety 1 4 Electronic Health 2 eric rerit HE a 1 4 SECTION TA S CURIT in nan eee 1a 1 Au sujet des Notes Attention et avertissement sise 1a 1 Consignes de s curit 1a 2 Protection ORT A 1a 2
101. tructions d utilisation expliqu es dans ce manuel et signalent les risques de blessures ou de mort au cas o ces instructions ne seraient pas suivies correctement Les messages de PRECAUTION pr c dent les instructions d utilisation contenues dans ce manuel et signalent que le mat riel risque d tre endommag si les instructions ne sont pas suivies correctement Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur proximit loigner toute mati re inflammable une distance d au moins 10 m du poste de coupage Tremper le m tal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des mat riaux combustibles Ne jamais couper des r cipients pouvant contenir des mati res inflammables avant de les avoir vid s et nettoy s correctement A rer toute atmosph re potentiellement inflammable avant d utiliser un syst me plasma Lors de l utilisation d oxyg ne comme gaz plasma un syst me de ventilation par aspiration est n cessaire Pr vention des explosions Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s Ne pas couper de r cipients contenant des mati res combustibles LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT Risque d explosion Argon hydrog ne et m thane L hy
102. vec cette pour s assurer qu il n est ni endommag ni fendu pi ce font partie du circuit lectrique Remplacer imm diatement un cordon endommag Un Ne jamais toucher le corps de la torche la pi ce couper c ble d nud peut tuer ou l eau de la table eau pendant le fonctionnement du Inspecter et remplacer les cables de la torche qui sont syst me plasma us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du Pr vention des chocs lectriques coupage Laisser la pi ce couper en place ou sur la Tous les syst mes plasma Hypertherm utilisent des hautes table de travail le c ble de retour connect lors du tensions pour le coupage souvent de 200 400 V On doit coupage prendre les pr cautions suivantes quand on utilise le Avant de v rifier de nettoyer ou de remplacer les pi ces syst me plasma de la torche couper l alimentation ou d brancher la prise Porter des bottes et des gants isolants et garder le corps de courant et les v tements au sec Ne jamais contourner ou court circuiter les verrouillages Ne pas se tenir s asseoir ou se coucher sur une surface de s curit mouill e ni la toucher quand on utilise le syst me Avant d enlever le capot du syst me ou de la source de plasma courant couper l alimentation lectrique Attendre ensuite S isoler de la surface de travail et du sol en utilisant des 5 minutes pour que les condensateurs se d chargent tapis isolants secs ou des c
103. vice Manual 9 96 MAINTENANCE TORCH CHECK cont Start Circuit Check If the torch start trigger is pressed and there is no pilot arc there could be a problem with the torch start circuit A WARNING 2 Set the Powermax800 power switch to O off unplug the power cable and disconnect the gas supply Always wait 5 minutes before removing any cover of the power supply 1 Disconnect power and gas See warning above 2 Remove the power supply cover 3 Locate fuses F3 and F4 on the control board See Fig 3 6 4 Checkto see if the fuses are open If the fuses are open replace the torch the torch leads and the control board fuse s See Section 4 Parts List or Section 5 Parts List CE to order new components If the fuses are OK the gas supply is OK pressing the torch switch closes the connection between JP8 sockets 5 amp 6 and the torch does not start replace the control board If the fuses are OK the gas supply is OK pressing the torch switch does not close connection between JP8 sockets 5 amp 6 and the torch does not start replace the torch and the torch leads powermaxa800 Service Manual 3 31 9 96 MAINTENANCE PAC121TS TORCH PARTS REMOVAL AND REPLACEMENT Torch Main Body Removal and Replacement To remove and replace the torch main body order the torch main body with cap on sensor switch and refer to the following procedure and Figures 3 7 and 3 8 1 Set the Powermax800 power switch to of
104. wer supplies if you have the machine interface option Available only with the machine interface option Single phase cord with plug used on 208 240 480V systems 200 230 400V Three phase cord without plug 129115 not shown in Figure 4 4 4 8 powermax800 Service Manual 11 96 Parts List POWER SUPPLY 208 240 480V 200 230 400V 1 ore 200 230 400V Three phase power cord not shown in Figure 4 4 Figure 4 4 Powermax800 Rear 4 9 powermax800 Service Manual 9 96 Parts List PAC121TS Torch Assembly and 25 7 6 m Lead 083003 PAC121TS Torch Assembly and 50 15 2 m Lead 083004 Part Number Description 001288 Handle PAC121T 002244 adc eR Safety Trigger PAC121T 005094 eri es Switch Torch Pushbutton Electrode Air 020361 rette eet eret Ring Swirl 027254 de nna Trigger Spring PAC 121T 027460 2 11 nes Ring Gutcha 075340 e aT aa Screws P S 4 x 5 8 PH RND S B 120282 icti een Nozzle PAC121 50A Shield 120283 nen Shield PAC121 50A 120301 re Cap Retaining 120556 Torch Main Body w Switch PAC121T 044019 items O Ring BUNA 90Duro 614X 070 12900 1 S rm ne Torch Lead 25 ft 7 6 m T290027 Torch Lead 50 ft 15 2 m 044009 2 2 4 1 Quick Disconnect O Ring not shown Used only in 083003 Used only in 083004 Note See page 4 12 fo
105. x If your system uses hydrogen remember that this is a flammable gas that presents an explosion WARNING Hydrogen Explosion Hazard hazard Keep flames away from cylinders containing hydrogen mixtures and hoses that carry hydrogen mixtures Also keep flames and sparks away from the torch when using argon hydrogen as the plasma gas Compressed Gas Cylinders Handle and use compressed gas cylinders in accor dance with safety standards published by the U S Compressed Gas Association CGA American Weld ing Society AWS Canadian Standards Association CSA or applicable national or local codes Never use a cylinder that leaks or is physically damaged SAFETY Never use a cylinder that is not upright and secured in place Never move or transport a cylinder without its protective valve cover in place Never use a gas cylinder or its contents for any purpose other than that for which it is intended Never lubricate cylinder valves with oil or grease Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use hammers wrenches or other tools to open stuck cylinder valves Pressure Regulators Be certain that all pressure regulators are in proper working condition Never use a regulator for any gas other than that for which it is intended Never use a regulator that leaks creeps excessively or is physically d

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