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Powermax 1000 Service Manual, Revision 1

1. Current amps mes Mode switch adjustment A LT knob Pressure TTT gauge Indicator LEDs lia regulator Y Indicator LEDs Green power ON LED When illuminated indicates that power is applied to the system and the power switch is ON 1 Note The LED should illuminate when the power is ON Gas pressure LED Yellow When flashing indicates that the gas pressure is below 60 psig 4 1 bar for cutting or 40 psig gt 2 8 bar for gouging Green When illuminated indicates acceptable gas pressure for torch operation Note The LED should illuminate when the power is ON Yellow torch cap LED When illuminated indicates that the retaining cap is loose not installed Note Turn the power OFF correct this fault condition then turn ON the power to extinguish the LED Yellow temp LED E When illuminated indicates that the power supply s temperature is too hot L Red fault LED When illuminated indicates that a fault condition exists which prevents system
2. powerrmaxti000 Service Manual 3 21 MAINTENANCE Test 4 pilot arc IGBT Q8 Check the resistance of the gate drive circuit R108 R110 f the values are not 15 of the values shown below replace the power board PCB2 and the pilot arc IGBT Q8 f the values are correct check the pilot arc IGBT Q8 with an IGBT Tester If it fails replace the power board PCB2 and the pilot arc IGBT Q8 Gate drive resistors R108 1kQ R110 10kQ Pilot arc IGBT 3 22 powermax1000 Service Manual MAINTENANCE Test 5 inverter IGBT Q6 and PFC IGBT Q7 Check the resistance of the gate drive circuit f the values are not 25 of the values shown below replace the power board PCB2 and the appropriate IGBT f the values are correct check both IGBTs with an IGBT tester If one IGBT fails replace the power board PCB2 and the failed IGBT 09 R123 R122 o
3. D4 24 VDC R1 24 VDC D5 24 VDC R2 18 VDC D7 10 VDC R9 6 VDC D9 18 VDC R18 5 VDC Visually inspect for damage D17 2 5 VDC R26 18 VDC R55 18 VDC E o 2 j oO ro o R10 2 R2 i BO o bs CBS tesa NN RIS mm n j HE us Je Se 4 SE 7 OCs Tims LS Pon a COE p TES DEI We Dus 5 Ke ee TP1 D t 8 v Tess jum d 5 s R73 tI 27 iz VA wu g e ear Pa 9 _ _ a S gt aes e T G e 9 r CE CJ 3 24 powermax1000 Service Manual MAINTENANCE Test 7 torch stuck open TSO Check the resistance between the pilot arc IGBT Q8 and J17 The value should be less than 1000 Switch to Gas Test mode and check the resistance again The value should be greater than gt 1kQ If the value is less than lt 1000 all the time check resistance between pilot arc IGBT Q8 and J17 with the torch removed If the value is less than lt 1 00KO replace the pilot arc IGBT Q8 If the resistance is always greater than gt 1000 then the electrode nozzle circuit is open Check the w
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6. 1 2 Electric Shock Gan uu RR 1 3 Cutting Gan Produce Toxic u u yuy u uk te e gate catus aja kara E 1 3 A Plasma Arc Can Cause Injury and aa g d ja nas e eure 1 4 Arc Rays Can Burn Eyes and Skin iii 1 4 Grounding uuu s ee LPS Duden te 1 4 Compressed Gas Equipment Safety sisi 1 5 Gas Cylinders Can Explode If Damaged e i 1 5 Noise Damage a abu ae xe ra 1 5 Pacemaker and Hearing Aid Operation usines 1 5 A Plasma Arc Can Damage Frozen 7 1 5 Additional Safety 1 5 Warning e in 1 6 Hypertherm Plasma Systems 1 1 RECOGNIZE SAFETY INFORMATION symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine understand the potential for personal injury and follow the related instructions to avoid the hazard Read carelully all safety messages in this manual and FOLLOW SAFETY INSTRUCTIONS safety labels on your machine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the contr
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8. 1olid snonunuoo jou seop Burso3 5 5 19 jno euin pue 1esdde jou s op A ddns 18 od 1ndino uonnios 2 5141 3 17 powerrmaxti000 Service Manual MAINTENANCE Control board LEDs If the red Fault LED illuminates no yellow LEDs are illuminated and the green AC and Gas pressure LEDs remain illuminated check the LEDs on the re ar of the control board PCB3 Diagnostic LEDS P1 UP CPA i i MID NORMAL SDF ISELF DIAGNOSTICS FAILURE Blinking at 1 sec rate CURRENT DOWN GOUGE pmb te Uu m INVERTER INTERLOCK Visible for 10 sec after event ITORCH STUCK OPEN Visible for 10 sec after event SPARE GAS STATUS 45 50 55 60 65 70 75 80 85 Q O O O O O O Q O Problem The Start LED on the control board PCB3 and the Fault LED are illuminated Start and XFR LEDs on the control board PCB3 are illuminated Arc transfer SDF LED on the control board PCB3 and Fault LED are illuminated Start and IF LEDs on the control board PCB3 and the Fault
9. Unplug the power cord from the power receptacle 3 Open ETR door and route the lead through the end cap ETR door End cap 3 32 powermax1000 Service Manual MAINTENANCE 4 Align the mark on the strain relief with the mark on the end cap Quick release collar 6 Slide the quick release collar forward to lock in the gas fitting Verify that the gas fitting is secure powerrmaxti000 Service Manual 3 33 MAINTENANCE Filter element replacement Disconnect the electrical power and the gas supply Remove the filter bowls from both the new and old filters A Pull down and hold the black release tab B Rotate the filter bowl in either direction until it releases C Pull the filter bowl down to remove it Do not discard the o ring If the o ring shows signs of wear or otherwise needs replacement verify that you have the correct o ring for the filter Each filter has a label on the side of the filter body For AF30 filters use part number 011105 For NAF3000 filters use part number 011094 Use a screwdriver to remove the old filter element from the filter housing Then install the new filter element Note Do not allow the filter element to turn when loosening the screw 3 Re install the filter bowl o
10. Keep as far away from the power supply as possible ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 Hypertherm Plasma Systems 5 AWS F5 2 Hecommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 6 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 7 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada 8 NFPA Standard 51B Cutting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code National Fi
11. RES 3 24 Test 7 torch stuck open TSO iicp oda od 3 25 Test 8 plasma Stait oss E 3 26 Test torch SONSON 3 26 Test 10 gas Solenoid E 3 27 Test 11 incoming line voltage 3 27 Test 12 pressure switch 3 27 m ee 3 27 powermax1000 Service Manual 3 1 MAINTENANCE Test 14 ecd m 3 28 Test 15 flyback circuit failure sise 3 28 T60 hand torch connector pinouts and assembly 3 29 T60M machine torch connector pinouts and assembly 3 30 Component replacement p p 3 31 Power cord replacement 3 31 Toreh replacement u 3 32 Filter element replacement sise 3 34 Work cable 3 35 Capacitor replacement sise 3 36 Heat sink component replacement sas e pe inna a ah te Y Eae tiennent 3 37 3 2 powermax1000 Service Manual MAINTENANCE Controls and indicators ON 1 OFF O switch S1
12. 120926 120925 zl 5 60A 120930 120928 120931 O ring 058519 gt E 220325 0 0 5 5 0 _ _ i 120928 220329 120926 120925 N s 120979 i m 9 6 i oi j J 220404 220061 For use with CE systems n CE countries unshielded consumables may only be used in UA mechanized torch applications a Maintain torch to work distance of 5 approximately 3 16 inch 4 8 o Use an ohmic sensing cap when a ES 220061 compatible torch height controller is 5 installed O ring NM 0 058519 s sms us 40 O sl 120979 120928 220006 Unshielded 60A 0 i 120979 120928 220007 powermax1000 Service Manual 5 7 PARTS TORCH AND CONSUMABLES Recommended spare parts Part number 058519 027055 128644 128638 075586 002244 027254 128642 128564 128640 128639 128888 128889 083172 083175 Description Torch o ring Silicone lubricant 1 4 oz tube Kit T60 torch handle replacement Kit ETR connector replacement T60 torch handle screw 5 required T60 torch trigger assembly with spring Replacement trigger spring T60 Kit T60 start switch replacement Kit T60 hand torch main body replacement Kit machine torch main body replacement Kit T60 T60M torch cap sensor replacement Kit FineCut consumables Kit FineCut consumables CE T60 hand
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15. Se former la technique du coupage et lire les instructions avant de manipuler l quipement ou de proc der au coupage Ne pas retirer ou peindre recouvrir les tiquettes de s curit Hypertherm Syst mes plasma Secc on 1b SEGURIDAD En esta secci n Reconocimiento de informaci n de seguridad ss 1b 2 Siga las instrucciones de seguridad data dei 1b 2 Peligro Advertencia PrecauCciOn cari terrea aa 1b 2 Los cortes pueden provocar incendios o 1b 2 Prevenci n ante el fuego Prevenci n ante explosiones 1b 2 Peligro de explosi n arg n hidr geno y metano si 1b 2 Detonaci n de hidr geno con el corte de aluminio ss 1b 2 El choque el ctrico puede provocar la Muerte 1b 3 Prevenci n ante el electrochoque 16 3 Eos cortes pueden producir humos TOXICOS d 1b 3 El arco de plasma puede causar lesiones y quemaduras 1b 4 Antorchas de encendido mnstamt nen 1 1b 4 Los rayos del arco pueden producir quemaduras en los ojos y en la 1b 4 Protecci n para los ojos Protecci n para la piel re
16. Unplug the solenoid valve If the LEDs no longer flash replace the solenoid valve If the lights are still flashing plug the solenoid valve in again and perform the next step Unplug the CNC interface cable or the ON OFF pendant on the back of the machine If the lights are still flashing measure for 5 VDC on the power board R15 or J5 pin 2 to TP1 If the value is not a constant 5 VDC 0 5 disconnect the control board and measure for 5 VDC again If it is still not a constant 5 VDC replace the power board PCB2 If no problems are found while completing the previous steps replace the control board 3 28 powermax1000 Service Manual MAINTENANCE T60 hand torch connector pinouts and assembly J18 1 WHITE 2 Lacu re m b RP ROSE ELECTRODE 4 oo Z 5 RED 727 NOZZLE X D key 7 NOTE PIN 6 IS THE KEYING FEATURE FOR 60A AND 80A TORCHES 9 10 VIOLET START 11 ORANGE 12 BLUE CAP Red dot Blue rubber seal Pin 1 White wires plunger Pin 3 N Red wire nozzle Not used Pin 12 blue wire cap sensor Right handle _ AT ob i Spring Screws 5 Trigger powermax1000 Service Manual 3 29 MAINTENANCE T60M machine torch connector pinouts and assembly 1 WHITE 2
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18. 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 L hydrog 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 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 AVERTISSEMENT Risque d explosion argon hydrog ne et m thane 1a 2 2 12 01 Hypertherm Syst mes plasma S CURIT ds e Y Toucher une pi ce lectrique sous tension peut provoquer un choc lectrique fatal ou des br lures graves La mise en fonctionnement du syst me plasma ferme un circuit lectrique entre la torche et la pi ce couper La pi
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20. 4 F 2 is ud Inverter PFC R82 9940 R87 9940 R83 6 10 R56 4 12 R65 9950 R98 10 R75 6 10 R84 10 40 R96 40 PFC IGBT 07 powerrmaxti000 Service Manual 3 23 MAINTENANCE Test 6 flyback circuit DC power supply circuit 5 VDC 10 VDC 18 VDC and 24 VDC R20 0 759 Verify that the diodes listed below are not short circuited by checking their resistance approximately 2kQ Note Check voltage to ground TP1
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22. Equipment used for calibration or mea surement g Immunity of other equipment in the en vironment User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out Hypertherm Plasma Systems The size of the surrounding area to be considered will depend on the structure of the building and other activities that are tak ing place The surrounding area may extend beyond the boundaries of the premises METHODS OF REDUCING EMISSIONS Mains Supply Cutting equipment must be connected to the mains supply according to the manufactur 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 per manently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connect ed to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation
23. N a v i 5 o lt al 5 5 If gt 5 00 sec CPA timeout Reattach causes transfer 25 1ms 1 75A ms Setpoint CPA OPERATION NOTE UNIT IS ALREADY IN TRANSFER MODE powermax1000 Service Manual WIRING DIAGRAMS powermax1000 Service Manual DOMESTIC UNIT CORD T2 POWER TRANSFORMER YEL BRN BRN CE UNIT BLU BRN GRN YEI U1 ULN2003A 042188 RT7 60 0 20 109024 INSTALL JUMPER 108056 CE UNITS ONLY PREFLOW OUTPUT CONTROL BD am or 0 10uF 50V 009994 Q1 IRLZ44N aN 0220 OUTPUT 109223 CURRENT INDUCTOR DIAGNOSTIC LED S PILOT ARC IGBT up GEA SELF DIAGNOSTICS FAILURE O MID NORMAL BLINKING 1 SEC RATE 5 1V 109109 CURRENT mE GOUGE INVERTER INTERLOCK VISIBLE FOR 10 SEC AFTER EVENT SENSOR TORCH STUCK VISIBLE FOR 10 SEC AFTER EVENT Re WORK LEAD 009115 SP SPARE 40 POSITION RIBBON CABLE GAS STATUS 45 50 55 60 65 70 75 80 85 0000000000 0 C41 0 01uF 100VDC 009990 C52 SY 0 10uF 50V 009994 008924 087000 DOMESTIC 087007 CE 083169 DOMESTIC 083170 CE MACHINE INTERFACE INPUT VOLTAGE 200 600vac 230 400vac 200 600vac 230 400vac 5 1 3PH 3P
24. Wear correct ear protection DO NOT REMOVE THIS MARKING WARNING INSTANT START Arc starts instantly after torch switch is depressed 8 99 AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Couper l alimentation avant d effectuer le d pann ge Couper l alimentation avant de d monter la torche Utiliser exclusivement les torches indiqu es dans le manual d instructions Le raccordement au r seau de cette machine de coupage arc plasma doit tre comforme aux codes de l lectricit pertinents Le coupage arc plasma comporte des risques pour l utilisateur et les personnes se trouvant dans la zone de travail Avant le coupage lire et comprendre les instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area f ventilation is inadequate use an approved respirator WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the state of California to cause birth defects and in some cases cancer Heat splatter and sparks cause fire and burns Do not cut near combustible material Do not cut containers that have held combustibles Do not have on your person
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26. of torque 3 Install the power supply cover for C94 Screws for C98 Remove and install screws from power board side Remove and install capacitors from fan side Correct installation 3 36 powermax1000 Service Manual MAINTENANCE Heat sink component replacement 1 Install the components to the heat sink as shown below 2 Use new thermal pads on the temperature sensor 3 Use thermal grease on all components Apply a thin coat 3 mils or a thickness equivalent to a sheet of paper to the component install with screws and tighten to required torque 4 Re torque after 2 minutes Repeat until torque is maintained 5 Clean the excess grease from the heat sink Thermal grease 10cc Notes Apply thermal grease and torque to 8 in Ib 9 kg cm Apply thermal grease and torque to 20 in Ib 23 kg cm Apply thermal grease and torque to 35 in Ib 40 kg cm powermax1000 Service Manual 3 37 MAINTENANCE 3 38 powermax1000 Service Manual Section 4 PARTS POWER SUPPLY this section 4 2 Initerioririglit S u CE 4 3 Back interior LLL 4 4 InteriOr TAN u D 4 5 Heat sink assembly EE 4 6 Recommende
27. 128634 Kit 15 ft 4 6 m torch lead replacement 1 11 128633 Kit 25 ft 7 6 m torch lead replacement 1 12 128635 Kit 35 ft 10 7 m torch lead replacement 1 13 128641 Kit 50 ft 15 2 m torch lead replacement 1 14 128894 Kit 75 ft 22 5 m torch lead replacement 1 15 128638 Kit ETR connector replacement 1 128645 Kit 6 Torch mounting for reassembly after installation 1 Top assembly includes the following consumables See 760M consumable configurations for descriptions of consumable parts 120926 Electrode 1 120925 Swirl ring 1 120928 Retaining cap 1 120930 Shield 1 120931 Nozzle 1 5 4 powermax1000 Service Manual PARTS TORCH AND CONSUMABLES powermax1000 Service Manual 5 5 PARTS TORCH AND CONSUMABLES T60 consumable configurations Shield Retaining cap Nozzle Electrode Swirl ring O ring 9 058519 5 40 5 120929 120928 120932 5 i e 4 120926 120925 mc T 120929 120928 120931 O ring 0 058519 2 E iL 220325 5 0 0 M4 O 4 120928 220329 120926 220327 6 120979 use with systems O ring 058519 60 3 5 120977 120928 220059 120926 120925 5 6 powermax1000 Service Manual PARTS TORCH AND CONSUMABLES T60M consumable configurations Shield Retaining cap Nozzle Electrode Swirl ring a O ring 5 058519 40 4 5 NP S 2 0 0 N
28. Coloque en primer lugar el alambre de toma a tierra del cord n de alimentaci n primaria en el esp rrago luego coloque cualquier otro alambre de tierra sobre el conductor de tierra del cable Ajuste firmemente la tuerca de retenci n Aseg rese de que todas las conexiones el ctricas est n firmemente realizadas para evitar sobrecalentamientos 1b 4 4 11 03 HYPERTHERM Sistemas plasma SEGURIDAD SEGURIDAD DE LOS EQUIPOS DE GAS COMPRIMIDO Nunca lubrique reguladores o v lvulas de cilindros con aceite o grasa Utilice solamente cilindros reguladores mangueras y conectores de gas correctos que hayan sido dise ados para la aplicaci n espec fica Mantenga todo el equipo de gas comprimido y las piezas relacionadas en buen estado Coloque etiquetas y c digos de color en todas las mangueras de gas para identificar el tipo de gas que conduce cada una Consulte los c digos locales o nacionales aplicables LOS CILINDROS DE GAS PUEDEN S EXPLOTAR SI ESTAN DANADOS ES Uh Ba us Los cilindros de gas contienen gas bajo alta presi n Un cilindro da ado puede explotar Manipule y utilice los cilindros de gas comprimido de acuerdo con los c digos locales o nacionales aplicables No use nunca un cilindro que no est de pie y bien sujeto Mantenga la tapa de protecci n en su lugar encima de la v lvula excepto cuando el cilindro se encuentre en uso o conectado para ser
29. Gas cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accordance with applicable national or local codes Never use a cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing Use approved ear protection when using plasma system Warn others nearby about the noise hazard A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch PACEMAKER AND HEARING AID OPERATION and hearing aid operation can affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one side away from your Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your
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31. Section 1 Safety Recognize satety Information Deep 1 2 Follow Safety INSTUCIONS EE 1 2 Cutting Cause fire explosion s as ki aj sana Dex aaa da Mes 1 2 SHOCK CAN u u EUER 1 3 Cutting Can EE 1 3 plasma arc can cause injury and 2 1 uuu uu uuu err tede nee Ae 1 4 Arc rays can burn eyes and Skin ___ 1 4 eire uelim E 1 4 Compressed gas equipment safely mission aid d 1 5 Gas cylinders can explode if sienne 1 5 u lu uu bn cabernet ade nai 1 5 Pacemaker and hearing aid operation I sise 1 5 A plasma arc damage frozen eec 1 5 Geelen ed Ee EE 1 5 Vd Elsen He EMERICUS 1 6 Section 1a S curit Identifier les consignes de s curit DE Le SP ERE 1a 2 Suivre les instructions 1a 2 Danger Avertissement Pr ca tiOn aga g da ijas ratus aaa s E Ra 1 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Pr vention des incendies Pr vention des ss 1a 2 Risque d explosion argon hydrog ne
32. TTE 4 5 128707 Kit EI In PER dus CH EP 4 5 128691 ene Ner erts E sua sas 4 5 127198 Thermal grease 10 ss 4 6 128677 eee Kit Output diode Bridge oir da 4 6 LLO KE Kit 4 6 12870855 Kit PFC IGBT RE 4 6 128696 as a Kit Input diode Brldg 4 6 1286990 Kit Pilot are LEE RRE 4 6 powermax1000 Service Manual 4 7 PARTS POWER SUPPLY powermax1000 Service Manual Section 5 PARTS TORCH AND CONSUMABLES n this section 160 hand torch assembly sites uU n 5 2 T60M machine torch assembly sise 5 4 TOO consumable CONTIGUIALIONS M 5 6 T60M consumable configurations 5 7 Recommended spare Ut 5 8 powermax1000 Service Manual 5 1 PARTS TORCH AND CONSUMABLES T60 hand torch assembly Item Part number Description Quantity 083172 T60 hand torch assembly with 25 ft 7 6 m lead 083171 T60 hand torch assembly with 50 ft 15 2 m lead 083208 T60 hand torch assembly with 75 ft 22 5 m lead 1 128564 Kit T60 torch main body replacement 1 2 027889 Retaining clip 1 3 058519 O ring 1 4 128639 Kit Cap off sensor replacement 1 5 075571 Cap off sensor screws 6 128521 Kit T60 T60M torch head r
33. The cutting equipment should not be modified in any way except for those changes and adjust ments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Cutting Cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered However metallic compo nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equip ment 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 permitte
34. cas de dommages 1a 5 Le bruit peut provoquer des probl mes auditifs 1a 5 Pacemakers et proth ses auditives 99 1a 5 Un arc plasma peut endommager les tuyaux gege 1a 5 tig ette d SEcUNTE soenoe oaoa Era a a Ta a A a aeaa eea aa aeea eaa eE AERE TAARE 1a 6 Hypertherm Syst mes plasma 1a 1 2 12 01 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 AVERTI
35. correspondent aux num ros des images AVERTISSEMENT Protect yourself and others Read and under Pour votre protection et celle des autres lire et stand this marking comprendre ces consignes Disconnect power source before servicing Couper l alimentation avant d effectuer le d pann ge Disconnect power source before disassembly of Couper l alimentation avant de d monter la torche the torch Utiliser exclusivement les torches indiqu es dans le Use torches specified in the instruction manual manual d instructions This plasma cutting machine must be connected Le raccordement au r seau de cette machine de to power source in accordance with applicable coupage arc plasma doit tre comforme aux codes electrical codes de l lectricit pertinents Plasma arc cutting can be injurious to operator Le coupage arc plasma comporte des risques pour and persons in the work area Before operating l utilisateur et les personnes se trouvant dans la zone read and understand the manufacturer s instruc de travail Avant le coupage lire et comprendre les tions and know your employer s safety practices instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise Electric shock can kill Fumes and gases can injure your health Do not touch live electrical parts Keep your head out of the fumes Keep panels and covers in place Provide ventilation exhaust at the arc when the machine is co
36. instant neo El arco de plasma se enciende inmediatamente despu s de activarse el interruptor de la antorcha EL ARCO DE PLASMA PUEDE CAUSAR LESIONES QUEMADURAS El arco de plasma puede cortar a trav s de guantes y de la piel con rapidez Mant ngase alejado de la punta de la antorcha No sostenga el metal junto al trayecto de corte Nunca apunte la antorcha hacia Ud mismo o hacia otras personas Protecci n para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles ultravioleta e infrarrojo que pueden quemar los ojos y la piel Utilice protecci n para los ojos de conformidad con los c digos locales o nacionales aplicables Col quese protectores para los ojos gafas o anteojos protectores con protectores laterales y bien un casco de soldar con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco N mero del cristal Corriente del arco AWS EE UU ISO 4850 Hasta 100A No 8 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 M s de 400 A No 14 14 LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS OJOS Y EN LA PIEL Protecci n para la piel Vista ropa de protecci n para proteger la piel contra quemaduras causadas por la radiaci n ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro Roipa de combusti n retardada y
37. l2 200 208 VAC 1PH 40 230 240 VAC 1PH 50 X Ton Tbase 480 VAC 1PH 50 Ton time minutes 200 208 VAC 3PH 40 10 minutes 230 240 VAC 3PH 50 380 400 415 VAC 3PH 50 480 VAC 3PH 50 600 VAC 3PH 50 Operating temperature 14 to 104 F 10 to 40 C Rated AC phases PH and line frequency Hz PH Hz Standard model 1 3 50 60 CE model 3 50 60 Rated input voltage U1 rated input U1 Volts AC rms l1 Amps rms current and at rated output 200 208 VAC 1PH 50 32 Ue and l gt cutting only 230 240 VAC 1PH 44 31 480 VAC 1PH 22 15 5 200 208 VAC 3PH 30 19 11 VX used to determine 230 240 VAC 3PH 26 18 rating of power cord 380 400 415 VAC 3PH 15 10 5 480 12 8 5 600 VAC 3PH 11 8 Power factor U1 Volts AC rms Harmonic power factor Displacement power factor 200 208 VAC 1PH 0 99 0 99 230 240 VAC 1PH 0 99 0 99 480 VAC 1PH 0 91 0 99 200 208 VAC 3PH 0 94 0 99 230 240 VAC 3PH 0 94 0 99 380 400 415 VAC 3PH 0 94 0 99 480 0 94 0 99 600 0 80 0 99 Rsce short circuit ratio CE model only U1 Volts rms 400 153 230 97 This equipment conforms to 67000 3 72 provided that Asce min 153 at 400 3PH and 97 at 230 3PH IP code degree of protection provided by enclosure IP23CS IP International Protection 2 No ingress foreign objects 212 5mm 0 5 in 3 No h
38. not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Pilot arc can cause burns Keep the torch nozzle away from yourself and others when the switch is depressed Wear correct eye and body protection NE PAS ENLEVER CET AVIS AVERTISSEMENT AMORCAGE INSTANTAN L arc s amorce aussit t qu on enclenche l interrupteur de la torche 1b 6 2 12 01 2 1 2 2 3 1 3 2 3 3 4 1 4 2 4 3 5 1 Las chispas producidas corte pueden causar explosiones o incendios Mantenga los materiales inflamables lejos del lugar de corte Tenga a mano un extinguidor de incendios y aseg rese de que alguien est preparado para utilizarlo No corte dep sitos cerrados El arco de plasma puede causar quemaduras y lesiones Apague la fuente de energ a antes de desarmar la antorcha No sostenga el material junto al trayecto de corte Proteja su cuerpo completamente Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque Col quese guantes aislantes No utilice guantes da ados o mojados A slese de la pieza de trabajo y de la tierra Antes de trabajar en una m quina desconecte el enchufe de entrada o la potencia primaria La inhalaci n de los humos provenientes del rea de corte puede ser nociva para la salud Mantenga la cabe
39. oT shorted IGB Rocker Switch Collector iuh IGBT Tester red Emitter Gate black yellow Indicator LEDs and device tests Red fail LED When illuminated this LED indicates that the IGBT failed the test for an open IGBT when the switch is pressed to the right or for a shorted IGBT when the switch is pressed to the left Green pass LED VA When illuminated this LED indicates that the IGBT passed the test for an open IGBT when the switch is pressed to the right or for a shorted IGBT when the switch is pressed to the left Red low battery LED E When illuminated this LED indicates that the remaining voltage in the battery is insufficient to power the test circuitry Replace the battery Note The Hypertherm IGBT tester requires a minimum of 8V to properly power its circuitry IGBT test preparation Before testing with the Hypertherm IGBT tester connect the colored leads to the IGBT as shown below Before an IGBT can be tested it must be electrically isolated from all circuits If the IGBT is installed in a power supply remove the power board and any lead connections before testing powermax1000 Service Manual 3 9 MAINTENANCE Caution Failure to isolate the IGBT may result in false readings and or damage to the IGBT tester The illustrations below depict three common IGBT configurations Each con
40. of sensitivity In such cases it may be neces sary to use other measures to further reduce interference This plasma equipment is designed for use only in an industrial environment INSTALLATION AND USE The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electro magnetic disturbances are detected then it shall be the responsibility of the user to re solve the situation with the technical assis tance 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 ASSESSMENT OF AREA Before installing the equipment the user shall make an assessment of potential elec tromagnetic 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 equip ment 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 hear ing aids f
41. of the possibility of such damages LIABILITY CAP In no event shall Hypertherm s liability whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim INSURANCE At all times you will have and maintain insurance in such quantities and types and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products NATIONAL AND LOCAL CODES National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices TRANSFER OF RIGHTS You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Hypertherm Plasma Systems TABLE OF CONTENTS Electromagnetic i WE Cu u uu diets ii
42. operation Yellow low line voltage LED Ly When illuminated indicates that line voltage is below 170 VAC or above 680 VAC On CE units it can also indicate a missing phase powerrmaxti000 Service Manual 3 3 MAINTENANCE Theory of operation General Refer to the Functional description and Sequence of operation sections below and to Section 6 Wiring diagrams Functional description AC power enters the system through the power switch S1 to the input diode bridge D24 The voltage from the diode bridge supplies the Power Factor Correction PFC Boost Converter which provides a 750 VDC bus voltage The bus voltage then supplies voltage and current to the inverter and the flyback circuit power supply DC to DC converter on the power board PCB2 The power board provides noise suppression and spike protection A soft start is implemented via the power board resistor and relay K1 The PFC Boost Converter consists of an isolated gate bipolar transistor IGBT Q7 choke and control circuit It provides a 750 VDC bus voltage when the input AC voltage is between 170 and 540 VAC When the input voltage is above 540 VAC the bus voltage will rise to V 2 The inverter consists of an IGBT Q6 the power transformer T2 a current sense transformer and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit that is rectified by the output diode The output circuitry consists of 2
43. que cubra todas las partes expuestas Pantalones sin dobladillos para impedir que recojan chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar rea de corte Prepare el rea de corte para reducir la reflexi n y la transmisi n de la luz ultravioleta Pinte las paredes y dem s superficies con colores oscuros para reducir la reflexi n Utilice pantallas o barreras protectoras para proteger a los dem s de los destellos Advierta a los dem s que no debe mirarse el arco Utilice carteles o letreros SEGURIDAD DE TOMA A TIERRA Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra de conformidad con los c digos el ctricos nacionales o locales apropiados Potencia primaria de entrada Aseg rese de que el alambre de toma a tierra del cord n de alimentaci n est conectado al terminal de tierra en la caja del interruptor de corriente Sila instalaci n del sistema de plasma supone la conexi n del cord n de alimentaci n primaria a la fuente de energ a aseg rese de conectar correctamente el alambre de toma a tierra del cord n de alimentaci n primaria
44. torch assembly with 25 ft 7 6 m lead T60M machine torch assembly with 25 ft 7 6 m lead powermax1000 Service Manual 6 WIRING DIAGRAMS n this section Timing MAYAS e S 6 2 Gelee Ee 6 5 powerrmaxti000 Service Manual 6 1 510 SNIAYY HO 3153903 53903 ONI WH3HLN3dAH WOYA NOISSIWiid LNOHLIM SISOdYNd 1 75A ms 10 0sec Postflow 1 75A ms Digitized XFR signal valid Consumable Re Seat A8 alva duvHS 30 3383 38 LSNW Ltd 05 25 NOI1V2I88V3 9 1 SNOLDVM4 9350 38 LON AtlvL3lHdOtdd 500 IVWIDIO 14 SI DECH 197 MNDAQ 147 TIV INV SIHL 02 71 52 91 SDNVASTOL V08 09 W3H2S 2313 RE 2010 3uejsuo yuo 031312345 JSIMUSHLO SS3 INN Sc 9 09 0105 55 0 HN J8AOUEH 0105 08 LINN 303 NMOHS SINIYA I LNIYYND T 09 08 000 02900 COI CZ lt GO BOIS AYTI HDYOL SI 5002 N LINN v09
45. 22 5 m lead 2 4 powermax1000 Service Manual SPECIFICATIONS Dimensions T60 hand torch dimensions T60M machine torch dimensions 1 00 15 25 25 b 387 mm 1 H IET 2 03 52mm L A Go mm NEN k 35 mm 32 pitch 0 125 3 2 mm width 0 125 3 2 mm height powerrmaxti000 Service Manual 2 5 SPECIFICATIONS Symbols and markings S MARK The 5 mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The hand torches must have shielded consumable parts to maintain S mark compliance IEC symbols The following symbols may appear on the power supply data plate control labels and switches Direct current DC CGO BES inverter based power source au Alternating current AC Plasma torch in the TEST 7 position cooling and cutting D agp gas exiting nozzle _NF Plasma torch cutting and gouging T Power is 1D AC input power connection O Power is off The terminal for the external Volt amp curve drooping protective earth conductor characteristic 2 6 powermax1000 Service Manual Section 3 In this section Controls 5 M 3 3 MR S 3 3 Theory of operatio
46. 3 ELECTRODE gt 5 6 WHITE SE 7 8 RED 9 ORANGE 10 11 ORANGE 12 BLUE Red rubber seal Pin 1 White wires plunger Pin 3 Orange wire cap sensor Strain relief Positioning sleeve Mounting Z S sleeve A Screws 3 30 powermax1000 Service Manual MAINTENANCE Component replacement ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See warnings on page 3 7 before proceeding Power cord replacement Disconnect the electrical power and the gas supply before removing the old power cord 1 Insert the new power cord through the strain relief Install the power cord connections where shown 2 3 Tighten the strain relief onto the power cord 4 Install the power supply cover 5 Reconnect the electrical power and the gas supply L1 L2 Ground PE Ground PE Single phase Three phase Standard unit standard unit cEunt TT Sue or Grey Y sem w powerrmaxti000 Service Manual 3 31 MAINTENANCE Torch replacement Turn OFF O the power switch
47. D25 N sech Reference Section 3 Heat sink component replacement for torque specifications powermax1000 Service Manual PARTS POWER SUPPLY Recommended spare parts Part number Description Page reference 008965 Current adjustment knob ad a rokai 4 2 128701 e Kit Control board domestic 4 3 128702 av in Kit Control board CE iiis rec de E Ra ds 4 3 128659 Kit Pressure 4 3 12880 lirica Pressure regulator cereo timeat 4 3 128022 GG a a Kit Gas manifold with solenoid valve 4 3 1238405 etes Work cable with clamp 15 ft 4 6 4 3 An Kit Power board 99 4 3 1289069 eene Kit RCD resistor replacement S N lt 1000 013717 4 3 128672 S S Kit Power switch 4 4 128 A A EM Fiter PCB CE only uuu tenerent n dia 4 4 128627 aaa 4 5 ODLOK e uy u uu S su u PETI ASS S AS SS 4 5 011094 O ring NAF3000 filter 4 5 vesi Osri g scc
48. EILLES 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 concus 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 BOUTEILLES DE GAZ COMPRIME PEUVENT EXPLOSER EN CAS DE DOMMAGES 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 co
49. H 1 3 PH 3PH GRN YEL 24VDC 100MA MAX 150 150 Pressure P ENK Q POWER SWITCH SD we oa Eeer POWER BD POBA CONTROL BD PCBS Ss RU PESE TEMP SENSOR BD PCBA ELIO 000 TIMING DIAGRAM Box 5010 Hanover NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE THIS DRAWING AND ALL INFORMATION 2PLDECIMAL 01 CONTAINED THEREON IS CONSIDERED 3 PL DECIMAL 2005 PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 FOR MANUFACTURING OR FABRICATION ANGULAR 4 502 PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND SHARP EDGES BREAK SHARP EDGES IF NECESSARY FROM HYPERTHERM NC WITH CHAMFER OR RADIUS 015 MAX
50. Jo SI e9eIdXJOM au pue SI pea eui 1941 eoejdai ueuj peoue eq jou 51 eu ssoJoe U9101 eu JIUA 159 90 1991 pue Jamod ay eg 51591 OM ay jo auo J G 1591 woad J 18 ay 10119 eui 2494 pieoq iemod pue suid u w q Jeduun eoejd pue Al H S777 2208 0 00 995 ay Jo ay uo 47 eui 40949 pezisiepun ue doip 4210 ay indu Z uonoes eu si Je od 1291119818 Jeu 8IN SJOW pue ysni uapou Seul pue uone eyeudoidde oeuo y 45 ejqeun EgOd preoq 80 1891 10 OM 1004 19 uo Aney god preoq p109 uolsu 1x3 A ddns esnj JO JexeeJg
51. LED are illuminated Inverter interlock Start and TSO LEDs on the control board PCB3 Torch stuck in open position Start and SP LEDs on the control board PCB3 and the Fault LED are illuminated Control board failure This may mean Continuous start signal Self diagnostic failure Solution Shorted start wires or stuck Check start wires blue and Cause start trigger switch orange wires in torch for a short circuit Check the CNC cable for a start signal Machine interface pins 3 and 4 Receiving start signal from the CNC Normal operation Microprocessor failure Replace control board If SDF LED remains illuminated replace power board PCB2 Perform Test 14 and Test 5 Perform Test 7 Faulty control board PCB3 Replace control board Faulty power board PCB2 faulty PFC IGBT Q7 or faulty inverter IGBT Q6 Any or all of these parts can be faulty Torch plunger stuck consumables are worn or defective Pilot Arc IGBT powermax1000 Service Manual MAINTENANCE Test 1 voltage input Check the line voltage to the top of the power switch S1 Check the input voltage to the input diode bridge The AC voltage between any 2 input wires should equal the line voltage f there is proper voltage to the power switch and low voltage to the input diode replace the power switch For CE systems check the voltage at the CE filter I
52. N 128963 For systems with higher serial numbers replace the power board Note All values can be 15 Bus bleed and soft start Bus bleed and soft start resistors for serial numbers resistors for serial numbers below 1000 016236 above 1000 016236 R118 30 R124 75kQ R119 25kQ R125 75kQ R120 25kQ R126 75kQ R127 75kQ Note Bulk capacitors must be out of circuit R126 20 8k R120 21 2k R125 21 0k R127 21 2k Q Y R124 24 1k R119 24 1k Inverter IGBT Q6 750 VDC 375 VDC 375 VDC C94 C98 375 VDC 375 VDC 3 20 powermax1000 Service Manual MAINTENANCE Test 3 output diodes Check each diode connection 1 and 3 with an ohm meter in diode test mode For each diode the value should be open with the meter leads in one direction and 0 1V to 1 0V with the meter leads reversed The diode is shorted if the value is less than 0 1V Replace the diode The diode is open if the value is greater than 1 0V in both directions Replace the diode Note In each case common black should be on 3 Top 3102 179 3 to 1 1 8V Bottom 3102 180V 3 to 1 2 1 8V
53. S MARKING WARNING INSTANT START Arc starts instantly after torch switch is depressed Insulate yourself from work and ground Keep gloves shoes clothing work area Arc rays can injure eyes and burn skin AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Couper l alimentation avant d effectuer le d pann ge Couper l alimentation avant de d monter la torche Utiliser exclusivement les torches indiqu es dans le manual d instructions Le raccordement au r seau de cette machine de coupage arc plasma doit tre comforme aux codes de l lectricit pertinents Le coupage arc plasma comporte des risques pour l utilisateur et les personnes se trouvant dans la zone de travail Avant le coupage lire et comprendre les instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise your breathing zone and the general area If ventilation is inadequate use an approved respirator WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from to the state of California to cause birth defects and in some cases cancer Heat splatter and sparks cause fire and burns Do not cut near combustible material Do
54. SSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSEMENT sont situ es sur la machine pour signaler certains dangers sp cifiques Les messages d AVERTISSEMENT pr c dent les instructions 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 PR CAUTION 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
55. a de 1b 4 Seguridad de toma eere epe laa 1b 4 Cable de trabajo Mesa de trabajo Potencia primaria de 1b 4 Seguridad de los equipos de gas comprimido siens 1b 5 Los cilindros de gas pueden explotar si est n 1b 5 El ruido pued deteriorar la AUN iiic eiae ie 1b 5 Operaci n de marcapasos y de aud fonos iii 1b 5 Un arco plasma puede da ar tubos aiaia 1b 5 Etiqueta de advertencia 16 6 HYPERTHERM Sistemas plasma 1b 1 2 12 01 SEGURIDAD RECONOCIMIENTO DE INFORMACION DE SEGURIDAD Los s mbolos que se muestran en esta secci n se utilizan para identificar los posibles peligros Cuando vea un s mbolo de seguridad en este manual o en su m quina recuerde que existe la posibilidad de que se produzcan lesiones personales y siga las instrucciones correspondientes para evitar el peligro SIGA LAS INSTRUCCIONES DE SEGURIDAD Lea atentamente todos los mensajes de seguridad de este manual y las etiquetas de seguridad en su m quina Mantenga las etiquetas de seguridad de su m quina en buen estado Reemplace las etiquetas que se pierdan o se da en inmediatamente Aprenda a utilizar la m quina y a utilizar los controles la manera
56. a la toma a tierra EL CHOQUE EL CTRICO PUEDE PROVOCAR LA MUERTE Instale este equipo y con ctelo a tierra seg n el manual de instrucciones y de conformidad con los c digos locales y nacionales Inspeccione el cord n de alimentaci n primaria con frecuencia para asegurarse de que no est ni agrietado Si el cord n de alimentaci n primaria est dafiado reempl celo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha y reempl celas cuando se encuentren da adas No toque la pieza ni los recortes cuando se est cortando Deje la pieza en su lugar o sobre la mesa de trabajo con el cable de trabajo conectado en todo momento Antes de inspeccionar limpiar o cambiar las piezas de la antorcha desconecte la potencia primaria o desenchufe la fuente de energ a Nunca evite o descuide los bloqueos de seguridad Antes de retirar la cubierta de una fuente de energ a o del gabinete de un sistema desconecte la potencia primaria de entrada Espere 5 minutos despu s de desconectar la potencia primaria para permitir la descarga de los condensadores Nunca opere el sistema de plasma sin que las tapas de la fuente de energ a est n en su lugar Las conexiones expuestas de la fuente de energ a presentan un serio riesgo el ctrico Al hacer conexiones de entrada conecte el conductor de conexi n a tierra en primer lugar Cada sistema de plasma Hypertherm est dise ado para s
57. al o quemaduras graves Al hacer funcionar el sistema de plasma se completa un circuito el ctrico entre la antorcha y la pieza a cortar La pieza a cortar es una parte del circuito el ctrico como tambi n cualquier cosa que se encuentre en contacto con ella Nunca toque el cuerpo de la antorcha la pieza a cortar o el agua en una mesa de agua cuando el sistema de plasma se encuentre en funcionamiento I Prevenci n ante electrochogue Todos los sistemas por plasma de Hypertherm usan alto voltaje en el proceso de corte son comunes los voltajes CD de 200 a 400 Tome las siguientes precauciones cuando se utiliza el eguipo de plasma Use guantes y botas aislantes y mantenga el cuerpo y la ropa secos No se siente se pare o se ponga sobre cualquier super ficie h meda cuando est trabajando con el equipo A slese el ctricamente de la pieza a cortar y de la tierra utilizando alfombrillas o cubiertas de aislamiento secas lo suficientemente grandes como para impedir todo contacto f sico con la pieza a cortar o con la tierra Si su nica opci n es trabajar en una rea h meda o cerca de ella sea muy cauteloso Instale un interruptor de corriente adecuado en cuanto a fusibles en una pared cercana a la fuente de energ a Este interruptor permitir al operador desconectar r pidamente la fuente de energ a en caso de emergencia utilizar una mesa de agua aseg rese de que sta se encuentre correctamente conectada
58. any combustibles such as a butane lighter or matches Pilot arc can cause burns Keep the torch nozzle away from yourself and others when the switch is depressed Wear correct eye and body protection NE PAS ENLEVER CET AVIS AVERTISSEMENT AMOR AGE INSTANTAN L arc s amorce aussit t qu on enclenche l interrupteur la torche 110391 Rev A 1 1 1 2 Cutting sparks can cause explosion or fire Keep flammables away from cutting Keep a fire extinguisher nearby and have a watchperson to use it Do not cut on any closed containers The plasma arc can cause injury and burns Turn off power before disassembling torch Do not hold the material near cutting path Wear complete body protection Electric shock from torch or wiring can kill Protect yourself from electric shock Wear insulating gloves Do not wear wet or damaged gloves Insulate yourself from work and ground Disconnect input plug or power before working on machine Breathing cutting fumes can be hazardous to your health Keep your head out of the fumes Use forced ventilation or local exhaust to remove the fumes Use ventilating fan to remove the fumes Arc rays can burn eyes and injure skin Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Become trained and read the instructions befor
59. armful ingress spraying water C AC line circuits protected against ingress of tool 22 5 mm dia x 100 mm long 0 1 in x 4 0 in S fan stationary during water test WARNING DO NOT OPERATE IN THE RAIN Toppling Tilting with or without wheel kit Up to 15 incline Gas type Air Nitrogen Gas quality Clean moisture free oil free Gas inlet pressure and flow 90 psig 6 1 bar 400 scfh 6 7 scfm 189 l min 2 2 powermax1000 Service Manual SPECIFICATIONS Dimensions and weight Weight of power supply without torch 5 in mm Ce powerrmaxti000 Service Manual 2 3 SPECIFICATIONS T60 torches Handheld cutting capacity at 60 amps Recommended capacity 3 4 inch 19 mm Maximum capacity 1 inch 25 mm Severance capacity 1 1 4 inch 32 mm Mechanized cutting capacity at 60 amps Recommended capacity 3 8 inch 10 mm Maximum capacity 1 2 inch 12 mm Gouging capability metal removal rate on mild steel Weight 10 0 pounds 4 5 kg hour 6 9 pounds 3 1 kg with 25 ft 7 5 m lead 13 6 pounds 6 2 kg with 50 ft 15 m lead 20 6 pounds 9 4 kg with 75 ft 22 5 m lead 4 5 pounds 2 0 kg with 15 ft 4 5 m lead 8 3 pounds 3 8 kg with 25 ft 7 5 m lead 9 9 pounds 4 5 kg with 35 ft 10 7 m lead 15 0 pounds 6 8 kg with 50 ft 15 m lead 21 7 pounds 9 9 kg with 75 ft
60. blessures voire la mort Conserver le poste de coupage bien a r ou utiliser un masque respiratoire homologu Ne pas proc der au coupage pr s d endroits s effectuent le d graissage le nettoyage ou la vapori sation Certains solvants chlor s se d composent sous l effet des rayons ultraviolets et forment du phosg ne Ne pas couper des m taux peints ou contenant des mati res toxiques comme le zinc galvanis le plomb le cadmium ou le b ryllium moins que la zone de travail LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES soit tr s bien ventil e et que l op rateur porte un masque respiratoire Les rev tements et m taux contenant ces mati res peuvent produire des vapeurs toxiques lors du coupage Ne jamais couper de r cipients pouvant contenir des mati res inflammables avant de les avoir vid s et nettoy s correctement Quand on utilise ce produit pour le soudage ou le coupage il d gage des fum es et des gaz qui contiennent des produits chimiques qui selon l tat de Californie provoquent des anomalies cong nitales et dans certains cas le cancer Hypertherm Syst mes plasma 1a 3 2 12 01 S CURIT Torches allumage instantan L arc plasma s allume imm diatement apr s que la torche soit mise en marche V 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 torc
61. ce font partie du circuit lectrique Ne jamais toucher le corps de la torche la pi ce couper ou l eau de la table eau pendant le fonctionnement du syst me plasma Pr vention des chocs lectriques Tous les syst mes plasma Hypertherm utilisent des hautes tensions pour le coupage souvent de 200 400 V On doit prendre les pr cautions suivantes quand on utilise le syst me plasma Porter des bottes et des gants isolants et garder le corps et les v tements au sec Ne pas se tenir s asseoir ou se coucher sur une surface mouill e ni la toucher quand on utilise le syst me plasma S isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol S il s av re n cessaire de travailler dans ou pr s d un endroit humide proc der avec une extr me prudence Installer un sectionneur avec fusibles appropri s proximit de la source de courant Ce dispositif permet l op rateur d arr ter rapidement la source de courant en cas d urgence En cas d utilisation d une table eau s assurer que cette derni re est correctement mise la terre pi ce couper et tout autre l ment en contact avec cette LES CHOCS LECTRIQUES PEUVENT TRE FATALS Installer et mettre la terre l quipement selon les instructions du pr sent manuel et conform ment aux codes lectriques locaux et nationaux Inspecte
62. correcta No permita que sea utilizada por alguien que no conozca su funcionamiento Mantenga su m quina en buenas condiciones de funcionamiento La realizaci n de modificaciones no autorizadas a la m quina puede comprometer la seguridad y la vida til de la m quina PELIGRO ADVERTENCIA PRECAUCI N Las palabras PELIGRO y ADVERTENCIA se utilizan conjuntamente con un s mbolo de seguridad La palabra PELIGRO se utiliza para identificar los mayores peligros Encontrar etiquetas de seguridad con las inscripciones PELIGRO y ADVERTENCIA en su m quina junto a peligros espec ficos En este manual la palabra ADVERTENCIA va seguida de instrucciones que si no se siguen correctamente pueden provocar lesiones e inclusive la muerte En este manual la palabra PRECAUCI N va seguida de instrucciones que si no se siguen correctamente pueden provocar da os en el equipo Prevenci n ante el fuego Aseg rese de que el rea sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables coloc ndolos a por lo menos 10 metros del rea de corte Remoje los metales calientes o permita que se enfr en antes de que entren en contacto con materiales combustibles Nunca corte dep sitos que contengan materiales inflamables primero es necesario vaciarlos y limpiarlos debidamente Antes de realizar cortes en atm sferas potencialmente inflamables aseg rese de ventila
63. current transfer sensors located on the power board the pilot arc IGBT Q8 and the output choke The control board s microprocessor monitors and regulates system operation and safety circuits The current adjustment knob is used to set to the current to the desired value The system compares the set point to the output current by monitoring the current sensor and adjusting the pulse width output of the inverter IGBT Q6 The control board PCB3 includes a pilot arc control switch which allows the operator to turn ON the pilot arc useful when cutting expanded metal turn OFF the pilot arc for maximum life of consumables or to increase the pilot arc to 20A useful for gouging or non transferred arc cutting 3 4 powermax1000 Service Manual Sequence of operation MAINTENANCE Power OFF Le Connect the gas supply to the filter on the power unit Connect the torch to the power supply Connect the work lead to the workpiece Apply power at the line voltage disconnect box Set the ON OFF switch S1 to ON 1 The power ON LED and the gas pressure LED illuminate green indicating the system is ready for operation The fault LEDs should be extinguished see Troubleshooting guide for more information Turn the current adjustment knob fully counterclockwise to the gas test position Check the air pressure setting The gas solenoid valve V1 opens to purge the system and to allow the setting of pres
64. d the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be au thorized 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 TS 62081 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 01 25 05 WARRANTY WARNING Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty WARNING You are responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment GENERAL Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship if Hypertherm is notified of a defect i with respect to the power supply within a period of two 2 years from the date of i
65. d spare parts 4 7 powermax1000 Service Manual 4 1 PARTS POWER SUPPLY Exterior ll NOOB WP number 128686 128685 128689 128687 008965 128630 123645 011096 128629 128690 128688 128973 Description Kit Labels domestic Kit Labels CE Kit Front panel domestic Kit Front panel CE Current adjustment knob Kit End panel screws Ground clamp Regulator knob Kit Cover screws Kit Power supply cover with labels domestic Kit Power supply cover with labels CE Kit Rear panel powermaxtooo Qty oO AA o mk mk N Service Manual PARTS POWER SUPPLY Interior right side D 10 2 3 9 4 Part Item number Description Designator Qty 1 128701 Kit Control board domestic PCB3 1 128702 Kit Control board CE PCB3 1 2 128659 Kit Pressure sensor 1 3 128801 Kit Pressure regulator 1 4 123604 Pilot arc IGBT cable 1 5 128622 Kit Gas manifold with solenoid valve V1 1 6 128628 Kit ETR Box 1 7 046116 Tubing 8mm OD 6mm ID nylon 3 ft 8 128963 Kit RCD resistor replacement S N 1000 013717 1 9 108211 On Off Knob 1 10 128662 Kit Machine interface 1 11 128665 Kit Strain rel
66. d the IGBT tester for damage 2 Verify that the battery voltage is greater than 8V 3 Test the IGBT Tester itself as shown below If the results do not match the table replace the lead connections 4 Connect leads Short test Open test None Pass Fail Red to Black Fail Pass Schematic for building an IGBT tester Legend Collector 1 C1 Emitter 2 E2 Collector 2 Emitter 1 C2 E1 Gate 1 G1 Emitter 1 E1 Emitter 2 E2 Gate 2 G2 R3 2 0K 009036 D1 R4 2 0K 009036 OO GQ D Red LED lamp gt 109092 9 VDC N O Red Minigrabber battery F pushbutton test clip switch 1 Minigrabber test cli 4 Rt 3 01M 009464 Black Minigrabber test clip 2 Q1 150A 1400V 109125 powermax1000 Service Manual 3 11 MAINTENANCE IGBT device test using non Hypertherm tester The device tester shown in Schematic for building an IGBT testerhas one LED and one pushbutton switch that are used in combination to perform two tests 1 Visually inspect the IGBT for cracks or black marks If damaged replace the IGBT 2 Verify that the 9V battery reads greater than gt 8 0V 3 Connect the test leads as shown below Note The IGBT must be electrically isolated before the test is performed 4 With the test leads connected and without pressing the pushbutton switch the LED should not illuminate If the LED is illuminated th
67. e working on the machine or cutting Do not remove or paint over cover warning labels Hypertherm Plasma Systems Section 1a SECURITE Dans cette section Identifier les consignes de s curit issues 1a 2 Suivre les Instructions S CUFIT cii draugs tekst ed haer tede ee send detecto esi a uk tag des 1a 2 Danger Avertissement 1 aaa a aa a aa aa 1 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Pr vention des incendies Pr vention des 1a 2 Risque d explosion argon hydrog ne et m thane sis 1a 2 D tonation de l hydrog ne lors du coupage de l aluminium 1a 2 Les chocs lectriques peuvent tre Totale 1a 3 Pr vention des chocs lectriques siennes 1a 3 Le coupage peut produire des vapeurs toxiques see 1a 3 L arc plasma peut provoquer des blessures ou des 1a 4 Torches a allumage EE 1 4 Les rayons de l arc peuvent br ler les yeux et la peau si 1a 4 Protection des yeux Protection de la peau Zone de coupage 1a 4 Mise la masse et a la ter repete ualet 1a 4 C ble de retour Table de travail 1a 4 S curit des bouteilles de gaz comprim iii 1a 5 Les bouteilles de gaz comprim peuvent exploser en
68. en the IGBT is shorted Replace the IGBT 5 With the test leads connected press the push button switch This time the LED should illuminate If the LED does not illuminate then the IGBT is open Replace the IGBT IGBT Inverter IGBT PFC IGBT Pilot arc Test 1 Yellow lead Yellow lead Gate 2 G2 Yellow lead 7 Gate G Gate G r s Le Black lead Black lead Emitter Emitter TO MIS Ld Black lead Emitter 2 E2 Red lead Red lead Collector C Lo Collector C LOL Red lead Collector 2 C2 IGBT Inverter Test 2 Yellow lead Gate 1 G1 Red lead Collector 1 C1 Black lead Emitter 1 E1 3 12 powermax1000 Service Manual MAINTENANCE Power switch S1 Power factor circuit Input diode Inverter circuit Flyback circuit Gas manifold R g E m O LL D Inverter IGBT 06 Board common 1 Torch J18 Control board PCB3 Output diodes Pilot arc IGBT Q8 Work lead powermax1000 Service Manual 3 13 MAINTENANCE ob 159 pieoq Jo quiesse Josues eJnsseJd Ayne
69. ep your body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground d A gt ELECTRIC SHOCK KILL Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge N
70. epair kit 1 7 128644 Kit T60 torch handle replacement 1 8 075586 Handle screws 5 9 002244 Safety trigger 1 10 027254 Spring 1 11 128681 Kit 60 25 ft 7 6 m torch lead replacement 1 12 128682 Kit 60 50 ft 15 2 m torch lead replacement 1 13 128893 Kit T60 75 ft 22 5 m torch lead replacement 1 14 128638 Kit ETR connector replacement 1 15 128642 Kit T60 Start switch replacement 1 assembly includes the following consumables See 760 consumable configurations tor descriptions of consumable parts 120926 Electrode 1 120925 Swirl ring 1 120928 Retaining cap 1 120929 Shield 1 120931 Nozzle 1 5 2 powermax1000 Service Manual PARTS TORCH AND CONSUMABLES powermax1000 Service Manual 5 3 PARTS TORCH AND CONSUMABLES T60M machine torch assembly Item Part number Description Quantity 083175 T60M machine torch assembly with 15 ft 4 6 m lead 083174 T60M machine torch assembly with 25 ft 7 6 m lead 083176 T60M machine torch assembly with 35 ft 10 7 m lead 083177 T60M machine torch assembly with 50 ft 15 2 m lead 083209 T60M machine torch assembly with 75 ft 22 5 m lead 1 128640 Kit T60M torch main body replacement 1 2 027889 Retaining clip 1 3 058519 O ring 1 4 128639 Kit Cap sensor replacement 1 5 075571 Cap sensor screws 6 128521 Kit T60 T60M torch head repair 1 7 128643 Kit Torch Mounting Sleeve Replacement 1 8 075004 Torch mounting screws 3 9 128710 Torch positioning sleeve 1 10
71. er utilizado s lo con antorchas Hypertherm espec ficas No utilice antorchas diferentes que podr an recalentarse y ser peligrosas Los cortes pueden producir gases y humos t xicos que agotan el ox geno y causan lesiones o inclusive la muerte Mantenga el rea de corte bien ventilada o utilice un respirador con suministro de aire aprobado e No realice sus cortes en sitios que se hallen cerca de operaciones de desengrasado limpieza o aplicaci n de aerosoles Los vapores de ciertos solventes clorados se descomponen y forman gas fosgeno al quedar expuestos a la radiaci n ultravioleta No corte metales que contengan materiales t xicos o que est n recubiertos con ellos tales como el cinc galvanizado el plomo el cadmio o el berilio a menos LOS CORTES PUEDEN PRODUCIR HUMOS T XICOS que el rea se halle bien ventilada y el operador lleve puesto un respirador con suministro de aire Los recubrimientos y todo metal que contenga estos elementos pueden producir gases o humos t xicos al ser cortados Nunca corte dep sitos con materiales potencialmente t xicos en su interior primero es necesario vaciarlos y limpiarlos debidamente Este producto cuando se lo usa para soldar o cortar produce humo y gases que se conocen en el estado de California como causantes de defectos de nacimiento y en algunos casos c ncer HYPERTHERM Sistemas plasma 1b 3 4 11 03 SEGURIDAD Antorchas de encendido
72. erials CUTTING CAN CAUSE FIRE OR EXPLOSION WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma A When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation Refer to the Appendix section of this manual for aeration manifold details WARNING Hydrogen Detonation with Aluminum Cutting 11 98 Hypertherm Plasma Systems Touching live electrical parts can cause fatal shock or severe burn Operating the plasma system completes electrical circuit between the torch and the workpiece The workpiece and anything touching the workpiece are part of the electrical circuit Never touch the torch body workpiece or the water in a water table when the plasma system is operating Electric Shock Prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and boots and ke
73. et m thane sisi 1a 2 D tonation de l hydrog ne lors du coupage de l aluminium 1a 2 Les chocs lectriques peuvent tre fatale 1a 3 Prevention des Chocs lectriques oic tete io tet haha cete aa ptt aded pe acc ie ea decur 1a 3 Le coupage peut produire des vapeurs 1a 3 L arc plasma peut provoquer des blessures ou des 1a 4 Torches allumage instantan iii 1a 4 Les rayons de l arc peuvent br ler les yeux et lapeau un 1a 4 Protection des yeux Protection de la peau Zone de coupage 1a 4 Mise la mass et la telle teca thee tite pen estate ins ed Ra 1a 4 C ble de retour Table de travail Alimentation 1a 4 S curit des bouteilles gaz iii 1a 5 Les bouteilles de gaz comprim peuvent exploser cas de dommages 1a 5 Le bruit peut provoquer des probl mes audtte sr 1a 5 Pacemakers et proth ses auditives secciones dy sabia 1a 5 Un arc plasma peut endommager les tuyaux 1 5 ESC In 1 6 powermax1000 Service Manual iii TABLE OF CONTENTS Secc on 1b Seguridad Reconocimiento de informaci n de seguridad
74. ever operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death Keep the cutting area well ventilated or use approved air supplied respirator Do not cut in locations near degreasing cleaning or spraying operations The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation Do not cut metal coated or containing toxic materi als such as zinc galvanized lead cadmium or CUTTING CAN PRODUCE TOXIC FUMES beryllium unless the area is well ventilated and the operator wears an air supplied respirator The coatings and any metals containing these elements can produce toxic fumes when cut Never cut containers with potentially toxic materials inside they must be emptied and properly cleaned first This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer Hypertherm Plasma Systems 1 3 8 99 I
75. f there is proper voltage to the CE filter and low voltage to the input diode replace the CE filter Check the output voltage of the input diode bridge Output VDC Line Voltage x 1 414 VDC Note All values can be 15 sack Green Ground Input diode bridge Power switch S1 9 gu Line voltage Line voltage Line voltage Single phase Line voltage x 1 414 powerrmaxti000 Service Manual 3 19 MAINTENANCE Test 2 voltage balance Test to check the balance of the bus voltage the power factor circuit and the soft start circuit Verify the system s serial number Serial numbers lower than 1000 016236 have a different power board from systems with serial numbers higher than 1000 016236 Remove screws from capacitors C94 and C98 before measuring the resistors listed below Check the voltage across the inverter IGBT Q6 Check the voltage across the capacitors C94 C98 before and during torch operation Voltage across both capacitors should be 375 VDC On systems with serial numbers below 1000 016236 if the capacitors are not balanced at 375 VDC install the RCD resistor kit P
76. g am IGBT tester u unas a EL e PEE CLE ds 3 11 IGBT device test using non Hypertherm tester sis 3 12 Troubleshooting quide testo E E A 3 14 Gontrolibo rd 0 3 18 1 5 1 date ae ains 3 19 Test 2 voltage balance c gprs rat s aga r ts 3 20 MOSES SOUP UT em 3 21 Test4 pilotare IGBT 3 22 Test 5 inverter IGBT Q6 and PFC IGBT OZ 3 23 6 xc mE 3 24 Test 7 torch stuck open TSO ln 3 25 Teste plasma ME 3 26 Test 9 Cap SONS uv 3 26 gas SOLOMON M 3 27 Test 11 incoming line voltage VACR 3 27 Test 12 pressure SWITCH A eap ne er e Bu ues 3 27 Test 19 SM en a a a 3 27 Test AUX E 3 28 Test 15 flyback circuit failure Ene Rr ad na npn Sr equ 3 28 T60 hand torch connector pinouts and assembly 3 29 T60M machine torch connector pinouts and assembly 3 30 Component replacement x stas xt ipt o teu e ecran ini a g raga 3 31 Power replacement uuu EE 3 31 lee replace
77. he 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 et encore masque de soudure avec des verres teint s appropri s pour prot ger 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 N 8 NO 11 100 200 A N 10 11 12 200 400 A 12 N 13 Plus de 400A 14 N 14 Protection dela 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
78. i Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service 6 15 05 France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S r l Via Torino 2 20123 Milano ltalia 39 02 725 46 312 Tel 39 02 725 46 400 Fax 39 02 725 46 314 Technical Service Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 49 73 7843 Tel Technical Service Japan Representative office 1952 14 Yata Natsumegi Mishima City Shizuoka Pref 411 0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax HYPERTHERM BRASIL LTDA Jati 33 07180 350 Cumbica Guarulhos SP Brasil 55 11 6482 1087 Tel 55 11 6482 0591 Fax ELECTROMAGNETIC COMPATIBILITY EMC EMC INTRODUCTION Hypertherm s CE marked equipment is built in compliance with standard EN50199 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 may not be adequate to completely eliminate interfer ence when the affected equipment is in close proximity or has a high degree
79. ie 1b 2 Siga las instrucciones cereo ethernet 1b 2 Peligro Advertencia EE 1b 2 Los cortes pueden provocar incendios o 1b 2 Prevenci n ante el fuego Prevenci n ante explosiones Us 1b 2 Peligro de explosi n arg n hidr geno y metang 1b 2 Detonaci n de hidr geno con el corte de aluminio si 1b 2 El choque el ctrico puede provocar la Muerte 1b 3 Prevenci n ante el electrochoqle irc edic cde sabe e Pav bec adi t da 1b 3 Los cortes pueden producir humos t xicos iii 1b 3 El arco de plasma puede causar lesiones y quemaduras 1b 4 Antorchas de encendido 10 4 Los rayos del arco pueden producir quemaduras los ojos y en la 1b 4 Protecci n para los ojos Protecci n para la piel rea de 1b 4 Seguridad de toma a tia tie ime o teri Pai tiara 1b 4 Cable de trabajo Mesa de trabajo Potencia primaria de 1b 4 Seguridad de los equipos de gas comprimido issues 1b 5 Los cilindros de gas pueden explotar si est n da ados 1b 5 El ruido puede deteriorar la audici n 1b 5 Operaci n de
80. ief arc voltage 1 12 128695 Kit Power board PCB2 1 13 123602 Gate drive cables 3 powermax1000 Service Manual 4 3 PARTS POWER SUPPLY Back interior right side Item N Part number 128672 128706 128666 128705 Description Kit Power switch Kit EMI filter PCB CE only Kit 8 ft 2 5 m power cable domestic 3PH Kit 8 ft 2 5 m power cable CE 3PH Designator 51 PCB1 sch powermax1000 Service Manual Interior fan side Part number 1 128627 011093 011094 011105 128707 128693 128691 128692 128694 OO P oh Description Kit Filter Air filter element O ring NAF3000 filter O ring AF30 filter Kit Fan Kit Inductor input choke Kit Capacitor Kit Power transformer Kit Inductor output choke powermax1000 Service Manual PARTS POWER SUPPLY Designator M1 C94 C98 T2 L1 Qty A AN Amd PARTS POWER SUPPLY Heat sink assembly Item Joo BR 0 IN Part number 127128 128677 128697 128700 128708 128696 128670 128699 128669 Description Thermal grease 10 cc Kit Kit Kit Kit Kit Kit Kit Kit Output diode bridge Inverter IGBT Temperature Sensor PFC IGBT Input diode bridge Snubber resister 7 5 Pilot arc IGBT Snubber resister 20 Q WAAAY Designator Qty
81. iring to the torch Replace all consumables and verify that the torch will fire Note The retaining cap should be snug and not over tightened f the torch plunger does not move freely in the torch head replace the torch head Check to see if the pilot arc IGBT Q8 is open by putting a jumper wire from J14 to the Pilot Arc IGBT Q8 Then attempt to fire the torch If the torch fires replace the Pilot Arc IGBT 08 Note All values are 25 Pilot arc IGBT Q8 J14 powermax1000 Service Manual 3 25 MAINTENANCE Test 8 plasma start After turning ON the power put a jumper wire between red and white on the machine interface J19 The torch should produce an arc Note This only applies to the machine torch If the torch fires inspect the machine interface cable and verify the start signal from the CNC by verifying that the START LED on the control board illuminates see Coy7tro board LEDs If torch does not fire verify that the Start LED on the control board PCB3 also is not illuminating To verify hand torch operation pull the trigger and verify that the Start LED illuminates see board LEDS If the Start LED is OFF verify continuity between the purple and orange wires on the Easy Torch Removal ETR connector of the torch lead If the Start LED is OFF and the trigger works correctly put a jumper wire between pins 3 and 4
82. manguera de la antorcha en su cuerpo Mant ngase tan lejos de la fuente de energ a como sea posible HYPERTHERM Sistemas plasma 1b 5 2 12 01 SEGURIDAD Etiqueta de advertencia Esta etiqueta de advertencia se encuentra adherida a la fuente de energ a Es importante que el operador y el t cnico de mantenimiento comprendan el sentido de estos s mbolos de advertencia seg n se describen El texto numerado corresponde a los cuadros numerados de la etiqueta WARNING Protect yourself and others Read and under stand this marking Disconnect power source before servicing Disconnect power source before disassembly of the torch Use torches specified in the instruction manual This plasma cutting machine must be connected to power source in accordance with applicable electrical codes Plasma arc cutting can be injurious to operator and persons in the work area Before operating read and understand the manufacturer s instruc tions and know your employer s safety practices Electric shock can kill Do not touch live electrical parts Keep all panels and covers in place when the machine is connected to a power source wear insulating gloves shoes and clothing torch and this machinery dry Explosion will result if pressurized containers are cut Wear correct eye and body protection Noise can damage hearing Wear correct ear protection 0 90 gt DO NOT REMOVE THI
83. marcapasos y de audifonos iii 1b 5 Un arco plasma puede da ar tubos 1b 5 Etiqueta de Ad VOTEN o ete Retro quud urhe tex das ai Nurs ok Dar ds 1b 6 Section 2 Specifications xeu 2 2 DIMENSIONS and t 2 3 TOOTOO S PEE 2 4 DIM NSIONS m M m 2 5 Symbols and 2 6 Marin sua 2 6 lECISYMOOIS 2 6 Section3 Maintenance Gontrolsiand Tee 3 3 Indicator u uuu 3 3 E 3 4 General M AREE 3 4 Funcional 27 REDEEM 3 4 Sequence ee Ee EE 3 5 Troubleshooting Pr parations dll ev qupa uk 3 6 eur EE 3 6 Troubleshooting procedures and sequence see 3 6 Extemal INS u uu ELT 3 6 Int rnaliinsp ci0N s Em 3 7 Initial resistance cepe a ee e e acta 3 7 iv powermax1000 Service Manual TABLE OF CONTENTS Check POW SWITCH EE 3 8 Hypertherm IGBT tester iere Kr ni Fo TS ip 3 9 Indicator LEDS and device test uu uu uuu 3 9 ee le EE 3 10 IGBT device test using the Hypertherm tester sisi 3 10 Troubleshoot the Hypertherm IGBT tester sisi 3 11 Schematic for buildin
84. ment Em 3 32 3 34 Work Cable replacement 3 35 LEER 3 36 Heat sink component replacement LLL IILI aysa as e 3 37 Section 4 Parts power supply Sage cM 4 2 INTO 4 3 ccc 4 4 Interior fan RL id 4 5 uuu u atuk 4 6 spare PAS EE 4 7 Section5 Parts torch and consumables TOO hand torch RE nl u L uu das Pure xxx UR 5 2 TOOM machine torcmasSembIy dat dace n Madd td 5 4 powermax1000 Service Manual v TABLE OF CONTENTS 0 a 5 6 TOOM Consumable 5 7 a ca gl ar gk 5 8 Section6 Wiring diagrams EE T E 6 2 IST ed ENEE 6 5 vi powermax1000 Service Manual Section 1 SAFETY In this section Recognize Safety lut eu e ioi codo eese din ed RD 1 2 Follow Satety Instructions s riit 1 2 Cutting Can Cause Fire puer
85. n cases 3 4 General sra eaan cg de S e 3 4 Functional descripto Ua 3 4 Sequence of operation iii 3 5 Troubleshooting preparato serre danse M 3 6 Ee aa EE 3 6 Troubleshooting procedures and sequence ss 3 6 External inspection E m 3 6 Internal uu eer 3 7 Initial r sistance eld GE E 3 7 Check poWer switeltu u 3 8 Hypertherm eleg 3 9 Indicator LEDS and device tests inst nates a rk rea dis ad nite 3 9 IGBT test preparation 3 10 IGBT device test using the Hypertherm tester issues 3 10 Troubleshoot the Hypertherm IGBT tester iii 3 11 Schematic for building an IGBT tester 3 11 IGBT device test using non Hypertherm tester sise 3 12 Troubleshooting guid D 3 14 Gontrol Boafd TE 3 18 Test 2 l ee 3 19 Test 3 20 Test 3 o tput GODS D Re 3 21 Test 4 pilot arc IGBT Op 3 22 Test 5 inverter IGBT and PFC IGBT 07 3 23 Testo TIVDACK CIU
86. nection on the IGBT is labeled with an abbreviation They may be labeled as C E G or 1 2 3 with a schematic that shows numbers and pin functions IGBT Inverter Test 1 Yellow lead Gate 2 62 ap Black lead Emitter 2 lead Collector 2 2 B 2 IGBT Inverter Red lead Black lead Emitter 1 ETT Test 2 N Yellow lead p oe Collector 1 C1 A IGBT PFC Yellow lead Gate G Black lead Emitter Red lead O Collector C Lo IGBT device test using the Hypertherm tester IGBT Pilot arc Yellow lead Gate G Black lead Emitter E Red lead Collector C Using the Hypertherm IGBT tester press and hold the switch in the desired position to perform the tests described in the following table Switch LED position Fail Pass Battery This may mean Corrective action Left X IGBT is shorted Replace IGBT Left X IGBT passed short test None Left X Battery below 8V Replace battery Left Dead battery Replace battery Right X IGBT is open Replace IGBT Right X IGBT passed open test None Right X Battery below 8V Replace battery Right Dead battery Replace battery 3 10 powermax1000 Service Manual MAINTENANCE Troubleshoot the Hypertherm IGBT tester 1 Inspect the leads an
87. nnected to a both to keep the fumes and gases from power source your breathing zone and the general area Insulate yourself from work and ground f ventilation is inadequate use an wear insulating gloves shoes and approved respirator clothing In WARNING This product when used for welding or cutting gloves shoes clothing work area produces fumes or gases which contain chemicals known torch and this machinery dry to the state of California to cause birth defects and in some cases cancer Heat splatter and sparks cause fire and Explosion will result if pressurized burns containers are cut 2 Do cut near combustible material Do not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Arc rays can injure eyes and burn skin Wear correct eye and body protection Pilot arc can cause burns can Keep the torch nozzle away from yourself ear corea E and others when the switch is depressed Wear correct eye and body protection DO NOT REMOVE THIS MARKING NE PAS ENLEVER CET AVIS WARNING AVERTISSEMENT INSTANT START AMORCAGE INSTANTAN Arc starts instantly after L arc s amorce aussit t qu on torch switch is depressed enclenche l interrupteur de la torche 1a 6 2 12 01 1 1 1 1 2 Les tincelles produites par le coupage peuvent provoquer une e
88. nstant On Torches Plasma arc comes on immediately when the torch Switch is activated A PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc will cut quickly through gloves and skin Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields and a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays Lens Shade Arc Current AWS USA ISO 4850 Up to 100A No 8 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Over 400A No 14 No 14 RAYS CAN BURN EYES AND SKIN Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective
89. of U22 If the Start LED illuminates replace the power board PCB2 If it does not illuminate replace the control board PCB3 Test 9 torch cap sensor Turn ON the power If the torch cap sensor LED goes out ETR connector J18 3 26 Remove the ETR connector J18 from the power supply Check the continuity of pins 11 and 12 at the connector end of the torch with consumables installed in torch If open check the wiring in the torch leads and cap sensing switch Put a jumper wire between pins 3 and 4 of U23 with the power OFF replace the power board PCB2 If the LED remains illuminated replace the control board PCBS powermax1000 Service Manual MAINTENANCE Test 10 gas solenoid f the air is continuously running disconnect the gas solenoid connector J20 from the power board PCB2 If the air does not shut off replace the valve f the air does shut off disconnect the ribbon cable J4 from the power board PCB2 and reconnect J20 If the air remains off replace the control board PCB3 If
90. ols properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION A signal word DANGER or WARNING is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific hazards WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly Fire Prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosion Prevention Do not use the plasma system if explosive dust or vapors may be present Do not cut pressurized cylinders pipes or any closed container Do not cut containers that have held combustible mat
91. om J2 pin 1 to pin 2 to short it Check the voltage across the fan on the power board PCB2 J1 pins 1 and 2 The voltage should read 24 VDC if not remove fan connector J1 and check the voltage on the power board PCB2 J1 pins 1 and 2 again If the voltage is 24 VDC continue to the next step if not perform Test 6 flyback circuit Place a jumper wire between the fan transistor Q1 case to ground TP1 If the fan turns on continue to the next step If not replace the fan Check the voltage between the left side of R7 and ground TP1 If the VDC is zero 0 replace the control board PCB3 If the value is 5 VDC replace the power board PCB2 powermax1000 Service Manual 3 27 MAINTENANCE Test 14 AUX switch If the AUX switch on the I O switch 51 is open when the system is powered up the IF LED on the control board will illuminate when the torch trigger is pulled or the start switch is pressed Remove the J3 connector from the power board With the ON OFF switch in the OFF O position and the unit unplugged from electrical power the AUX Switch should read as open With the I O switch in the ON I position the AUX switch should read as closed Test 15 flyback circuit failure Multiple flashing indicator LEDs can signal a failure in the flyback circuit Unplug the fan If the LEDs no longer flash replace the fan If the lights are still flashing plug the fan in again and perform the next step
92. ower board or control board Do not cut away or remove any protective conformal coating from either board To do so will risk a short circuit between the AC input circuit and the output circuit and may result in serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards Internal inspection 1 Set the ON OFF switch 51 to O OFF unplug the power cord and disconnect the gas supply 2 Remove the power supply s cover by removing the 12 securing screws 3 Inspect the inside of the power supply especially on the side with the power board Look for broken or loose wiring connections burn and char marks damaged components and so on Repair or replace as necessary Initial resistance check All resistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform the steps in nterna inspection before continuing in this section e If resistance values not close 425 to the values given in this section isolate the problem by removing wires attached to the resistance check points or component until the problem is found e After the problem has been located and repaired refer to the Sequence of operation flow diagram in this section to test the power supply for
93. powermax1000 Plasma Cutting System Service Manual 804300 Revision 1 an se a da Eee 84 H Gite The world leader in plasma cutting technology powermaxtooo Service Manual P N 804300 Revision 1 May 2006 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2006 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 Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service technical service Qhypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service Qhypertherm com Customer Service Email Hypertherm Automation 5 Technology Drive Suite 300 West Lebanon NH 03784 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm 5 Pte No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 1308 09 Careri Building 432 West Hua
94. proper operation powerrmaxti000 Service Manual 3 7 MAINTENANCE Check power switch 1 With the power disconnected set the ON OFF switch S1 to ON I 2 Check the resistance across the input leads 3 Check the resistance from the input leads to ground Notes With the power disconnected and the ON OFF switch S1 set to OFF O all should read as open All electrical values shown are 25 2 4 2 4 gt 2 4 gt 20 If no problems were found during the visual inspection or the initial resistance check and the power supply still does not operate correctly see the 7 oubleshooting guide Note The roubleshooting guide provides most probable causes and solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before purchasing a major replacement component verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility 3 8 powermax1000 Service Manual MAINTENANCE Hypertherm IGBT tester Use the Hypertherm IGBT tester part number 128883 as described in the following sections or assemble your own IGBT tester from the schematic diagram shown in GB7 fester schematic and use it to test the IGBTs NU AN S Pass LED Circuit green diagram e Fail LED red Low battery LED red 5 ES Test for Zi open IGBT 3 Test
95. r bien requiere tener un sistema de ventilaci n de escape Prevenci n ante explosiones No corte en atm sferas que contengan polvo o vapores explosivos cerrado No corte dep sitos que hayan contenido materiales combustibles Al realizar cortes utilizando ox geno como gas plasma se No corte dep sitos o tubos a presi n ni cualquier dep sito LOS CORTES PUEDEN PROVOCAR INCENDIOS O EXPLOSIONES ADVERTENCIA Peligro de explosi n Arg n Hidr geno y metano A El hidr geno y el metano son gases inflamables que suponen un peligro de explosi n Mantenga el fuego lejos de los cilindros y las mangueras que contengan mezclas de hidr geno o metano Mantenga la llama y las chispas lejos de la antorcha al utilizar metano o arg n hidr geno como plasma A Al cortar aluminio bajo agua o con agua en contacto con el lado inferior del aluminio puede acumularse gas hidr geno bajo la pieza a cortar y detonar durante la operaci n de corte por plasma Instale un multiple de aireaci n en el fondo de la mesa de agua para eliminar la posibilidad de la detonaci n del hidr geno Consulte la secci n del ap ndice de este manual para conocer detalles acerca del multiple de aireaci n ADVERTENCIA Detonaci n de hidr geno con el corte de aluminio 1b 2 2 12 01 HYPERTHERM Sistemas plasma SEGURIDAD e N El contacto directo con piezas el ctricas conectadas puede provocar un electrochoque fat
96. r fr quemment le cordon d alimentation primaire pour s assurer qu il n est ni endommag ni fendu Remplacer imm diatement un cordon endommag Un c ble d nud peut tuer Inspecter et remplacer les c bles de la torche qui sont us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du coupage Laisser la pi ce couper en place ou sur la table de travail le c ble de retour connect lors du coupage Avant de v rifier de nettoyer ou de remplacer les pi ces de la torche couper l alimentation ou d brancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de s curit Avant d enlever le capot du syst me ou de la source de courant couper l alimentation lectrique Attendre ensuite 5 minutes pour que les condensateurs se d chargent Ne jamais faire fonctionner le syst me plasma sans que les capots de la source de courant ne soient en place Les raccords expos s de la source de courant sont extr mement dangereux Lors de l installation des connexions attacher tout d abord la prise de terre appropri e Chaque syst me plasma Hypertherm est concu pour tre utilis uniquement avec des torches Hypertherm sp cifiques Ne pas utiliser des torches inappropri es qui pourraient surchauffer et pr senter des risques pour la s curit Le coupage peut produire des vapeurs et des gaz toxiques qui r duisent le niveau d oxyg ne dans l air et peuvent provoquer des
97. re Protection Association 470 Atlantic Avenue Boston MA 02210 10 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 11 98 WARNING LABEL This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on the label Protect yourself and others Read and under stand this marking Disconnect power source before servicing Disconnect power source before disassembly of the torch Use torches specified in the instruction manual This plasma cutting machine must be connected to power source in accordance with applicable electrical codes Plasma arc cutting can be injurious to operator and persons in the work area Before operating read and understand the manufacturer s instruc tions and know your employer s safety practices Electric shock can kill Do not touch live electrical parts Keep all panels and covers in place when the machine is connected to a power source Insulate yourself from work and ground wear insulating gloves shoes and clothing Keep gloves shoes clothing work area torch and this machinery dry Explosion will result if pressurized containers are cut Arc rays can injure eyes and burn skin Wear correct eye and body protection Noise can damage hearing
98. screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs GROUNDING SAFETY Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table the work table to an earth ground in accordance with appropriate national or local electrical codes 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 connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating 1 4 5 6 02 Hypertherm Plasma Systems COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and fittings designed for the specific application Maintain all compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes GAS CYLINDERS CAN S EXPLODE IF DAMAGED
99. sure Set the gas pressure see the Setup section in the Operator Manual Select the desired cutting amps with the current adjustment knob Gas solenoid valve V1 closes Set the power switch S1 to OFF O The gas solenoid valve V1 closes The gas flow stops The arc extinguishes Postflow continues for 10 seconds Move the torch to make a cut The workpiece drops after the cut Release the plasma start trigger on the hand torch or the remote start switch for the machine torch The gas solenoid valve V1 opens The gas flow starts The cutting arc starts Position the torch above the workpiece Pull the plasma start trigger on the hand torch or press the remote start switch for the machine torch The gas flow stops powermax1000 Service Manual The power circuits are ready MAINTENANCE Troubleshooting preparation The complexity of the circuits requires 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 nearest Hypertherm Technical Services Department listed in the front of this manual Test equipment Multimeter IGBT tester part number 128883 Troubleshooting procedures and sequence When performing the troubleshooting procedures Refer to Section 6 for the
100. system wiring diagram Refer to Section 4 to locate power supply components Refer to Section 5 for torch components After the problem has been located and repaired refer to the Sequence of Operation diagram in this section to test the power supply for proper operation a Troubleshooting guide External inspection Internal inspection Y Resistance checks p Power OFF and disconnected Troubleshooting tests External inspection 1 Inspect the exterior of the power supply for damage to the cover and external components 2 Inspect the torch and the torch lead for damage 3 6 powermax1000 Service Manual MAINTENANCE DANGER ELECTRIC SHOCK CAN KILL Turn off the power and remove the input power plug from its receptacle before removing the cover from the power supply If the power supply is connected directly to a line disconnect box switch the line disconnect to OFF O In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death Do not attempt to repair the p
101. the air flow returns replace the power board PCB2 Test 11 incoming line voltage VACR Check the voltage on output of the input diode which uE should equal 1 414 multiplied by the input voltage la p If value is low check the input voltage or replace 25 gt the diode R50 If the value is correct check the voltage between the ee D left side of R25 and ground 1 should read 4 969 mV V f the value is correct replace the control board PCB3 If not replace the power board PCB2 and the PFC IGBT Q7 ay al Test 12 pressure switch ip Check the voltage from the right side of R50 to ground TP1 It should be approximately equal to 0 0463 VDC multiplied by psi For example when the air regulator is 8 set to 80 psi the voltage should be approximately 3 7 m VDC j f the value is correct replace the control board I PCB3 If not replace the pressure switch 5 Test 13 fan Force the fan into an over temperature condition place a jumper wire fr
102. tional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm PATENT INDEMNITY Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm 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 will defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other product not supplied by 9 01 Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement and Hypertherm s obligation to indemnify shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim LIMITATION OF LIABILITY In no event shall Hypertherm be liable to any person or entity for any incidental consequential indirect or punitive damages including but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise and even if advised
103. 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 C ble de retour Bien fixer le c ble de retour ou de masse la pi ce couper ou la table de travail de facon assurer un 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 1a 4 5 6 02 Hypertherm Syst mes plasma S CURIT S CURIT DES BOUT
104. ts delivery to you with the exception of Powermax Series power supplies which shall be within a period of three 3 years from the date of delivery to you and ii with respect to the torch and leads within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise damaged Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall be returned with Hypertherm s prior authorization which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty Distributors OEMs may offer different or addi
105. upage 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 UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELES Les tuyaux gel s peuvent tre endommag s ou clater si l on essaie de les d geler avec une torche plasma PACEMAKERS ET PROTHESES AUDITIVES N Les champs magn tiques produits par les courants 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 ou 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 Se tenir le plus loin possible de la source de courant Hypertherm Syst mes plasma 1a 5 2 12 01 S CURIT tiquette de s curit Cette tiquette est affich e sur la source de courant est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Les num ros de la liste
106. utilizado No permita nunca el contacto el ctrico entre el arco de plasma y un cilindro No exponga nunca los cilindros a calor excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la v lvula del cilindro EL RUIDO PUEDE DETERIORAR LA AUDICION La exposici n prolongada al ruido propio de las operaciones de corte y ranurado puede dafiar la audici n Utilice un m todo de protecci n de los o dos aprobado al utilizar el sistema de plasma Advierta a las dem s personas que se encuentren en las cercan as acerca del peligro que supone el ruido excesivo UN ARCO PLASMA PUEDE DANAR TUBOS CONGELADOS Se puede hacer da o a los tubos congelados o se los puede reventar si uno trata de descongelarlos con una antorcha por plasma OPERACION DE MARCAPASOS Y KR DE AUD FONOS ayy N Los campos magn ticos producidos por las elevadas corrientes pueden afectar la operaci n de marcapasos y de aud fonos Las personas que lleven marcapasos y aud fonos deber n consultar a un m dico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magn ticos Mantenga el cable de trabajo y la manguera de la antorcha a un lado lejos del cuerpo Dirija la manguera antorcha lo m s cerca posible del cable de trabajo No envuelva el cable de trabajo ni la
107. ver the new filter element A Slide the filter bowl over the filter element B Align the marks on the filter bowl and the filter body C Rotate the filter bowl until it locks in place 3 34 powermax1000 Service Manual MAINTENANCE Work cable replacement Disconnect the electrical power gas supply and torch lead before removing the old work cable 1 Install the strain relief on the power supply and secure it with a nut 2 Tighten the strain relief collar onto the cable Proper torque is critical 3 Connect the work cable to the power board Caution This is a high current connection at J14 Tighten the nut to 10 in Ib 12 kg cm of torque 4 Install the ETR barrier 5 Install the power supply cover Connect to J14 Strain relief barrier Work cable powermax1000 Service Manual 3 35 MAINTENANCE Capacitor replacement Removal 1 Disconnect the electrical power and the gas supply then remove the power supply cover 2 Remove the two screws that secure the capacitor either C94 or C98 to the PC board 3 Remove the fan assembly 4 Remove the capacitor from the fan side of the power supply Installation 1 Align the bleeder hole on the capacitor with the view hole on the power board 2 Install the new capacitor and secure it with 2 screws Tighten the screws to 20 in Ib 24 kg cm
108. xplosion ou un incendie Pendant le coupage loigner toute mati re inflammable Conserver un extincteur proximit et s assurer qu une personne soit pr te l utiliser Ne jamais couper de r cipients ferm s L arc plasma peut provoquer des blessures et des br lures Couper l alimentation avant de d monter la torche Ne pas tenir la surface couper pr s de la trajectoire de coupe Porter des v tements de protection couvrant tout le corps Un choc lectrique caus par la torche ou les c bles peut tre fatal Se prot ger contre les risques de chocs lectriques Porter des gants isolants Ne pas porter de gants mouill s ou abim s S isoler de la surface de travail et du sol D brancher la prise ou la source de courant avant de manipuler l quipement L inhalation des vapeurs produites par le coupage peut tre dangereuse pour la sant Garder le visage l cart des vapeurs Utiliser un syst me de ventilation par aspiration ou d chappement localis pour dissiper les vapeurs Utiliser un ventilateur pour dissiper les vapeurs Les rayons de l arc peuvent br ler les yeux et provoquer des l sions de la peau Porter un casque et des lunettes de s curit Se prot ger les oreilles et porter une chemise dont le col peut tre d boutonn Porter un casque de soudure dont la protection filtrante est suffisante Porter des v tements protecteurs couvrant la totalit du corps
109. za fuera de los gases t xicos Utilice ventilaci n forzada o un sistema local de escape para eliminar los humos Utilice un ventilador para eliminar los humos Los rayos del arco pueden producir quemaduras en los ojos y en la piel Utilice un sombrero y gafas de seguridad Utilice protecci n para los o dos y abr chese el bot n del cuello de la camisa Utilice un casco de soldar con el filtro de sombreado adecuado Proteja su cuerpo completamente Antes de trabajar en la m quina o de proceder a cortar capac tese y lea las instrucciones completamente No retire las etiquetas de advertencia ni las cubra con pintura HYPERTHERM Sistemas plasma Section 2 SPECIFICATIONS In this section ovile 2 2 Dimensions ANA u PE 2 3 TOO TONOS M 2 4 DIMENSIONS Gad 2 5 Syrnbols arid MEANKINGS m 2 6 Masses OR 2 6 Jaes deor cael 2 6 powermax1000 Service Manual 2 1 SPECIFICATIONS Power supply Rated open circuit voltage Uo 300 VDC Output characteristic Drooping Defined as a plot of output voltage versus output current Rated output current 15 20A 60A Hypertherm standard rated output 140 VDC voltage U2 Duty cycle X at 104 F 40 C at U1 Volts AC rms X rated conditions U1 l1 U2

Powermax 1000 Service Manual, Revision 1

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