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6/15/05

Hypertherm, Inc.

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

800-643-9878 Tel (Technical Service)

[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[email protected] (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 (S) Pte Ltd.

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 Huai 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)

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, Italia
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.

Rua Jati, 33
CEP 07180-350 Cumbica
Guarulhos, SP - Brasil
55 11 6482 1087 Tel
55 11 6482 0591 Fax

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Summary of Contents for MAX42

Page 1: ...Plasma Arc Cutting System Service Manual SM116 801160 Rev 2 MAX42 ...

Page 2: ...serial number MX42 8553 Revision 2 May 1995 Copyright 1995 Hypertherm Inc All Rights Reserved Hypertherm and MAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Hanover NH USA www hypertherm com ...

Page 3: ...vice Hypertherm Shanghai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai 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 France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 332...

Page 4: ...ual Page i ATTENTION 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 is not covered by the Hypertherm warranty ...

Page 5: ...EIR CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF ITS WARRANTY PATENT INDEMNITY Except only in cases of Products not manufactured by HYPERTHERM or manufactured by a person other than HYPERTHERM not in strict conformity with HYPERTHERM s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by HYPERTHERM HYPERTHERM agrees to indemnify prote...

Page 6: ...cs électriques b 3 Le coupage peut produire des vapeurs toxiques b 3 L arc plasma peut provoquer des blessures ou des brûlures b 4 Torches à allumage instantané b 4 Les rayons de l arc peuvent brûler les yeux et la peau b 4 Protection des yeux Protection de la peau Zone de coupage b 4 Mise à la masse et à la terre b 4 Câble de retour Table de travail Alimentation b 4 Sécurité des bouteilles de gaz...

Page 7: ... 5 Power Unit 1 5 Disconnect Switch Box 1 5 PAC121T Trigger Torch 1 6 PAC121P Pushbutton Torch 1 6 PAC121M Machine Torch 1 6 SECTION 2 THEORY OF OPERATION 2 1 General 2 2 Principles of Operation 2 2 Circuit Descriptions 2 3 Control Circuits 2 3 Power Circuits 2 4 SECTION 3 MAINTENANCE 3 1 General 3 2 Test Equipment Tools 3 2 Visual Inspection 3 2 Checkout Procedures 3 2 Initial Resistance Checks 3...

Page 8: ... 1 PH 60 Hz 1 2 Figure 2 1 MAX42 Power Unit Block Diagram 2 2 Figure 3 1 PAC121T Torch Assembly 3 19 Figure 3 2 PAC121P Torch Assembly 3 21 Figure 3 3 PAC121M Torch Assembly 3 23 Figure 3 4 Filter Regulator Pressure Adjustment 3 25 Figure 4 1 MAX42 Power Unit 208 240 VAC 1 PH 60 Hz Exploded View 4 3 4 4 Figure 4 2 Enclosure Left Half Exploded View 4 5 Figure 4 3 Front Panel Subassembly Exploded Vi...

Page 9: ...er 1 and 2 PC BD Assy PCB6 Schematic Diagram 5 12 Figure 5 9 FET Pack Snubber 3 and 4 PC BD Assy PCB7 Schematic Diagram 5 13 Figure 5 10 FET Packs 1 and 2 Schematic Diagrams 5 14 Figure 5 11 FET Packs 3 and 4 Schematic Diagrams 5 15 Figure 5 12 Inverter Modulator PC BD Assy PCB12 Schematic Diagram 2 Sheets 5 16 Figure 5 13 Control Power Supply PC BD Assy PCB13 Schematic Diagram 5 18 Figure 5 14 Co...

Page 10: ... Shock Can Kill a 3 Cutting Can Produce Toxic Fumes a 3 A Plasma Arc Can Cause Injury and Burns a 4 Arc Rays Can Burn Eyes and Skin a 4 Grounding Safety a 4 Compressed Gas Equipment Safety a 5 Gas Cylinders Can Explode If Damaged a 5 Noise Can Damage Hearing a 5 Pacemaker and Hearing Aid Operation a 5 A Plasma Arc Can Damage Frozen Pipes a 5 Additional Safety Information a 5 ...

Page 11: ... 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...

Page 12: ... 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...

Page 13: ...rdant 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 screens or barriers to protect...

Page 14: ...s possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible PACEMAKER AND HEARING AID OPERATION 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 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and...

Page 15: ... fatals b 3 Prévention des chocs électriques b 3 Le coupage peut produire des vapeurs toxiques b 3 L arc plasma peut provoquer des blessures ou des brûlures b 4 Torches à allumage instantané b 4 Les rayons de l arc peuvent brûler les yeux et la peau b 4 Protection des yeux Protection de la peau Zone de coupage b 4 Mise à la masse et à la terre b 4 Câble de retour Table de travail Alimentation b 4 ...

Page 16: ...e sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais ...

Page 17: ...ors du coupage Laisser la pièce à couper en place ou sur la table de travail le câble de retour connecté lors du coupage Avant de vérifier de nettoyer ou de remplacer les pièces de la torche couper l alimentation ou débrancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de sécurité Avant d enlever le capot du système ou de la source de courant couper l alimentatio...

Page 18: ...sées du corps Pantalon sans revers pour éviter que des étincelles 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 Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette Peindre les murs et autres surfaces de couleur sombre pour réduire ...

Page 19: ... jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs Utiliser un casque de protection homologué lors de l utilisation du système plasma Prévenir les per...

Page 20: ...c 3 Prevención ante el electrochoque c 3 Los cortes pueden producir humos tóxicos c 3 El arco de plasma puede causar lesiones y quemaduras c 4 Antorchas de encendido instantáneo c 4 Los rayos del arco pueden producir quemaduras en los ojos y en la piel c 4 Protección para los ojos Protección para la piel Área de corte c 4 Seguridad de toma a tierra c 4 Cable de trabajo Mesa de trabajo Potencia pri...

Page 21: ...r daños en el equipo Prevención ante el fuego Asegúrese de que el área sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables colocándolos a por lo menos 10 metros del área de corte Remoje los metales calientes o permita que se enfríen antes de que entren en contacto con materiales combustibles Nunca corte depósitos que contengan mate...

Page 22: ...ando se encuentren dañadas No toque la pieza ni los recortes cuando se está 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 energía Nunca evite o descuide los bloqueos de seguridad Antes de retirar la cubierta de...

Page 23: ...es 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 Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión Utilice pantallas o bar...

Page 24: ...r excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro La exposición prolongada al ruido propio de las operaciones de corte y ranurado puede dañar la audición Utilice un método de protección de los oídos aprobado al utilizar el sistema de plasma Advierta a las demás personas que se encuentren en las cercanías ac...

Page 25: ...hes 1 3 Description 1 4 Power Unit 1 4 Major Subassemblies and Components 1 4 Specifications 1 5 Power Unit 1 5 Disconnect Switch Box 1 5 PAC121T Trigger Torch 1 6 PAC121P Pushbutton Torch 1 6 PAC121M Machine Torch 1 6 Section 1 INTRODUCTION MAX42 Service Manual Page 1 1 ...

Page 26: ...ted by wiring diagrams printed circuit board schematics and a parts list This indexed parts list is supported by exploded view illustrations which provide the user with the ability to locate subassemblies and components for testing and removal and replacement The complexity of the circuits and the accessibility of the subassemblies and compo nents require that maintenance personnel have a working ...

Page 27: ...l etc In addition if the MAX42 Power Unit must be operated in order to determine if the malfunction was corrected refer to the MAX42 Instruction Manual IM 85 part num ber 800850 Section 1 Safety for operating precautions WARNING INSTANT ON TORCHES WARNING The PAC121 hand held torches and machine torch are instant on torches These torches fire produce a plasma arc immediately after torch switch clo...

Page 28: ...ls up to 1 16 inch thick while the 40 amp setting is used for thicker metals Cylinder air shop air or nitrogen can be used as long as it is free of moisture oil and particulate matter contamination Major Subassemblies and Components The MAX42 Power Unit consists of the following major subassemblies and compo nents listed in Table 1 1 Part Number 001216 002183 w line chokes 001216 w o line chokes 0...

Page 29: ...et or that the ground wire is properly connected to the ground in the disconnect box Gas Requirements Gas Type Air or Nitrogen Gas Quality Clean Dry Oil Free Gas Flow Pressure input to regulator 270 scfh 4 5 scfm 80 125 psig 127 l min 5 5 8 6 bar Gas Pressure Setting at power unit regulator 80 psig 5 4 bar Physical Characteristics Width 8 inches 20 cm Height 13 inches 33 cm Length 20 inches 51 cm ...

Page 30: ... 25 ft 7 6 m lead PAC121P Pushbutton Torch Maximum cutting thickness range 1 2 inch 13 mm Maximum current at 80 duty cycle 40 C 40 amps Gas Flow 270 scfh 4 5 scfm at 70 psi 127 l min at 4 8 bar Weight 6 pounds 2 7 kg with 25 ft 7 6 m lead PAC121M Machine Torch Maximum cutting thickness range 1 2 inch 13 mm Maximum current at 80 duty cycle 40 C 40 amps Gas Flow 270 scfh 4 5 scfm at 70 psi 127 l min...

Page 31: ...In this section General 2 2 Principles of Operation 2 2 Circuit Descriptions 2 3 Control Circuits 2 3 Power Circuits 2 4 Section 2 THEORY OF OPERATION MAX42 Service Manual Page 2 1 ...

Page 32: ...AC current 20 Khz by the inverter 3 The isolation transformer couples the voltage from the inverter to the secondary rectifier 4 The secondary rectifier converts the AC back to DC for the output current to the torch and to the pilot arc controller The pilot arc controller provides current control between the nozzle and electrode 5 The feedback loop control board modulator board and current sensor ...

Page 33: ...erforms the following functions 1 It monitors the pressure switch PS1 and the thermostat TS1 Indicator LT1 lights when the operating temperature and the incoming gas pressure are within operating limits It goes out when either pressure switch PS1 opens because the incoming gas pressure is too low or when thermostat TS1 opens because the duty cycle rating was exceeded causing the power unit to over...

Page 34: ... 100 pulses per second at 50 Hz The DC output of PCB3 is input to the capacitor bank printed circuit boards PCB4 and PCB5 Capacitor Bank Circuit The capacitor bank circuit which consists of PCB4 and PCB5 acts as a filter to smooth out the ripple of the DC pulse output of PCB3 When the DC pulse output of PCB3 begins to fall the capacitors discharge thereby maintaining a constant DC pulse level outp...

Page 35: ...nd less to the nozzle When the voltage between the workpiece and the nozzle reduces to the preset level the pilot arc controller turns off the current path to the nozzle and arc transfer is complete During cutting the pilot arc controller monitors the workpiece to nozzle voltage If this voltage increases past the preset level the current path is turned on and current is diverted to the nozzle A gr...

Page 36: ...ement 3 18 Torch Main Body Removal and Replacement 3 18 Torch Switch Removal and Replacement 3 19 PAC121P Torch Parts Removal and Replacement 3 20 Torch Main Body Removal and Replacement 3 20 Torch Switch Removal and Replacement 3 20 PAC121M Torch Parts Removal and Replacement 3 22 Torch Main Body Removal and Replacement 3 22 Filter Regulator Pressure Adjustment 3 24 Filter Regulator Filter Cleani...

Page 37: ...kout procedures are provided for the 208 240 VAC 60 Hz single phase power supply These procedures include the Initial Resistance Checks and the Corrective Maintenance Checks These checkout procedures are presented in a flow diagram format in order to aid the technician in performing the checkout in the proper sequence Refer to the wiring diagrams Figures 5 1 and 5 2 when performing the checkout pr...

Page 38: ...ING SHOCK HAZARD Always unplug the power supply prior to per forming resistance checks in the power unit Dangerous voltages exist within the power unit which could cause serious injury or death If questions or problems arise during servicing call the Hypertherm Technical Services department at 1 800 643 0030 Caution After the power unit has been received for maintenance always perform the initial ...

Page 39: ...MAX42 power switch S1 to OFF 0 unplug the power cord and discon nect the gas supply 2 Remove the left and right enclosures of the power supply To do this refer to Figure 4 1 Remove the 6 screws 1 3 screws 2 and 5 nuts 12 from the right enclosure 3 and left enclosure 11 to access the power supply interior 3 Move the right and left enclosures away from the power supply Note that there are inductors ...

Page 40: ... the capacitor packs may be blown Fig 4 8 2 Look for damage or dark discoloration Indication is low or 0 ohms Indication is high or infinity Yes Meter indicates a short Replace PCB3 Yes No 2 Yes Disconnect cables W132 135 from TB1 Fig 4 8 6 Measure the resistance across each inductor L2 L5 Fig 4 1 11 between the disconnected cable terminal and power switch S1 Observe for an indication of 1 ohm or ...

Page 41: ...etween PCB3 and T5 No Repair connector plug Replace T5 No T5 okay Yes Yes Meter indicates 90 115 ohms Check resistors R1 and R2 on PCB2 Fig 4 9 13 Measure resistance across each resistor Observe for an indication of 5 ohms Recheck resistor and relays K1 and K2 on PCB2 Replace resistor if faulty Replace PCB3 if a relay is faulty Plug making good electrical contact Measure resistance across terminal...

Page 42: ... following corrective maintenance checks WARNING SHOCK HAZARD Always use caution when servicing a power supply when plugged in and the covers are removed Dangerous voltages exist within the power supply which could cause injury or death If questions or problems arise during servicing call the Hypertherm Technical Services department at 1 800 643 0030 1 Plug in the power supply power cord and conne...

Page 43: ...h TB2 Yes No Connections are making good contact Replace control PC BD Assy PCB14 Tighten or repair all connections as required or replace connectors and cables as required Replace torch main body Fig 4 12 Disconnect torch lead Measure resistance between TB2 7 and torch lead receptacle J1 Fig 4 5 1 pin 2 and TB2 9 and J1 pin 8 for 0 ohms Replace torch main body Fig 4 12 or torch lead Unplug power ...

Page 44: ...ded Reconnect connector between PCB3 and T5 Measure voltage between terminals 1 and 2 of T5 for 208 240 VAC Meter indicates 208 240 VAC To page 3 10 No Yes Replace T5 Unsolder connections at E10 and E11 on PCB13 to isolate T5 Measure between cables W128 and W129 for18 VAC Replace PCB13 Yes No 3 Disconnect connector between PCB3 Fig 4 7 13 and T5 Fig 4 6 15 Measure voltage between sockets on female...

Page 45: ... on P101 for 11 5 12 VDC Disconnect P107 J107 at PCB13 Fig 4 6 11 Measure voltage between sockets 1 and 3 on J107 for 11 5 12 VDC Yes No No Yes Replace PCB14 Replace voltage regulator LM350 Fig 4 6 9 Replace voltage regulator LM350 Fig 4 6 9 or fan M1 Fig 4 7 1 3 Meter indicates voltage lower than 11 5 12 VDC Meter indicates 11 5 12 VDC ...

Page 46: ...ter indicates PS1 closed Replace PS1 Disconnect P103J103 at PCB14 Fig 4 3 6 and check connections Yes No Connectors making good contact Repair connections as required No No Disconnect cables W122 and W123 from temperature switch TS1 Fig 4 7 14 Measure resistance across terminals of TS1 for closed indication Meter indicates TS1 closed Replace TS1 Disconnect P106 J106 at PCB14 and check connections ...

Page 47: ... hold GAS TEST switch S2 and adjust for 70 psi dynamic indication at pressure regulator gauge Refer to regulator pressure adjustment in this Section Check P102 J102 at PCB14 Fig 4 3 6 wires W106 W109 air solenoid V1 Fig 4 5 6 and pressure regulator Fig 4 6 9 Repair or replace as required If no faults are found replace PCB14 Check voltage regulator LM350 Fig 4 6 9 air solenoid valve V1 Fig 4 5 6 an...

Page 48: ...Set power switch to OFF 0 and unplug power cord Measure resistance at TB2 11 and 13 Fig 4 6 7 while depressing torch start switch Observe for a switch closed indication Disconnect torch lead Measure resistance between TB2 11 and connector torch lead receptacle J1 pin 7 and TB2 13 and J1 pin 6 for 0 ohms Replace torch start switch Fig 4 12 or torch lead Tighten or repair all connections as required...

Page 49: ...dicates 11 VDC Yes Disconnect P46 J46 at PCB12 Measure voltage between sockets 1 and 3 and 2 and 4 on P46 for 15 VDC Meter indicates 15 VDC Cables and connections okay Yes No Replace PCB14 Repair or replace as required Check cables W120 and W121 between P118 at PCB12 and P105 at PCB14 for good electrical connections Replace PCB14 Check fuse F1 on PCB12 8 Cables and connections okay No Yes Repair o...

Page 50: ...VDC Replace PCB15 Replace PCB14 Connect work clamp to workpiece Set AMPS control to minimum 15 amps Depress torch start switch to transfer arc to cut workpiece Arc transfers to workpiece Set AMPS control to maximum 40 amps Depress torch start switch to transfer arc to cut workpiece to see if cutting current is adjustable Replace PCB14 Cutting current is adjustable Reassemble the power supply Refer...

Page 51: ...ing the temperature and air pressure are within the range of operation ACTION Push and hold TEST switch S2 to check air pressure Release TEST switch RESULT Air solenoid valve V1 opens to purge system and to allow setting of pressure Gas flow stops ACTION Connect work cable to workpiece and position torch on workpiece Depress plasma start switch on torch or remote start switch for machine torches R...

Page 52: ...e torch leads Note Disconnect wires by pulling on terminals Do not pull on wires 6 Disconnect the red wire attached to the pilot arc tab 7 Disconnect torch main body and torch lead gas fittings using 5 16 and 7 16 wrenches 8 Connect and tighten the new torch main body with the torch lead gas fittings 9 Connect the terminal of the two white wires from the torch lead to the black plunger wire termin...

Page 53: ...g the two 2 splices at the torch lead violet wires 5 Replace the torch switch by crimping the switch leads and the violet leads from the torch lead together with the splices 6 Install the torch switch back into handle Be certain that torch switch slides into position above safety trigger and that trigger movement activates the button of the switch and then releases 7 Position handle halves togethe...

Page 54: ...ires 5 Disconnect torch main body and torch lead gas fitting using 5 16 and 7 16 wrenches 6 Connect the new torch main body and torch lead gas fitting using the wrenches 7 Connect the terminals connecting the two white wires from the torch lead to the black plunger wire from the torch main body 8 Connect the bullet receptacle and plug connecting the red wire from the torch lead to the red wire fro...

Page 55: ...ead violet wires 6 Replace the torch switch by crimping the switch leads and the violet leads from the torch lead together with the splices 7 Slide the protective PVC tubing back over the connections 8 Install the torch main body torch switch and wire bundle into one of the handle halves 9 Position the handle halves together be careful not to pinch any wires and replace the five 5 screws to secure...

Page 56: ...e to the torch main body 6 Unscrew the torch position sleeve 020620 from the torch sleeve 020559 and slide it back out of the way 7 Remove the screw 075322 securing the red wire from the torch lead to the torch main body Note Disconnect wires by pulling on terminals Do not pull on wires 8 Disconnect the terminals between the two 2 white wires from the torch lead and the black plunger wire from the...

Page 57: ...r 19 When the nozzle electrode and swirl ring are properly in place replace the retaining cap When the retaining cap is tightened the microswitch will click indicating that the torch main body has been replaced correctly 20 Align the connector plug key on torch lead with the connector receptacle key slot on power supply and push it in until the pins seat 21 Turn the connector securing ring clockwi...

Page 58: ... in and hold and view the pressure gauge while adjusting the adjustment knob Adjust until the pressure gauge reads 70 psi 4 8 bar 4 Release TEST switch and push the locking ring down to secure the adjustment knob FILTER REGULATOR FILTER CLEANING OR REPLACEMENT To clean or replace the filter regulator filter perform the following procedure and refer to Figure 3 4 1 Always disconnect the gas supply ...

Page 59: ...MAINTENANCE MAX42 Service Manual Page 3 25 Adjustment Knob Locking Ring Red Filter Bowl Filter Regulator Figure 3 4 Filter Regulator Pressure Adjustment ...

Page 60: ...Assembly Magnetic Tray 029328 4 14 Input Capacitor Bank 029298 4 16 Inductor Power I O 029293 4 17 PAC121 Torch Assembly and Leads 4 18 PAC121T Torch Assembly and Lead 25 Ft 7 63 M 071065 4 18 PAC121T Torch Assembly and Lead 50 Ft 15 25 M 071066 4 18 PAC121P Torch Assembly and Lead 25 Ft 7 63 M 071069 4 20 PAC121P Torch Assembly and Lead 50 Ft 15 25 M 071070 4 20 PAC121M Torch Assembly and Lead 25...

Page 61: ...X 3 8 PH TRS S Z Cord Primary Power 8 3 SO 7 3 Ft M S 10 32 X 3 8 PH PAN SS Lockwasher 10 Internal Tooth SS Rear Panel Subassembly Plate Mounting Exhaust Enclosure Left Half 1 PH w line chokes Enclosure Left Half 1 PH w o line chokes Hexnut 10 32 Blk Ox S B Inverter Subsystem Assembly 208 240V Hood Fan Inverter Circuit Breaker 1A 240V 40 A 1 PH M S 6 32 X 1 4 PH TRS SS Front Panel SA 1 PH Cable Gr...

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Page 67: ...1 4 20 S Z Lockwasher 6 Int Tooth SS M S 6 32 X 5 8 PH PAN SS Terminal Strip Blk 7 Pos 2 Row Insulator Cover TO 3 IC Regulator Voltage 3 Amp LM350K PC BD Air Pack P S PC BD Assy Control Power Supply Spacer 6 32 X 3 8 M X F Lockwasher 6 Int Tooth SS M S 6 32 X 5 8 PH PAN SS Transformer Cntrl 208 240 1 PH 60 Hz M S 8 32 X 3 8 PH PAN SS Lockwasher 8 Int Tooth SS 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 2 2 Inde...

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Page 69: ...SS M S 10 32 X 3 8 PH PAN SS Lockwasher 10 Int Tooth SS Bracket Assy Magnetic Tray 208 240V PC BD Assy Inverter Modulator M S 6 32 X 3 8 SL BIN Nylon SHDCAP 8 32 X 1 1 4 HX SSB Spacer Phenol M S 6 32 X 3 8 PH PAN BRS Lockwasher 6 Int Tooth BRS BRZ PC BD Assy Input Rectifier Thermostat 75 C Heatsink Subassembly Hexnut 6 32 BRS 1 4 4 4 4 1 1 3 2 2 10 34 1 1 1 24 Index No Ref Desig Part No Descriptio...

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Page 71: ...041213 075184 008525 M S 8 32 X 3 8 PH PAN SS Lockwasher 8 Int Tooth BRS BRZ Bracket Heatsink FET Pack Module Bracket Heatsink PC BD Assy Output Rectifier Snubber PC BD Assy FET Pack Snubber PC BD Assy FET Pack Snubber Lockwasher 6 Int Tooth BRS BRZ Spacer Hex Brass 6 32 X 1 4 5 5 1 1 1 1 1 1 24 24 Index No Ref Desig Part No Description Quantity PCB8 PCB7 PCB6 1 2 3 7 8 6 4 9 10 1 2 5 ...

Page 72: ...ter I O Standoff 6 32 X 3 4 LG HX NYL Spacer 8 X 1 2 Phenol Lockwasher 6 Int Tooth SS M S 6 32 X 1 4 PH PAN SS PC BD Assy Inverter P S 208 240 M S 10 32 X 3 8 PH PAN SS Lockwasher 10 Int Tooth SS PC BD Assy Gate Drive Transformer Plate Transformer Mounting Plate Mounting Exhaust M S 10 32 X 2 1 4 PH PAN SS Bracket Mounting Fan Transformer SA Power HF 1 240 480V Transformer SA Power HF 2 240 480V S...

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Page 76: ...044009 Quick Disconnect O Ring see Figure 5 8 027283 Ring Gutcha 020350 Nozzle 020351 Electrode Air 020361 Ring Swirl 020930 Cap Retaining PAC121T Torch Assembly and Lead 50 Ft 15 25 M 071066 001288 Handle PAC121T 075340 Screws P S 4 x 5 8 PH RND S B 002244 Safety Trigger PAC121T 027254 Trigger Spring PAC 121T 005094 Switch Torch Pushbutton 020932 Torch Main Body w Switch PAC121T 029550 Torch Lead...

Page 77: ...01288 Torch Lead 029549 25 7 63 m 029550 50 15 25 m Gutcha Ring 027283 Torch Pushbutton Switch 005094 Figure 4 12 PAC121T Torch Assembly and Leads Handle 001288 Trigger Spring 027254 Torch Main Body w Switch 020932 Safety Trigger 002244 Screw 5 075340 ...

Page 78: ...4 Black PVC 020350 Nozzle 020351 Electrode Air 020361 Ring Swirl 020930 Cap Retaining PAC121P Torch Assembly and Lead 50 Ft 15 25 M 071070 001215 Handle PAC121P 075365 Screws P S 6 x 3 4 PH RND S B 005094 Switch Torch Pushbutton 120013 Torch Main Body w Switch PAC121P 029392 Torch Lead 50 ft 15 25 m 044009 Quick Disconnect O Ring see Figure 5 8 027283 Ring Gutcha 046080 Tubing 1 1 4 Black PVC 0203...

Page 79: ...LIST PVC Tubing 046080 Handle 001215 Torch Lead 029391 25 7 63 m 029392 50 15 25 m Torch Main Body w Switch 120013 Torch Pushbutton Switch 005094 Gutcha Ring 027283 Handle 001215 Screw 5 075365 Figure 4 13 PAC121P Torch Assembly and Leads ...

Page 80: ...de Extended 020361 Ring Swirl 020930 Cap Retaining PAC121M Torch Assembly and Lead 50 Ft 15 25 M 071068 020620 Sleeve Torch Position PAC121M 020619 Sleeve Insulator PAC121M 020229 Ring Locking PAC121M 020559 Sleeve Machine Torch PAC121M 120007 Torch Main Body w Switch PAC121M 028452 Torch Lead 50 ft 15 25 m 044009 Quick Disconnect O Ring see Figure 5 8 075321 Socket Cap 4 40 x 1 2 HX SS 075322 M S...

Page 81: ...28461 25 028462 50 028463 75 Torch Lead 028451 25 028452 50 Figure 4 14 PAC121M Torch Assembly with Leads and Optional On Off Pendant Torch Main Body 120007 Locking Ring 020229 Torch Lead See Fig 4 14 On Off Pendant See Fig 4 14 O Ring 044016 Screw 3 075321 Screw 075322 Sleeve Insulator 020619 Torch Position Sleeve 020620 Retaining Cap 020930 Torch Sleeve 020559 ...

Page 82: ...Assy PCB4 and PCB5 Schematic Diagrams 5 11 Figure 5 8 FET Pack Snubber 1 and 2 PCB6 Schematic Diagram 5 12 Figure 5 9 FET Pack Snubber 3 and 4 PCB7 Schematic Diagram 5 13 Figure 5 10 FET Packs 1 and 2 Schematic Diagrams 5 14 Figure 5 11 FET Packs 3 and 4 Schematic Diagrams 5 15 Figure 5 12 Inverter Modulator PC BD Assy PCB12 Schematic Diagram 2 Sheets 5 16 Figure 5 13 Control Power Supply PC BD As...

Page 83: ...IRING DIAGRAMS SCHEMATICS GENERAL This section provides maintenance personnel with the wiring diagrams pneumatic flow diagram and printed circuit board assembly schematic diagrams required to troubleshoot and maintain the power unit ...

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