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Hypertherm Powermax 125, Service Manual

The Hypertherm Powermax 125 is a high-performance cutting system that delivers superior results. Unlock the full potential of this powerful tool by accessing the Service Manual, available for free download from manualshive.com. Equip yourself with the knowledge to maximize the capabilities of your Powermax 125.

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Powermax125

Service Manual 808070

10 – Torch Component Replacement

9.

Install the new shell halves onto the torch lead, making sure the strain relief fits in the slot of the shell and the wires 
are not pinched or do not interfere with the latch.

10.

Install and tighten the screws.

Summary of Contents for Powermax 125

Page 1: ...Powermax125 Plasma Arc Cutting System Service Manual 808070 Revision 1 English ...

Page 2: ..._______________________________________________________________ Maintenance notes ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ __________...

Page 3: ...Powermax125 Service Manual 808070 Revision 1 English April 2014 Hypertherm Inc Hanover NH 03755 USA ...

Page 4: ...41 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax 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 4973 7843 Tel Technical Serv...

Page 5: ...Safety information Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 80669C included with your product for important safety information ...

Page 6: ......

Page 7: ...les SC 16 Equipotential bonding SC 16 Earthing of the workpiece SC 16 Screening and shielding SC 16 Warranty SC 17 Attention SC 17 General SC 17 Patent indemnity SC 18 Limitation of liability SC 18 National and local codes SC 18 Liability cap SC 18 Insurance SC 18 Transfer of rights SC 18 1 Specifications 19 Safety information 19 Powermax125 System description 19 Power supply dimensions 20 Compone...

Page 8: ... disconnect switch 31 Requirements for grounding 31 Power connection for the Powermax125 32 Three phase power cord and plug installation 33 Decrease output current for lower rated power plugs 33 Extension cord recommendations 35 Engine driven generator recommendations 35 Prepare the gas supply 36 Additional gas filtration 36 Connect the gas supply 37 Minimum inlet pressure while gas is flowing 38 ...

Page 9: ...ch Setup 51 Introduction 51 Consumable life 51 Hand torch components 52 Duramax Hyamp 85 hand torch 52 Duramax Hyamp 15 hand torch 52 Choose the hand torch consumables 52 Drag cutting 105 125 A consumables 53 Drag cutting 45 A and 65 A consumables 53 Gouging consumables 53 FineCut consumables 53 Install the hand torch consumables 54 Connecting the torch lead 55 5 Hand Cutting 57 Using the hand tor...

Page 10: ... FineCut shielded with ohmic consumables 75 Install the machine torch consumables 75 Aligning the torch 75 Connecting the torch lead 76 Using the cut charts 77 Estimated kerf width compensation 78 Estimated kerf width compensation Metric mm 78 Estimated kerf width compensation English inches 79 125 A shielded consumables 80 125 A shielded cutting mild steel 81 125 A shielded cutting stainless stee...

Page 11: ...ing a workpiece using the machine torch 107 Common machine cutting faults 107 8 Troubleshooting and System Tests 109 Controls and indicators 109 Rear panel 109 Front panel 110 Status screen 110 Theory of operation 111 480 V and 600 V CSA 3 phase power supply functional description 111 400 V CE 380 V CCC 3 phase power supply functional description 111 Sequence of operation 112 Troubleshooting prepa...

Page 12: ...152 Test 3 Output diodes 154 Test 4 Inverter temperature sensor 154 For operational fault codes 0 40 2 and 0 40 3 or power board faults 2 10 0 and 2 10 1 155 Test 5 Flyback circuit DC minor voltages 156 Test 6 Torch stuck open torch stuck closed 158 Test 7 Start signal 160 Test 8 Torch cap switch 161 Test 9 Electronic regulator 162 Test 10 Pressure sensor 163 Test 11 Fan 164 Test 12 AUX switch 164...

Page 13: ...e thermal sensor 214 Replacing the fan shroud 216 Replacing the fan 217 Replacing the pressure transducer 219 Replacing the pressure switch 221 Replacing the gas filter assembly 223 Replacing the solenoid valve 225 Replacing the gas tubing 227 Replacing the bulk capacitors 229 Replacing the torch quick disconnect receptacle 231 Replacing the work lead receptacle 236 Replacing the output inductor 2...

Page 14: ...C 298 Interior fan side 299 Interior heatsink assembly 300 Duramax Hyamp 85 hand torch replacement parts 301 Duramax Hyamp 15 hand torch replacement parts 302 Hand torch consumables 303 Drag cutting 303 Gouging 303 FineCut 303 Duramax Hyamp 180 full length machine torch replacement parts 304 Duramax Hyamp 180 mini machine torch replacement parts 305 Machine torch consumables 306 Shielded 306 Gougi...

Page 15: ...ential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signaling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people...

Page 16: ... of the 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 steel work 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...

Page 17: ... date of delivery to you This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any product which has been incorrectly installed modified or otherwise dam...

Page 18: ...damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence 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 Liability cap In no event shall Hypertherm s liability if any whether such liability is bas...

Page 19: ...button torch connection to the power supply for quick torch changes The typical handheld Powermax125 system includes a Duramax Hyamp 85 hand torch with a starter consumable kit a box of spare electrodes and nozzles and a work lead cable Reference materials include operator manual quick setup card registration card setup DVD and safety manual The typical mechanized Powermax125 system includes a Dur...

Page 20: ...ystems include the following models 480 V CSA 480 V only 600 V CSA 600 V only 400 V CE 400 V only 380 V CCC 380 V only To maintain CE certification install power cord kit 228886 Power supply dimensions 508 mm 20 0 inches 592 mm 23 3 inches 274 mm 10 8 inches 432 mm 17 0 inches ...

Page 21: ...and 7 6 m 25 foot work lead 48 kg 106 pounds 48 kg 105 pounds 49 kg 108 pounds 45 kg 100 pounds Hand torch 7 6 m 25 feet 3 5 kg 7 7 pounds Hand torch 15 m 50 feet 6 2 kg 13 7 pounds Hand torch 23 m 75 feet 8 8 kg 19 5 pounds Machine torch 7 6 m 25 feet 3 7 kg 8 2 pounds Machine torch 11 m 35 feet 4 8 kg 10 6 pounds Machine torch 15 m 50 feet 6 4 kg 14 2 pounds Machine torch 23 m 75 feet 9 2 kg 20 ...

Page 22: ... 95 pure Recommended gas inlet flow rate pressure Cutting 260 slpm 550 scfh 9 2 scfm at 5 9 bar 85 psi for 7 6 m 25 foot and 15 m 50 foot torches 6 6 bar 95 psi for 23 m 75 foot torches Gouging 212 slpm 450 scfh 7 5 scfm at 4 1 bar 60 psi 1 Defined as a plot of output voltage versus output current 2 This Class A equipment is not intended for use in residential locations where the electrical power ...

Page 23: ...Duramax Hyamp 85 hand torch dimensions Duramax Hyamp 15 hand torch dimensions 31 2 cm 12 3 inches 3 5 cm 1 375 inch 11 4 cm 4 5 inches 85 6 8 cm 2 68 inches 29 5 cm 11 6 inches 6 8 cm 2 68 inches 5 85 cm 2 3 inches 15 3 5 cm 1 375 inch 35 3 cm 13 9 inches ...

Page 24: ...rch dimensions Duramax Hyamp 180 mini machine torch dimensions 3 5 cm 1 375 inches 40 6 cm 16 0 inches 4 4 cm 1 75 inches 4 2 cm 1 6 inch outer dimension 3 6 cm 1 4 inch flat sides 3 5 cm 1 375 inch 18 3 cm 7 2 inches 4 4 cm 1 75 inches 4 2 cm 1 6 inch outer dimension 3 6 cm 1 4 inch flat sides ...

Page 25: ... min 282 ipm 10 mm 3 8 inch 4390 mm min 173 ipm 12 mm 1 2 inch 2950 mm min 116 ipm 16 mm 5 8 inch 2110 mm min 83 ipm 20 mm 3 4 inch 1470 mm min 58 ipm 22 mm 7 8 inch 1170 mm min 46 ipm 25 mm 1 inch 940 mm min 37 ipm 32 mm 1 1 4 inches 610 mm min 24 ipm 38 mm 1 1 2 inches 457 mm min 18 ipm Gouging capacity Metal removal rate on mild steel 125 A 12 5 kg hour 27 pounds hour Duramax Hyamp series torch...

Page 26: ... data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking Eurasian Customs Union CU mark CE versions of Hypertherm products that include an EAC mark of conformity meet the product safety...

Page 27: ...ecific environment in which the system is used Refer to Noise can damage hearing in the Safety and Compliance Manual 80669C included with your system In addition you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at https www hypertherm com 1 Click Downloads library 2 Select a product from the Product type menu 3 Select Regulatory from the Category menu...

Page 28: ...utting Plate metal cutting Expanded metal cutting Gouging Torch lock AC input power connection The terminal for the external protective earth conductor Power is ON Power is OFF An inverter based power source either 1 phase or 3 phase Volt amperage curve drooping characteristic Power is ON LED System fault LED Inlet gas pressure fault LCD Missing or loose consumables LCD Power supply is out of temp...

Page 29: ... Before you set up and operate this Hypertherm system read the separate Safety and Compliance Manual 80669C included with your system for important safety information Claims Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance cal...

Page 30: ...installation 480 V 3 phase CSA certified 600 V 3 phase CSA certified 400 V 3 phase CE certified 380 V 3 phase CCC certified CSA and CE certified power supplies include a 3 m 10 foot power cord depending on the model CCC certified power supplies do not ship with a power cord To maintain CE certification install power cord kit 228886 or or 1 2 3 4 5 6 7 8 9 10 11 1 Operator Manual 2 Quick Setup Card...

Page 31: ...cessible to the operator Installation must be performed by a licensed electrician according to national and local codes The interrupt level of the switch must equal or exceed the continuous rating of the fuses In addition the switch should Isolate the electrical equipment and disconnect all live conductors from the incoming supply voltage when in the OFF position Have one OFF and one ON position t...

Page 32: ... output is 30 125 A 175 VDC Table 4 480 V CSA Table 5 600 V CSA Table 6 400 V CE Input voltage V 480 Input current A at rated output 21 9 kW 31 Input current A at arc stretch 50 Fuse slow blow A 50 Voltage tolerance 20 15 Input voltage V 600 Input current A at rated output 21 9 kW 24 Input current A at arc stretch 38 Fuse slow blow A 40 Voltage tolerance 10 15 Input voltage V 400 Input current A a...

Page 33: ...must be connected to the power cord by a licensed electrician Decrease output current for lower rated power plugs To operate the power supply at full output and 100 duty cycle as rated you must size your electrical service accordingly To operate the power supply using a lower rated power plug or service you must turn down the current amperage setting For more information on setting the current see...

Page 34: ...round the ground wire CSA and CCC models do not have ferrite cores on the power cord wires CCC models do not ship with a power cord To maintain CE certification install power cord kit 228886 L1 L2 L3 L1 L2 L3 Ground 419 mm 16 5 inches 203 mm 8 inches 6 mm 0 25 inch Route lead through strain relief and tighten CSA CCC power cords no ferrite cores CE power cord ferrite cores on power wires and groun...

Page 35: ...s in the following table and in Hypertherm power supply ratings on page 22 Based on the generator rating age and condition adjust the cutting current as needed If a fault occurs while using a generator turning the power switch quickly to OFF and then to ON again sometimes called a quick reset may not clear the fault Instead turn OFF the power supply and wait 60 to 70 seconds before turning it ON a...

Page 36: ...he range of 0 1 0 5 microns a maximum of 400 for particle sizes in the range of 0 5 1 microns and a maximum of 10 for particle sizes in the range of 1 5 microns The maximum water vapor dew point should be 40 C 40 F The maximum oil aerosol liquid and vapor content should be 0 1 mg m3 Additional gas filtration When site conditions introduce moisture oil or other contaminants into the gas line use a ...

Page 37: ...a 9 5 mm 3 8 inch internal diameter and a 1 4 NPT quick disconnect coupler CSA units or a 1 4 NPT x G 1 4 BSPP CE CCC units quick disconnect coupler WARNING Do not allow the gas supply pressure to exceed 9 3 bar 135 psi The filter bowl may explode if this pressure is exceeded The recommended inlet pressure while gas is flowing is 5 9 9 3 bar 85 135 psi ...

Page 38: ...rch lead length 7 6 m 25 feet 15 2 m 50 feet 22 9 m 75 feet Process Minimum inlet pressure Cutting 5 9 bar 85 psi 5 9 bar 85 psi 6 6 bar 95 psi Gouging 4 1 bar 60 psi 4 1 bar 60 psi 4 1 bar 60 psi Process Gas flow rate Cutting 260 slpm 550 scfh 9 2 scfm at a minimum 5 9 bar 85 psi for 7 6 m 25 foot and 15 m 50 foot torches 6 6 bar 95 psi for 23 m 75 foot torches Gouging 212 slpm 450 scfh 7 5 scfm ...

Page 39: ...g controls and indicators ON OFF switch adjustment knob automatic manual pressure setting mode selector current gas selector operating mode switch indicator LEDs and a status screen These controls and indicators are described on the following pages Rear controls ON I OFF O power switch Activates the power supply and its control circuits ...

Page 40: ... amperage This LED is illuminated in manual mode Manual mode should be used by experienced users who need to optimize the gas setting override the automatic gas setting for a specific cutting application When you switch from manual mode to automatic mode the power supply automatically sets the gas pressure and the amperage setting is unchanged When you switch from automatic mode to manual mode the...

Page 41: ...Same as the non continuous pilot arc mode except the torch is locked in the ON position when you release the trigger during a cut The torch goes out when the transfer is lost or the torch is retriggered This knob adjusts the amperage When operating in manual mode you can also use this knob to adjust the gas pressure overriding the automatic setting for optimized applications 1 2 3 4 5 6 7 8 9 10 1...

Page 42: ...started Indicates that the torch has received a start signal Torch is cutting Indicates that the cutting arc has transferred to the metal and the torch is cutting Remote control Indicates that a remote control or CNC is controlling the power supply using serial communications All local controls are disabled Electrode end of life detection manually disabled Indicates that the electrode end of life ...

Page 43: ...at the consumables are loose improperly installed or missing Turn OFF the power properly install the consumables and turn ON the system again to reset the power supply Temperature Indicates that the temperature of the power supply power module is outside the acceptable operating range Gas Indicates that the gas is disconnected from the rear of the power supply or there is a problem with the gas su...

Page 44: ...n on connecting the proper plug to the power cord refer to Power Supply Setup on page 29 Plug in the power cord and connect the gas supply line For more information about the electrical requirements and the gas supply requirements of the Powermax see Power Supply Setup on page 29 To connect the torch push the FastConnect connector into the receptacle on the front of the power supply You will attac...

Page 45: ...rn clockwise approximately 1 4 turn until the connector is fully seated against the stop in order to achieve an optimal electrical connection A loose connection will overheat the connector Frequently check the work lead for a reliable electrical connection CAUTION Make sure you use a work lead that is appropriate for your power supply Use a 125 A work lead with the Powermax125 The amperage is mark...

Page 46: ...mp to the workpiece See your table manufacturer s instructions Make sure that the ground clamp and the workpiece make good metal to metal contact Remove rust dirt paint coatings and other debris to ensure the work lead makes proper contact with the workpiece For the best cut quality attach the ground clamp as close as possible to the area being cut Turn on the system Set the ON OFF switch to the O...

Page 47: ...tatus screen or the Fault LED is illuminated or the power ON LED is blinking correct the fault condition before continuing More troubleshooting information is included later in this manual For cutting expanded metal grates metal containing holes or any job that requires a continuous pilot arc Using this mode to cut standard metal plate reduces consumable life For cutting or piercing metal This is ...

Page 48: ...elector illuminates Refer to Front controls and LEDs on page 40 2 Press the current gas selector until the selection cursor is opposite the gas pressure setting in the status screen 3 Turn the adjustment knob to adjust the gas pressure to the desired level Watch the arrow in the pressure bar as you adjust the pressure See Gas pressure indicators on page 42 Adjusting the current amperage Turn the a...

Page 49: ...rrent set below 55 A this feature is automatically disabled without displaying the icon on the status screen To manually disable the feature 1 Set the system to auto mode 2 Press the current gas selector button see Figure 1 5 times in quick succession less than one second apart The icon see Figure 1 displays on the status screen 3 To re enable the feature press the current gas selector button 5 ti...

Page 50: ...eats the temperature fault icon appears in the status screen the arc shuts off and the cooling fan continues to run You cannot resume cutting until the temperature fault icon disappears and the fault LED goes off The fan may run during normal operation of the system With a Powermax125 At 125 A 480 600 V CSA 400 V CE 380 V CCC the arc can remain on for 10 minutes out of 10 minutes without causing t...

Page 51: ...les on your torch will depend on a number of factors The thickness of the metal being cut The average length of the cut The air quality presence of oil moisture or other contaminants Whether you are piercing the metal or starting cuts from the edge Proper torch to work distance when gouging Proper pierce height Whether you are cutting in continuous pilot arc mode or normal mode Cutting with a cont...

Page 52: ...wn above use the same consumables Hand torches use shielded consumables Therefore you can drag the torch tip along the metal Consumables for hand cutting are shown below Notice that the retaining cap and electrode are the same for cutting gouging and FineCut applications Only the shield nozzle and swirl ring are different For the best cut quality on thin materials approximately 4 mm 10 GA or less ...

Page 53: ...nsumables 420000 Shield 220977 Retaining cap 220975 Nozzle 220997 Swirl ring 220971 Electrode 420172 Shield 220977 Retaining cap 420158 45 A 420169 65 A Nozzle 220997 Swirl ring 220971 Electrode 420112 Shield 220977 Retaining cap 420001 Nozzle 220997 Swirl ring 220971 Electrode 420152 Shield 220977 Retaining cap 420151 Nozzle 420159 Swirl ring 220971 Electrode ...

Page 54: ...s ship without consumables installed Pull off the vinyl cap before installing your consumables With the power switch in the OFF O position install the Powermax125 torch consumables as shown WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated Make sure the power is OFF before changing consumables Shield Retaining c...

Page 55: ...stem for connecting and disconnecting handheld and machine torch leads When connecting or disconnecting a torch first turn OFF the system To connect the torch push the connector into the receptacle on the front of the power supply To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button ...

Page 56: ...56 Powermax125 Service Manual 808070 4 Hand Torch Setup ...

Page 57: ...lasma arc comes on immediately when the torch trigger is activated The plasma arc will cut quickly through gloves and skin Wear correct and appropriate protective equipment Keep hands clothing and objects away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others ...

Page 58: ...nes Drag the torch tip lightly along the workpiece to maintain a steady cut While cutting make sure that sparks exit from the bottom of the workpiece The sparks should lag slightly behind the torch as you cut 15 30 angle from vertical If sparks spray up from the workpiece move the torch more slowly or set the output current higher With either hand torch hold the torch nozzle perpendicular to the w...

Page 59: ...or straight line cuts use a straight edge as a guide To cut circles use a template or a radius cutter attachment a circle cutting guide Start a cut from the edge of the workpiece 1 With the ground clamp attached to the workpiece hold the torch nozzle perpendicular 90 to the edge of the workpiece 2 Press the torch s trigger to start the arc Pause at the edge until the arc has cut completely through...

Page 60: ...rkpiece hold the torch at an approximate 30 angle to the workpiece with the torch tip within 1 5 mm 1 16 inch of the workpiece before firing the torch WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others Always wear proper protective equipment including gloves a...

Page 61: ...he workpiece Slowly rotate the torch to a perpendicular 90 position 3 Hold the torch in place while continuing to press the trigger When sparks exit below the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut ...

Page 62: ...r to Varying the gouge profile on page 64 and 125 A gouging profile chart on page 64 4 Maintain the same angle to the workpiece as you feed into the gouge Push the plasma arc in the direction of the gouge you want to create Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN S...

Page 63: ...rch to work standoff distance Angle of the torch to the workpiece Current output of the power supply Typical gouging profile 125 A Metal removal rate on mild steel 12 5 kg hour 27 pounds hour Speed Standoff Angle Operating parameters Speed 508 1270 mm min 20 50 ipm Standoff 6 4 10 2 mm 1 4 2 5 inch Angle 30 35 Width 10 mm 0 4 inch Depth 7 6 mm 0 3 inch ...

Page 64: ...wer supply will increase width and increase depth Decreasing the current of the power supply will decrease width and decrease depth 125 A gouging profile chart The following tables show the 125 A gouging profile at 30 and 35 on mild steel These settings are intended to serve as a starting point to help you determine the best gouging profile for a given cutting job Adjust these settings as needed f...

Page 65: ...s Width depth ratio 30 0 25 20 0 31 0 33 1 06 30 0 26 0 30 1 16 40 0 22 0 26 1 21 50 0 17 0 24 1 38 0 40 20 0 30 0 39 1 30 30 0 24 0 34 1 43 40 0 19 0 29 1 50 50 0 17 0 28 1 66 35 0 25 20 0 30 0 27 0 92 30 0 23 0 26 1 13 40 0 18 0 22 1 26 50 0 17 0 21 1 24 0 40 20 0 29 0 32 1 12 30 0 23 0 30 1 30 40 0 23 0 25 1 12 50 0 18 0 24 1 35 ...

Page 66: ...ched properly to the workpiece The gas pressure or gas flow rate is too low Gouging mode is selected on the power supply Cut quality is poor The causes can be The metal being cut is too thick for the amperage The wrong consumables are being used gouging consumables are installed instead of drag cutting consumables for example The torch is moving too quickly or too slowly The arc sputters and consu...

Page 67: ...our torch will depend on a number of factors The thickness of the metal being cut The average length of the cut The air quality presence of oil moisture or other contaminants Whether you are piercing the metal or starting cuts from the edge Proper torch to work distance when gouging Proper pierce height Whether you are cutting in continuous pilot arc mode or normal mode Cutting with a continuous p...

Page 68: ...ble or other equipment Choose and install the consumables Align the torch square to the plate Attach the torch lead to the power supply Set up the power supply for remote starting with either the remote start pendant or a machine interface cable 1 2 3 4 6 8 7 1 4 5 8 3 7 2 1 Consumables 2 Strain relief 3 Strain relief nut 4 Torch lead 5 Adapter not used in the full length machine torch 6 Positioni...

Page 69: ...orch lead can cause damage to the torch wires 1 Disconnect the torch lead from the power supply and remove the consumables from the torch 2 Unscrew the strain relief nut from the strain relief and slide the nut back along the torch lead 3 If you are disassembling the full length machine torch unscrew the strain relief from the positioning sleeve If you are disassembling the mini machine torch unsc...

Page 70: ...g sleeve off the front of the torch body 7 Disconnect the wire connector for the cap sensor switch 8 Remove the screw that secures the torch s pilot wire to the torch body 9 Use 5 16 inch and 1 2 inch wrenches or adjustable wrenches to loosen the nut that secures the gas supply line to the torch lead Set the torch body aside 10 Slide the coupler off the front of the torch lead 11 If you are disass...

Page 71: ...e torch at the same time skip this procedure and follow the instructions in Mount the torch on page 72 1 Follow the instructions in Disassemble the machine torch on page 69 2 Slide the adapter over the torch lead 3 Slide the coupler over the torch lead 4 Screw the adapter onto the coupler 5 Reconnect the gas supply line to the torch lead 6 Reattach the torch s pilot wire to the torch body using th...

Page 72: ...ng and reconnecting the torch parts maintain the same orientation between the torch head and torch lead Twisting the torch head in relation to the torch lead can cause damage to the torch wires 1 Follow the instructions in Disassemble the machine torch on page 69 Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting in the gas line when you rout...

Page 73: ... machine torch ship with a starter consumable kit as well as a box of spare electrodes and nozzles There are two starter mechanized consumable kits One includes the standard retaining cap and one includes the ohmic retaining cap Notice that the retaining cap electrode and swirl ring are the same for cutting gouging and FineCut applications Only the shield and nozzle are different Both styles of ma...

Page 74: ...shielded consumables 220976 Shield 420156 Ohmic sensing retaining cap 220975 Nozzle 220971 Electrode 220997 Swirl ring 420168 Shield 420156 Ohmic sensing retaining cap 420158 45 A 420169 65 A Nozzle 220971 Electrode 220997 Swirl ring 420112 Shield 220977 Retaining cap 420001 Nozzle 220971 Electrode 220997 Swirl ring 420152 Shield 420151 Nozzle 220971 Electrode 220997 Swirl ring 220977 Retaining ca...

Page 75: ...and Torch Setup on page 51 Aligning the torch Mount the machine torch perpendicular to the workpiece in order to get a vertical cut Use a square to align the torch at right angles to the workpiece Position the mounting bracket as low on the torch as possible to minimize vibration at the tip of the torch WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immedi...

Page 76: ...system for connecting and disconnecting handheld and machine torch leads When connecting or disconnecting a torch first turn OFF the system To connect the torch push the connector into the receptacle on the front of the power supply To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button ...

Page 77: ... remains stationary at the pierce height before the torch starts the cutting motion Best Quality Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 70 to 80 of the maximum speed ra...

Page 78: ...eel 125 A shielded 2 2 2 3 2 4 2 4 2 6 2 8 3 1 3 6 3 8 3 9 4 1 105 A shielded 2 2 1 2 2 2 3 2 4 2 5 2 7 3 3 2 65 A shielded 1 6 1 6 1 8 1 9 2 0 2 2 2 7 3 2 3 7 45 A shielded 1 6 1 4 1 3 1 5 1 6 FineCut 1 3 1 2 1 2 1 2 Stainless steel 125 A shielded 1 9 2 2 2 4 2 6 2 6 2 7 3 1 3 3 3 2 3 6 105 A shielded 1 6 1 9 2 2 2 3 2 4 2 5 2 9 2 9 2 9 65 A shielded 1 4 1 5 1 8 1 8 1 9 1 9 2 1 2 3 45 A shielded ...

Page 79: ... 048 0 052 0 061 0 062 0 064 FineCut 0 049 0 047 0 048 0 048 Stainless steel 125 A shielded 0 078 0 094 0 103 0 103 0 103 0 112 0 123 0 116 0 137 105 A shielded 0 067 0 085 0 091 0 094 0 093 0 111 0 116 0 116 65 A shielded 0 054 0 060 0 065 0 071 0 074 0 076 0 083 0 090 45 A shielded 0 056 0 042 0 048 0 062 0 065 0 068 FineCut 0 045 0 044 0 039 0 042 Aluminum 1 32 1 16 1 8 1 4 3 8 1 2 5 8 3 4 7 8 ...

Page 80: ...070 6 Machine Torch Setup 125 A shielded consumables 220976 Shield 220975 Nozzle 220977 Retaining cap 220997 Swirl ring 220971 Electrode 220976 Shield 420156 Ohmic sensing retaining cap 220975 Nozzle 220997 Swirl ring 220971 Electrode ...

Page 81: ... 178 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 1 4 0 18 0 36 200 0 2 188 158 225 155 3 8 0 4 114 158 138 158 1 2 0 5 75 158 93 158 5 8 0 45 250 0 6 50 162 66 164 3 4 0 8 42 164 48 163 7 8 2 0 31 168 37 166 1 3 5 23 169 30 167...

Page 82: ...2170 163 2710 157 16 11 5 250 0 7 1140 165 1460 162 20 1 2 940 167 1030 163 25 Edge Start 1 0 540 172 760 166 30 510 173 610 166 32 1 1 400 177 600 169 35 1 2 320 180 450 173 40 180 185 210 179 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts...

Page 83: ... 165 3070 162 16 11 5 250 0 6 1540 169 2090 163 20 2 0 1260 170 1500 167 25 3 5 850 174 1050 167 30 Edge Start 1 0 810 175 760 167 32 1 1 430 182 750 174 35 1 2 370 183 580 176 40 270 185 300 179 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm vol...

Page 84: ...070 6 Machine Torch Setup 105 A shielded consumables 220976 Shield 220975 Nozzle 220977 Retaining cap 220997 Swirl ring 220971 Electrode 220976 Shield 420156 Ohmic sensing retaining cap 220975 Nozzle 220997 Swirl ring 220971 Electrode ...

Page 85: ...0 0 8 2410 159 2730 153 12 0 7 1810 163 1980 156 16 11 5 250 1 0 1050 165 1230 155 20 1 3 780 168 850 157 25 Edge Start 1 0 540 174 580 162 30 420 176 440 168 32 1 2 370 177 400 170 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 1...

Page 86: ...59 3940 148 10 2230 160 2420 151 12 1460 162 1980 154 16 11 5 250 1 0 1050 166 950 156 20 2 5 660 169 730 158 25 Edge Start 1 0 440 174 520 162 30 330 176 450 167 32 1 2 290 177 420 169 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm vol...

Page 87: ...4 10 0 8 2660 164 3250 155 12 0 7 2020 167 2590 159 16 11 5 250 1 0 1350 169 1550 157 20 1 3 970 172 1020 161 25 Edge Start 1 0 660 176 800 167 30 460 180 580 174 32 1 2 390 182 490 176 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm vol...

Page 88: ...8070 6 Machine Torch Setup 65 A shielded consumables 220997 Swirl ring 220971 Electrode 420168 Shield 220977 Retaining cap 420169 Nozzle 420168 Shield 420156 Ohmic sensing retaining cap 420169 Nozzle 220997 Swirl ring 220971 Electrode ...

Page 89: ... 125 3275 124 8 2080 127 2235 126 10 4 5 300 0 7 1520 129 1490 128 12 1 2 960 131 1140 130 16 6 400 2 0 656 136 740 135 20 Edge start 355 141 450 140 25 215 146 270 146 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 16 GA 0 06 0 1...

Page 90: ...20 8240 122 4 0 5 4840 122 6110 123 6 2275 125 2840 125 8 0 7 1505 127 1860 127 10 4 5 300 1115 130 1245 128 12 1 2 720 133 925 130 16 Edge Start 465 137 505 136 20 320 141 345 141 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 16...

Page 91: ... 2 6565 125 8790 123 4 0 5 5320 126 7320 124 6 2845 129 4375 126 8 0 7 2015 133 2750 129 10 4 5 300 1535 136 1650 132 12 1 2 1055 139 1330 135 16 Edge Start 640 143 805 140 20 335 146 550 144 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts i...

Page 92: ...8070 6 Machine Torch Setup 45 A shielded consumables 420168 Shield 220977 Retaining cap 420158 Nozzle 220997 Swirl ring 220971 Electrode 420168 Shield 420156 Ohmic sensing retaining cap 420158 Nozzle 220997 Swirl ring 220971 Electrode ...

Page 93: ... 10760 120 1 5 0 1 8040 123 10160 123 2 1 5 3 8 250 0 3 6565 128 7770 125 3 0 4 3725 129 4890 128 4 2250 130 3550 130 6 0 5 1265 132 2050 130 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 26 GA 0 02 0 08 400 0 0 350 118 500 120 2...

Page 94: ...113 10760 120 1 5 0 1 7825 117 10160 120 2 1 5 3 8 250 0 3 6095 122 8615 122 3 0 4 3585 123 4405 123 4 2185 126 2565 126 6 0 5 975 132 1020 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 26 GA 0 02 0 08 400 0 0 350 113 500 120...

Page 95: ...econds mm min volts mm min volts 1 1 5 3 8 250 0 0 9145 126 11100 124 2 0 1 7470 125 9210 124 3 0 2 4675 125 6190 125 4 0 4 3700 129 4845 127 6 0 5 1740 135 2795 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage inches inches inches seconds ipm volts ipm volts 1 32 0 06 0 15 25...

Page 96: ... 808070 6 Machine Torch Setup FineCut consumables 420152 Shield 420151 Nozzle 220977 Retaining cap 220997 Swirl ring 220971 Electrode 420152 Shield 420156 Ohmic sensing retaining cap 420151 Nozzle 220997 Swirl ring 220971 Electrode ...

Page 97: ...s mm min volts 0 5 30 1 5 2 25 150 0 0 4330 83 0 6 4080 85 0 8 0 1 4065 85 1 40 0 2 4825 81 1 5 0 4 4825 79 2 45 4740 78 3 0 5 3445 80 4 1270 80 English Material Thickness Current Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Cut Speed Voltage inches A inches inches seconds ipm volts 26 GA 30 0 06 0 09 150 0 0 175 82 24 GA 160 85 22 GA 0 1 160 85 20 GA 160 85 18 GA 40 ...

Page 98: ...onds mm min volts 0 5 30 0 02 0 08 400 0 0 4825 77 0 6 4825 77 0 8 0 1 4825 73 1 40 0 2 4825 86 1 5 0 4 4825 72 2 45 4550 72 3 0 5 2335 70 4 995 72 English Material Thickness Current Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Cut Speed Voltage inches A inches inches seconds ipm volts 26 GA 30 0 02 0 08 400 0 0 190 77 24 GA 190 77 22 GA 0 1 190 74 20 GA 190 72 18 GA ...

Page 99: ...rt number 128650 7 6 m 25 feet Part number 128651 15 m 50 feet Part number 128652 23 m 75 feet Remove the machine interface receptacle cover on the rear of the power supply and plug the Hypertherm remote start pendant into the receptacle The remote start pendant is for use only with a machine torch It will not operate if a handheld torch is installed Receptacle for the remote start pendant or a ma...

Page 100: ...rt number 228350 7 6 m 25 feet or 228351 15 m 50 feet for wires terminated with spade connectors Use one of the following part numbers for a cable terminated with a D sub connector Compatible with Hypertherm products such as EDGE Pro Ti and Sensor PHC 223354 3 0 m 10 feet 223355 6 1 m 20 feet 223048 7 6 m 25 feet 223356 10 7 m 35 feet 123896 15 m 50 feet To use signals for arc transfer and plasma ...

Page 101: ...b connector on the other end plug it into the appropriate pin connector on the torch height controller or CNC Secure it with the screws on the D sub connector If you are using a cable with wires and spade connectors on the other end terminate the machine interface cable inside the electrical enclosure of the torch height controller or CNC controller to prevent unauthorized access to the connection...

Page 102: ...otes Connector sockets External cable wires Start start plasma Input Normally open 18 VDC open circuit voltage at START terminals Requires dry contact closure to activate 3 4 Green black Transfer start machine motion Output Normally open Dry contact closure when the arc transfers 120 VAC 1 A maximum at the machine interface relay 12 14 Red black Ground Ground 13 Voltage divider Output Divided arc ...

Page 103: ...er 3 Locate the voltage divider DIP switches on the left side of the power supply Figure 3 shows the default setting 50 1 with the number 4 switch up Figure 3 Voltage divider at default setting 50 1 4 Set the DIP switches to one of the following settings and replace the power supply cover If the Hypertherm five position voltage divider does not supply the required voltage for your application cont...

Page 104: ...e power supply If your power supply is not equipped with the RS 485 connector order kit 228539 Powermax65 85 105 125 RS 485 board with cables Follow the installation instructions in the Power Supply Component Replacement section of the Powermax125 Service Manual 808070 which you can download from the Downloads Library at www hypertherm com With the RS 485 connector installed 1 Shut OFF the power s...

Page 105: ...on However the following topics will help you optimize cut quality and maximize consumable life Setting up the torch and table Use a square to align the torch at right angles to the workpiece in two dimensions The torch may travel more smoothly if you clean check and tune the cutting table s rails and drive system Unsteady machine motion can cause a regular wavy pattern on the cut surface Ensure t...

Page 106: ...s are all positive or all negative Also consider the material being cut if the metal is magnetized or hardened you are more likely to experience cut angle problems Dross Some amount of dross will always be present when cutting with air plasma However you can minimize the amount and type of dross by adjusting your system correctly for your application Excess dross appears on the top edge of both pi...

Page 107: ...in distance approximately equal to the thickness of the material being pierced For example 20 mm 3 4 in material requires a 20 mm lead in To avoid damage to the shield from the buildup of molten material created by the pierce do not allow the torch to descend to cut height until it has cleared the puddle of molten material Different material chemistries can have an adverse effect on the pierce cap...

Page 108: ...ight with respect to the forward motion of the torch The torch to work distance cut height is too large or too small The cutting speed is not correct See the cut charts under Using the cut charts on page 77 The consumable life is shortened The gas setting is incorrect The arc current arc voltage travel speed and other variables are not set as recommended in the cut charts Firing the arc in the air...

Page 109: ...and System Tests Controls and indicators The system s controls and indicators are described in Basic System Operations on page 39 The following figures are included for reference Rear panel ON I OFF O power switch Activates the power supply and its control circuits ...

Page 110: ...g mode selector 4 Current gas selector 5 Power ON LED green 6 Operating mode switch 7 Adjustment knob 1 2 3 4 5 6 7 8 9 10 11 1 Torch is cutting 2 Torch start 3 Fault icon 4 Fault code 5 Visual pressure setting 6 Pressure setting 7 Pressure selection cursor 8 Current selection cursor 9 Current setting amperage 10 Electrode end of life detection manually disabled 11 Remote connected ...

Page 111: ...PCB1 sets the output current to the desired value 30 125 A The system compares this set point to the output current by monitoring the current sensors and adjusting the output of the inverter IGBT module Q12 400 V CE 380 V CCC 3 phase power supply functional description AC power enters the system through the power switch S1 to the input diode bridge D38 The voltage from the bridge provides a nomina...

Page 112: ...esired mode for cutting or gouging Set the amperage adjustment knob to the desired output current based on the thickness of the metal to be cut The gas pressure automatically adjusts for optimal cutting based on the selected settings Position the torch over the workpiece Pull the plasma start trigger on the hand torch or press the remote start switch for the machine torch The electronic regulator ...

Page 113: ...t equipment Multimeter IGBT tester 128883 Troubleshooting procedures and sequence When performing the troubleshooting procedures refer to Safety and Compliance Manual 80669C for detailed safety information Power Supply Component Replacement on page 165 or Torch Component Replacement on page 265 Troubleshooting and System Tests on page 109 Wiring Diagrams on page 315 After the problem has been loca...

Page 114: ...ical 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 power 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 ...

Page 115: ...check All resistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform the steps in Internal inspection above before continuing in this section The type of multimeter you use significantly affects the results of the tests in this section The resistance values in this manual are intended as a general reference point If resistance values indic...

Page 116: ...er switch resistance CE models have a ferrite core installed over the ground wire and over the power wires CSA models do not have ferrite cores CCC models do not ship with a power cord 480 V 600 V CSA models 400 V CE 380 V CCC models 400 kΩ 400 kΩ 20 MΩ 400 kΩ 350 kΩ 350 kΩ 350 kΩ 20 MΩ ...

Page 117: ...inspection or the initial resistance check and the power supply still does not operate correctly see the Troubleshooting guide on page 143 The Troubleshooting guide on page 143 provides most probable causes and solutions Study the Powermax125 schematic diagram on page 317 and understand the Theory of operation on page 111 before troubleshooting Before purchasing any major replacement component ver...

Page 118: ...following sections or assemble your own IGBT tester from the schematic diagram shown in Figure 10 on page 123 and use it to test the IGBTs Figure 7 128884 1 2 3 4 5 6 7 8 9 10 1 Test for shorted IGBT 2 Fail LED red 3 Pass LED green 4 Circuit diagram 5 Low battery LED red 6 Test for open IGBT 7 Rocker switch 8 Collector red 9 Gate yellow 10 Emitter black ...

Page 119: ... depict 3 common configurations of an IGBT Each connection on the IGBT will be labeled with an abbreviation Green pass LED 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 short circuited IGBT when the switch is pressed to the left Red fail LED When illuminated this LED indicates that the IGBT failed the test for an...

Page 120: ... IGBT pilot arc Test 1 Test 2 1 2 3 4 5 6 1 Yellow lead Gate G2 or 6 2 Black lead Emitter E2 or 2 3 Red lead Collector C2E1 or 1 4 Red lead Collector C1 or 3 5 Black lead Emitter C2E1 or 1 6 Yellow lead Gate G1 or 4 1 2 3 1 Yellow lead Gate 2 G2 or 6 2 Black lead Emitter 2 E2 or 2 3 Red lead Collector 2 C2 or 1 ...

Page 121: ...an 8 V 3 Test the IGBT Tester itself as shown in the following table If the results do not match the table replace the lead connections Switch Position LED This may mean Corrective action Fail Pass Battery Left X IGBT is short circuited Replace IGBT Left X IGBT passed the short circuit test None Left X Battery below 8 V Replace battery Left Dead battery Replace battery Right X IGBT is open Replace...

Page 122: ...ve the power board and any lead connections before testing 1 Inspect the IGBT for cracks or black marks If it is damaged replace the IGBT 2 Verify that the 9 V battery reads greater than 8 0 V 3 Connect the test leads as shown in Figure 10 4 With the test leads connected and without pressing the push button switch the LED should not illuminate If the LED is illuminated then the IGBT is shorted Rep...

Page 123: ...ested inside the dashed line 2 Collector C1 or 3 3 Emitter E2 or 2 4 Collector Emitter C2E1 or 1 5 Gate G1 or 4 6 Emitter E1 or 5 7 Emitter E2 or 2 8 Gate G2 or 6 9 Red minigrabber test clip 10 D1 Red LED lamp 109092 11 R3 2 0K 009036 12 R4 2 0K 009036 13 9 VDC battery 14 Normally open push button switch 15 R1 3 01M 009464 16 Black minigrabber test clip 17 Yellow minigrabber test clip ...

Page 124: ...2 IGBT pilot arc Test 1 Test 2 1 2 3 4 5 6 1 Yellow lead Gate G2 or 6 2 Black lead Emitter E2 or 2 3 Red lead Collector C2E1 or 1 4 Red lead Collector C1 or 3 5 Black lead Emitter C2E1 or 1 6 Yellow lead Gate G1 or 4 1 2 3 1 Yellow lead Gate 2 G2 or 6 2 Black lead Emitter 2 E2 or 2 3 Red lead Collector 2 C2 or 1 ...

Page 125: ...52 C151 TP7 TP9 TP8 W R B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 20 16 17 18 19 1 J11 2 J17 3 J18 4 Output inductor wires 5 Nozzle wires 6 Electrode wire 7 J32 8 Work lead 9 Transformer wires 10 Test points 11 4 μF Capacitors 12 PFC inductor wires 13 Ground 14 AC input wires 15 Power switch 16 Power board 17 Flyback circuit 18 Gate drive connectors 19 Digital signal processor DSP board 20 Control boa...

Page 126: ... TP7 TP9 TP8 W R B 1 2 3 4 5 6 7 13 14 8 10 11 12 9 20 15 16 17 18 19 1 J11 2 J17 3 J18 4 Output inductor wires 5 Nozzle wires 6 Electrode wire 7 J32 8 Work lead 9 Transformer wires 10 Test points 11 4 μF Capacitors 12 PFC inductor wires 13 Ground 14 AC input wires 15 Power switch 16 Power board 17 Flyback circuit 18 Gate drive connectors 19 Digital signal processor DSP board 20 Control board ...

Page 127: ...5 Power supply overview all systems power board removed 1 2 3 4 5 6 7 8 9 10 1 Output snubber resistor 2 Output diode bridge 3 Pilot arc IGBT 4 Inverter snubber resistor 5 Inverter IGBT module 6 Bulk capacitors 7 Ground 8 Input diode bridge 9 Power switch S1 10 Optional serial board ...

Page 128: ...ooting by accessing the service screen This screen displays recent fault codes arc hours the software version on your system and several additional details You can also run a gas test from this screen For example if a fault code displays on the status screen in the format N nn while you are operating the system you can check the service screen for an additional 4 digit fault code in the format N n...

Page 129: ...ed To exit the service screen simultaneously press the automatic manual and current gas mode selectors The operator screen displays Designator Description I Current set read C LCD contrast B LCD brightness percent P Pressure set read G Gas test enable 1 disable 0 VL Incoming AC line voltage TI Inverter module temperature C VB DC bus voltage AH Arc hours F Live 4 digit fault code for diagnosing sys...

Page 130: ... seconds 2 Select the gas test field by pressing the current gas mode selector until the asterisk is next to the G See Figure 18 3 Use the adjustment knob to set the gas test field from 0 to 1 Figure 18 4 Use the adjustment knob to set the gas test field back to 0 5 Simultaneously press the automatic manual and current gas mode selectors to exit the service screen WARNING Point the torch away from...

Page 131: ... table below describes a fault category and suggests solutions for each fault code Several of the fault solutions show a test number Refer to System tests on page 149 to perform the indicated numbered test If a fault occurs while using a generator turning the power switch quickly to OFF and then to ON again sometimes called a quick reset may not clear the fault Instead see Perform a cold restart o...

Page 132: ...nterpret the cut mode cut current or pressure information coming from the controller Fix the controller Check the interface cable 0 11 1 Remote controller current invalid Valid remote current settings for Powermax125 are 30 125 A 0 11 2 Remote controller pressure invalid Valid remote pressure setting for Powermax125 depends on the torch 0 12 1 Output gas pressure low On Off Adjust the gas inlet pr...

Page 133: ...e fault log in the service screen to identify the major fault Perform Test 12 AUX switch on page 164 if fault code 0 99 occurs after fault code 0 19 displays for 1 minute 0 20 0 Low gas pressure The gas pressure has fallen below the minimum pressure for that process mode and lead length On On Verify that the gas line is properly installed Replace the air filter element if it is dirty Replace the g...

Page 134: ... that air flows through the electronic regulator in gas test mode Replace the regulator if necessary Possible faulty DSP or power board Change the consumables For mechanized applications lock out the torch height control 0 22 0 No gas input On On Restore the gas supply Restart the power supply With proper air connected measure the resistance between J5 pins 1 and 2 If the circuit is shorted replac...

Page 135: ...ear to be installed correctly the torch may be damaged Test with a known working torch Perform Test 6 Torch stuck open torch stuck closed on page 158 If the problem persists contact your Hypertherm distributor or authorized repair facility 0 30 1 Torch stuck closed The nozzle and electrode will not separate after a start is received The regulator may not be functioning properly 0 32 0 End of consu...

Page 136: ...le limits listed in Basic System Operations on page 39 For an under temperature fault all units 30 C 22 F Move the unit to a warmer location Perform Test 4 Inverter temperature sensor on page 154 0 40 3 Inverter IGBT module over temperature 0 50 0 Retaining cap off On On Verify that proper consumables and retaining cap are installed Replace damaged parts Refer to Hand Torch Setup on page 51 or Mac...

Page 137: ...proper voltage phase to phase and phase to ground at the power source and at the machine 0 60 1 Under voltage Increase the supply voltage 0 60 2 Over voltage Decrease the supply voltage 0 61 0 AC input unstable Shutdown On On Test the machine from another AC power source Power down and correct the line resonance problem before continuing 0 98 0 Internal communication failure The control board and ...

Page 138: ...is possible that the DSP or power board has failed 1 10 0 Analog to Digital A D converter fault 1 20 0 I O fault 2 nn n Fault code Description Power LED Fault LED Fault icon Solutions 2 00 0 Analog to Digital A D converter value out of range On On Perform a cold restart If that does not fix the problem it is possible that the DSP or power board has failed 2 01 0 Auxiliary switch disconnected Check...

Page 139: ...d Powermax125 schematic diagram on page 317 Perform a continuity check on the FastConnect receptacle on the power supply using the instructions in Torch related faults continuity check on page 142 3 nn n Fault code Description Power LED Fault LED Fault icon Solutions 3 10 0 Fan speed The fan speed is below the minimum speed On On Clean the fan assembly Perform Test 11 Fan on page 164 3 10 1 Fan Ch...

Page 140: ...associated wiring particularly the 7 pin connector at J6 on the power board If necessary replace the electronic regulator 228687 3 41 0 Drive fault On On If an activation signal is sent to a device and the device does not activate machine motion relay or in rush relay for example this fault will occur 3 42 0 5 or 24 VDC fault The 5 or 24 VDC supply from the flyback circuit is out of range Perform ...

Page 141: ... capacitor 600 V CSA units Bus voltage is 810 VDC Nominal is 405 VDC for each capacitor Fault condition 295 or 515 VDC across either capacitor 400 V CE units Bus voltage is 540 VDC Nominal is 270 VDC for each capacitor Fault condition 200 or 360 VDC across either capacitor 380 V CCC units Bus voltage is 510 VDC Nominal is 255 VDC for each capacitor Fault condition 200 or 360 VDC across either capa...

Page 142: ...erform Test 3 Output diodes on page 154 Replace the module if either is faulty If necessary replace the power board 3 52 0 Shoot through 3 60 0 Power board On On The DSP does not recognize the power board The code is for future machines where the current DSP board will not work with future power boards 3 70 0 Internal serial communications fault There is a fault with the communication between the ...

Page 143: ...N at the main power panel or at the line disconnect switch box Verify that the line voltage is not too low more than 15 below the rated voltage Perform Test 1 Voltage input on page 150 to check the incoming voltage and the power switch Perform Test 12 AUX switch on page 164 Faulty power board fan or solenoid valve Perform Test 5 Flyback circuit DC minor voltages on page 156 Faulty power board or I...

Page 144: ...e ground clamp contacts the workpiece to allow a good metal to metal connection Inspect the ground clamp for damage and repair as necessary The pierce height distance may be too large Move the torch closer to the workpiece and fire the torch again Gas flows from the torch at power up when neither the torch trigger nor a remote start is activated The electronic regulator power board or control boar...

Page 145: ...o 9 3 bar 85 to 135 psi Repair air leaks or restrictions Manually adjust the gas pressure on the power supply Poor air quality Gas filter element is dirty Oil moisture or contaminants in the gas supply line Replace the gas filter element Add appropriate filtration and purge the lines with nitrogen to flush out oil and moisture Insufficient input power Undersized electrical supply installation Brea...

Page 146: ...rc mode If you are cutting expanded metal grate or any metal with holes set the mode switch to continuous pilot arc mode Check for loose connections at the ground clamp and at the power supply Reposition the work lead on the workpiece Clean the cutting surface to allow a better connection with the work lead Faulty fan The fan could be overloading the flyback circuit Perform Test 5 Flyback circuit ...

Page 147: ...ion Verify that the cutting mode switch is in the correct position Faulty pilot arc IGBT 1 Turn the power OFF 2 remove the consumables and 3 check the resistance between the cathode and the ground clamp If the resistance is less than 5 kΩ check the resistance across the pilot arc IGBT If that resistance is less than 5 kΩ replace the pilot arc IGBT Gas filter element is dirty Oil moisture or contam...

Page 148: ...t the gas line for moisture If necessary install or repair the gas filtration to the power supply See Power Supply Setup on page 29 Machine does not cut well does not appear to be cutting at full cutting power and the arc does not time out after 5 seconds Inadequate ground Poor work lead connection Verify that the work lead is attached to the workpiece and the workpiece is free of rust paint or ot...

Page 149: ...ocated at the top of the power board You can pry off most covers with your thumbnail However you may need to use a small blade screwdriver to carefully pry off some of the covers Be careful not to bend or break the connectors Figure 19 Test number Description Associated fault codes 1 Voltage input 0 60 ALL 2 DC power buss 3 43 0 3 Output diode bridge General 4 Temperature out of range 0 40 ALL 2 1...

Page 150: ...any 2 input wires should equal the line voltage If there is proper voltage to the power switch and low voltage to the input diode bridge replace the power switch Check the output voltage of the input diode bridge Output VDC Line Voltage x 1 414 VDC All values are 15 Figure 20 Wire colors may vary in power cords not purchased from Hypertherm 3 phase L1 Black CSA Brown CE L2 White CSA Black CE L3 Re...

Page 151: ...ode bridge output value is correct Display the service screen Figure 21 and confirm that the value VL is 15 of AC line voltage Figure 21 If there is a fault and the VL value is correct Verify the DSP board by replacing it with a known good board If the DSP board is not the problem replace the power board ...

Page 152: ... input power connected and the machine on See Figure 23 on page 153 Wear proper personal protective equipment PPE before testing powered equipment All values are 50 However this range is intended only for reference Resistance values can vary widely depending on the type of multimeter and the polarity used to measure the readings Check the inverter IGBT module voltages as described below The voltag...

Page 153: ...tem Tests Figure 23 J22 J21 J20 J19 J27 WORK LEAD J26 _ _ TP7 TP9 TP8 W R B 325 VDC 405 VDC 270 VDC 255 VDC 650 VDC 325 VDC 810 VDC 405 VDC 540 VDC 270 VDC 510 VDC 255 VDC 480 V CSA input Inverter IGBT 600 V CSA input 400 V CE input 380 V CCC input Bulk capacitors ...

Page 154: ... a pair Test 4 Inverter temperature sensor Symptom Fault code 0 40 appears in the operator screen Remove power and allow the system to reach room temperature at least 60 minutes after use If the system has a temperature interlock either fault code 0 40 or fault code 0 99 appears on the operator screen Display the service screen and check the F field for the live most recent fault code Fault code 0...

Page 155: ...pins 1 and 3 on the plug 3 If the resistance is not within 15 of 10 kΩ at approximately 25 C or 77 F replace the temperature sensor 4 If the value is correct remove the DSP board and measure the resistance between pins 1 and 3 on the power board with the temperature sensor disconnected The resistance should be approximately 57 6 kΩ 5 If the value is correct replace the DSP board 6 If the value is ...

Page 156: ...ered equipment The flyback circuit is the source of the minor DC voltages in the power supply It provides 3 3 VDC 5 VDC 24 VDC and 48 VDC Check the voltages as described in Table 12 If a value is not within 15 perform the appropriate test later in this section Table 12 Figure 25 Volts DC Test points use chassis for negative All units 48 J1 pin 1 24 J5 pin 1 5 0 J3 pin 3 3 3 J15 pin 4 DSP board J15...

Page 157: ...e solenoid valve If the value is still incorrect replace the power board If the 5 VDC value is incorrect Remove the pressure sensor connector J3 and repeat the test If the value is now correct replace the pressure sensor If the value is still incorrect remove the DSP board and repeat the test If the value is now correct replace the DSP board If the value is still incorrect replace the power board ...

Page 158: ...ng the service screen on page 128 move the cursor to G gas and use the adjustment knob to toggle to 1 gas test mode If air does not flow the regulator might be faulty Examine the fault log to see if any 3 20 n faults are logged See Run a gas test on page 130 Figure 27 Before continuing turn OFF the power If the resistance value is always less than 100 Ω remove the torch and recheck the resistance ...

Page 159: ...alues are 50 However this range is intended only for reference Resistance values can vary widely depending on the type of multimeter and the polarity used to measure the readings Check the function of the pilot arc IGBT Turn the machine OFF and disconnect the power Install a jumper wire at least 8 AWG from the work lead J27 to the pilot arc IGBT dual black wires Reconnect the power and turn on the...

Page 160: ...in 6 and pin 7 If there is very high resistance inspect the lead and trigger switch for opens and replace or repair as necessary If there is no problem found with the torch wiring or trigger switch and there is still no arc or start icon Turn the machine OFF and disconnect the power Remove the nozzle and electrode from the torch and reinstall the retaining cap Reconnect the power and turn the mach...

Page 161: ... cap sensor switch b If the resistance is approximately 0 Ω Reconnect the torch Measure for continuity between pin 1 and pin 2 at J17 on the power board If there is no continuity inspect and perform a resistance test on the torch disconnect c If there is no problem with the leads or switch test the circuit boards Turn OFF the machine and disconnect the power Put a jumper wire between J20 pins 1 an...

Page 162: ...he electronic regulator control cable J6 from the power board If air continues to flow replace the electronic regulator If the air stops flowing verify the DSP board by replacing it with a known good one If the DSP board is not the problem replace the power board Figure 30 1 2 3 4 5 1 Electronic regulator J6 2 Pressure switch auxiliary contactor J5 3 Pressure sensor J3 4 Inverter temperature senso...

Page 163: ...If not 5 0 VDC 5 perform Test 5 Flyback circuit DC minor voltages on page 156 4 From the service screen enable the gas test Note the flowing gas pressure in the P field to the right of the slash 5 Measure VDC between pin 2 and pin 1 The value should be 0 0463 times the pressure for example 68 psi 0 0463 VDC psi 3 148 VDC If the voltage measurement is within 10 of the correct value and you have a p...

Page 164: ... board connector between pin 1 and pin 4 of J1 If the voltage is 48 VDC replace the fan Otherwise perform Test 5 Flyback circuit DC minor voltages on page 156 c If the system passes the flyback circuit test If the voltage between pin 1 and pin 3 J1 is 0 VDC replace the DSP board If the voltage is greater than 0 VDC replace the power board Test 12 AUX switch Symptom Upon power up fault code 0 19 di...

Page 165: ... 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 power 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 ...

Page 166: ...Service Bulletin 807060 Disconnect the power and gas supply 1 Turn the plasma power supply switch to OFF O 2 Turn the line disconnect switch to OFF O 3 Disconnect the gas supply hose from the plasma power supply Figure 31 Kit number Description 228711 Kit Powermax65 85 105 125 machine interface for raw arc voltage strain relief 1 2 3 Power switch Gas supply Line disconnect switch ...

Page 167: ... the plastic retaining nut to finger tight only 2 Clean the filter bowl by removing any oil or other residue 3 Inspect the O ring at the top of the filter bowl If necessary replace the O ring with the one provided in the kit Apply a thin film of silicone lubricant to the O ring before installing 4 Insert the filter bowl with the thumb latch positioned approximately 45 degrees to the right of cente...

Page 168: ...808070 9 Power Supply Component Replacement Figure 32 1 2 3 4 5 7 6 1 Thumb latch 2 Rotate to remove 3 Filter bowl 4 Helpful to lift here when replacing the filter bowl 5 Rotate to install 6 Gas filter element 7 Plastic retaining nut ...

Page 169: ...e work lead cable 4 Strip 13 mm 0 5 inches off the end of the work lead cable 5 Insert the stripped end of the work lead cable into the new work lead connector Tighten the set screw to 115 2 kg cm 100 inch pounds Figure 34 6 Align the tabs in the rubber boot with the mating slots in the work lead connector Slide the rubber boot over the work lead connector until it is fully seated Figure 35 Kit nu...

Page 170: ...en it into the bracket See Figure 37 on page 171 4 Apply thread sealant to the other side of the adapter fitting and with the arrow pointing toward the power supply tighten the filter onto the adapter fitting 5 Apply thread sealant to the gas inlet fitting and tighten it into the filter Kit number Description 228890 Kit Eliminizer gas filter with protective metal cover for the Powermax105 125 CAUT...

Page 171: ...the rear of the power supply aligning the screw holes with the holes in the power supply cover 8 Install the 4 screws provided in the kit through the filter cover and power supply cover Tighten the screws to 23 kg cm 20 inch pounds 9 Reconnect the power and gas supply Figure 38 1 2 3 4 5 1 Gas inlet fitting 2 Bracket 3 Adapter fitting 4 Arrow pointing to power supply 5 Filter Screw Filter cover Sc...

Page 172: ...ower supply cover 1 Place the cover over the power supply aligning the slot in the top of the cover with the plastic tab in the front panel The slot and tab ensure that the vent in the side of the cover is over the fan See Figure 39 2 Tighten the 16 screws in the sides and top of the cover to 23 kg cm 20 inch pounds 3 Reconnect the power and gas supply Kit number Description 428115 Kit Powermax125...

Page 173: ...arrier 1 Slide the side and bottom edges of the component barrier behind the end panel edges and down to the base 2 Bend the bottom right of the component barrier at the perforation and insert it between the power cord wires and the edge of the power board 3 Bend the top right of the component barrier at the perforation and place over the top of the power switch 4 Center the barrier between the fr...

Page 174: ...racket 1 Complete the following procedures a See Disconnect the power and gas supply on page 166 b See Remove the power supply cover on page 172 c See Remove the component barrier on page 173 2 Remove the 2 mounting screws from the end panel bracket 3 Lift the end panel bracket straight up from the power supply Figure 41 1 2 1 2 ...

Page 175: ...the end panel bracket mounting tabs are positioned on the fan side of the power supply 2 Push the end panel bracket straight down onto the power supply 3 Tighten the 2 end panel bracket mounting screws to 11 5 kg cm 10 inch pounds Figure 42 4 Complete the following procedures a See Install the component barrier on page 173 b See Install the power supply cover on page 172 c Reconnect the power and ...

Page 176: ...procedures a See Disconnect the power and gas supply on page 166 b See Remove the power supply cover on page 172 c See Remove the component barrier on page 173 2 Disconnect the cable connectors at J18 and J32 Figure 44 Kit number Description 228884 Kit Powermax105 125 machine interface cable internal cable with voltage divider board CPC port J18 J32 Ground J22 J27 WORK LEAD J26 _ RED J18 ORG J17 J...

Page 177: ...ower board side to the fan side of the power supply 4 Remove the green yellow ground wire screw from the gas filter housing See Figure 45 5 Remove the CPC port by removing the 2 screws Figure 45 6 Remove the 2 screws from the voltage divider board and remove the voltage divider board and attached cables See Figure 46 on page 178 CPC port Ground wire screw ...

Page 178: ... tightening 2 of the supplied screws to 11 5 kg cm 10 inch pounds Figure 46 4 Route the CPC port and attached cables above the solenoid valve and over to the CPC port opening on the rear panel of the power supply See Figure 47 on page 179 5 Insert the CPC port into the CPC port opening from inside the power supply Be sure to position the port with the green yellow ground wire at the bottom of the ...

Page 179: ...ew that secures the large ground wire connected to the center panel Tighten the ground wire screw to 17 3 kg cm 15 inch pounds 8 Route the 2 cables through the right grommet one at a time and down the left side of the power board Figure 48 1 3 2 4 5 6 7 8 9 4 CPC port 5 CPC port ground wire 6 Large ground wire from center panel 7 Solenoid valve 8 Voltage divider board 9 Right grommet ...

Page 180: ...that is printed on the power board and push the cable connector into the power board connector Figure 49 11 From the fan side of the power supply secure both cables in the cable clip attached to the center panel under the left grommet 12 Set the voltage divider board See Set the voltage divider board on page 181 13 Complete the following procedures a See Install the component barrier on page 173 b...

Page 181: ...es to one of the settings shown in Figure 51 Figure 51 CAUTION The factory installed internal voltage divider provides a maximum of 16 V under open circuit conditions This is an impedance protected functional extra low voltage ELV output to prevent shock energy and fire under normal conditions at the machine interface receptacle and under single fault conditions with the machine interface wiring T...

Page 182: ...ace cable CPC to the power supply See Figure 52 on page 183 3 Terminate the machine interface cable spade terminals inside the electrical enclosure of listed and certified torch height controllers THCs or CNC controllers to prevent unauthorized access to the connections after installation Verify that the connections are correct and that all live parts are enclosed and protected before operating th...

Page 183: ...ng procedures a See Disconnect the power and gas supply on page 166 b See Remove the power supply cover on page 172 c See Remove the component barrier on page 173 d See Remove the end panel bracket on page 174 2 Pry up the right edge of the power switch label using a knife or blade screwdriver See Figure 53 3 Peel the right half of the label back to the perforation 4 Apply pressure to the left hal...

Page 184: ...125 Service Manual 808070 9 Power Supply Component Replacement Figure 53 1 6 5 4 3 2 1 Power switch label 2 Perforation 3 Right half of label 4 Left half of label 5 RS 485 connector mounting hole 6 RS 485 connector ...

Page 185: ... the rear panel with the red wire on top see Figure 54 by tightening the 2 supplied screws to 11 5 kg cm 10 inch pounds Figure 54 7 Route the RS 485 cable next to the 2 existing gray cables above the solenoid valve and through the cable clip attached to the center panel 8 Push the small connector from the RS 485 cable through the center grommet in the center panel Figure 55 Red wire Cable clip Sol...

Page 186: ...10 Push the ground wire connector through the center grommet Figure 56 11 From the power board side of the power supply secure the RS 485 board to the plastic mounting posts located on the center panel directly behind the DSP board Tighten the 2 supplied screws to 11 5 kg cm 10 inch pounds See Figure 58 on page 187 12 Attach the ground wire connector to the bottom left connector on the RS 485 boar...

Page 187: ...e J7 connector of the DSP board 15 Push the other connector onto the J2 connector of the RS 485 board Figure 58 16 Complete the following procedures a See Install the end panel bracket on page 175 b See Install the component barrier on page 173 c See Install the power supply cover on page 172 d Reconnect the power and gas supply 4 5 2 1 3 6 7 1 J1 connector 2 Long RS 485 cable 3 DSP board 4 J7 con...

Page 188: ...nent barrier on page 173 d See Remove the end panel bracket on page 174 2 From the fan side of the power supply push to disconnect the end of the hose nearest the rear panel See Figure 60 on page 189 Gently tilt the top of the rear panel away from the power supply as needed to work the gas tube free of the push to connect fitting Figure 59 CAUTION Do not allow dust or other contaminants into the g...

Page 189: ...ete the following procedures a See Install the end panel bracket on page 175 b See Install the component barrier on page 173 c See Install the power supply cover on page 172 d Reconnect the power and gas supply Figure 60 How to use push to connect fittings Push to connect To connect push the hose into the fitting until it stops Pull on the hose to verify that it is secure To release push the fitti...

Page 190: ...om the power board side of the power supply remove the screw securing the ground wire to the heatsink The ground wire screw is located behind the power board The power board is removed in Figure 61 to show the ground wire connection on the heatsink Kit number Description 428121 Kit Powermax125 power cord with strain relief 480 V and 600 V CSA 228886 Kit Powermax105 power cord with strain relief 23...

Page 191: ... the top of the power switch See Figure 62 on page 192 6 Pull the wires straight up to remove them from the power switch 7 On the outside of the power supply unscrew the power cord s strain relief retention nut so that the wires move freely Slide the nut back along the power cord 8 CSA models Pull the wires through the strain relief from outside the power supply to remove the power cord CE models ...

Page 192: ...x125 Service Manual 808070 9 Power Supply Component Replacement Figure 62 2 3 4 6 7 8 9 5 1 1 CSA power cord 2 CE power cord 3 Ferrite core 4 Rear panel 5 Strain relief retention nut 6 Power switch 7 L3 8 L2 9 L1 ...

Page 193: ...ve the remaining parts of the strain relief connector from the power supply Figure 63 Strain relief nut inside power supply 1 3 4 5 6 Strain relief on CE models Strain relief on CSA CCC models 1 4 5 6 2 1 Strain relief nut inside power supply 2 Aluminum washer CSA CCC models only 3 Strain relief adapter CSA CCC models only 4 Strain relief 5 Strain relief retention nut 6 Rear panel of power supply ...

Page 194: ...f from outside the power supply because of the ferrite core installed on the power wires CCC models do not ship with a power cord To install a power cord on a CCC system slide the power cord through the strain relief from the outside of the power supply or to maintain CE certification install power cord kit 228886 4 Route the 3 power wires up the chase inside the rear panel to the top of the power...

Page 195: ...ble 13 Power cord connections Wire CSA CE L1 Black Brown L2 White Black L3 Red Gray Wire colors may vary in power cords not purchased from Hypertherm 2 3 4 6 7 8 9 5 1 1 CSA power cord 2 CE power cord 3 Ferrite core 4 Rear panel 5 Strain relief retention nut 6 Power switch 7 L3 8 L2 9 L1 ...

Page 196: ...e heatsink by tightening the ground screw to 23 kg cm 20 inch pounds The power board is removed in Figure 66 to show the ground wire connection on the heatsink Figure 66 9 Complete the following procedures a See Connect the gas tube on page 189 b See Install the end panel bracket on page 175 c See Install the component barrier on page 173 d See Install the power supply cover on page 172 e Reconnec...

Page 197: ...ify that power to the system has been turned OFF and disconnected Loosen the set screws that secure the 3 power wires L1 L2 L3 to the top of the power switch See Figure 67 on page 198 5 Pull the wires straight up to remove them from the power switch 6 Loosen the set screws that secure the 2 wires red black to the auxiliary switch located on top of the power switch behind the L1 L2 L3 wires 7 Pull ...

Page 198: ... cap does not come off with the handle pull the cap off the post as well 12 Pry up the edge of the power switch label using a knife or blade screwdriver If the optional RS 485 connector is not installed the label extends to the right side of the inlet gas fitting 13 Peel off the entire label to expose the 4 mounting screws that secure the power switch to the rear panel 14 Disengage the power switc...

Page 199: ...ing careful to align the hole in the label with the corresponding hole in the rear panel 4 Push the power switch handle straight onto the post and tighten the handle screw to 11 5 kg cm 10 inch pounds Figure 68 Left half of label used when RS 485 connector is installed Figure 69 Full label used when RS 485 connector is not installed 1 2 3 4 4 5 6 1 Handle screw 2 Power switch handle 3 Left edge of...

Page 200: ... Tighten the T1 T2 T3 set screws to 23 kg cm 20 inch pounds 7 Insert the 3 power wires in the top of the power switch as shown in Figure 70 and Table 14 Tighten the L1 L2 L3 set screws to 23 kg cm 20 inch pounds 8 Lift up the end of the power supply base and carefully slide the rear panel against the base until the base sits securely on the panel Tighten the 3 mounting screws in the bottom of the ...

Page 201: ...ort distance 4 Remove the 3 screws that secure the control board to the front panel 2 screws are installed at the top of the control board one at each end The third screw not shown is installed in the middle of the control board along the bottom edge Access the third screw from the fan side of the power supply 5 Carefully slide the control board from behind the front panel toward the power board s...

Page 202: ...rent adjustment knob with the flat side of the control board post and push the knob straight onto the post Figure 71 6 Complete the following procedures a See Install the end panel bracket on page 175 b See Install the component barrier on page 173 c See Install the power supply cover on page 172 d Reconnect the power and gas supply 1 2 3 5 6 7 4 1 Current adjustment knob 2 Operating mode knob 3 P...

Page 203: ...n the back of the board 4 Carefully pull the DSP board straight out from the power board Do not bend the pins 5 Disconnect the ribbon cable from the J6 ribbon cable connector on the back of the DSP board Set the DSP board aside Install the DSP board See Figure 72 on page 204 1 Connect the ribbon cable from the control board to the J6 connector on the back of the DSP board 2 Carefully align the 2 r...

Page 204: ... following procedures a See Install the component barrier on page 173 b See Install the power supply cover on page 172 c Reconnect the power and gas supply 1 2 3 4 5 6 3 DSP front view DSP back view 1 DSP connector J7 2 DSP connector screws 2 3 DSP board 4 Connector pins 5 Power board 6 J6 connector ...

Page 205: ...See Remove the DSP board on page 203 2 Unplug the 5 wire connectors located at J1 J2 J3 J5 and J6 on the component side of the power board Figure 73 3 Disconnect the gate drive wire connectors J21 J22 from the power board 4 Remove the two 4 μF capacitors from the power board 5 Remove all the screws and bolts securing wires to the power board 6 Remove all the remaining screws from the power board e...

Page 206: ...drive wires through the respective openings in the board Verify that all the wires that were disconnected while removing the power board are now positioned in front of the power board 2 Tighten the 7 board mounting screws to 17 3 kg cm 15 inch pounds 3 Plug the gate drive wires into the respective connectors on the power board J22 and J21 Silkscreen printing above the openings in the board denotes...

Page 207: ... See Install the power supply cover on page 172 c Reconnect the power and gas supply Figure 74 480 V 600 V CSA power board 3 J6 J5 J3 J2 J1 J22 J21 J20 J19 J27 WORK LEAD J26 J25 _ _ RED J18 ORG J17 RED J32 J11 B R J28 C152 C151 TP7 TP9 TP8 W R B 1 2 4 5 6 7 8 9 12 14 16 11 10 15 15 17 3 3 3 13 3 3 3 1 Gate drive connectors 2 J11 3 Board mounting screws 7 4 J17 5 J18 6 Output inductor wires 7 Nozzl...

Page 208: ... TP7 TP9 TP8 W R B 1 2 4 5 6 7 8 9 12 17 10 18 3 11 3 13 14 15 3 16 3 3 3 1 Gate drive connectors 2 J11 3 Board mounting screws 7 4 J17 5 J18 6 Output inductor wires 7 Nozzle wires 8 Electrode wire 9 J32 10 Work lead 11 Transformer wires 12 4 μF capacitors 13 Capacitor screws 4 14 PFC inductor wires 15 Input diode bridge screws 5 16 AC input wires 3 17 Transformer mounting screws 18 J6 J5 J3 J2 an...

Page 209: ...de bridge was mounted using isopropyl alcohol to remove the old thermal grease from the heatsink 4 Apply a 0 0762 mm 0 003 inch layer of thermal grease about the thickness of a sheet of paper evenly to the input diode bridge mounting surface 5 Mount the input diode bridge to the heatsink by hand tightening the 2 supplied mounting screws 6 Step torque the 2 mounting screws to the proper torque valu...

Page 210: ... using isopropyl alcohol to remove the old thermal grease from the heatsink 6 Apply a 0 0762 mm 0 003 inch layer of thermal grease about the thickness of a sheet of paper evenly to the output diode bridge mounting surface 7 Mount the output diode bridge to the heatsink by hand tightening the 4 supplied mounting screws 8 Step torque the 4 mounting screws in a diagonal sequence to the proper torque ...

Page 211: ...sink 5 Apply a 0 0762 mm 0 003 inch layer of thermal grease about the thickness of a sheet of paper evenly to the pilot arc IGBT mounting surface 6 Mount the pilot arc IGBT to the heatsink by hand tightening the 2 supplied mounting screws 7 Step torque the 2 mounting screws to the proper torque value as shown in Figure 76 on page 215 8 Connect the supplied cable to the pilot arc IGBT terminals The...

Page 212: ...ule to the heatsink by hand tightening the 4 supplied mounting screws using the longer brass screw to capture the ring terminal of the thermal sensor between the screw head and the upper left mounting hole of the inverter IGBT module 8 Step torque the 4 mounting screws in a diagonal sequence to the proper torque value as shown in Figure 76 on page 215 9 Connect the supplied gate drive cables to th...

Page 213: ...to the heatsink as follows by hand tightening the 2 supplied mounting screws See Figure 76 on page 215 Kit 428137 Align the snubber resistor so the 2 threaded studs are on the bottom of the snubber resistor Kit 228898 Align the snubber resistor so the 2 threaded studs are on the left side of the snubber resistor 7 Step torque the 2 mounting screws to the proper torque value as shown in Figure 76 o...

Page 214: ...See Figure 76 on page 215 3 Remove the thermal sensor 4 Align the ring terminal of the new thermal sensor with the upper left hole in the inverter IGBT module 5 Hand tighten the supplied screw through the ring terminal then step torque the supplied screw to the proper value as shown in Figure 76 on page 215 6 Complete the following procedures a See Install the power board on page 206 b See Install...

Page 215: ...8137 2 Output diode bridge 2 Kit 428139 3 Pilot arc IGBT Kit 428138 4 Pilot arc IGBT gate drive cable 5 Snubber resistor 15 Ω 200 W Kit 228898 6 Inverter IGBT module Kit 428140 7 Input diode bridge Kit128746 8 Thermal sensor Kit 228805 9 Inverter IGBT module gate drive cables 1 2 2 2 2 1 1 Torque to 17 3 kg cm 15 inch pounds 2 Torque to 40 kg cm 35 inch pounds ...

Page 216: ...the fan shroud with two hands 3 Pull the fan shroud straight off the fan housing Figure 77 Install the fan shroud 1 Align the 3 plastic posts on the back side of the fan shroud with the corresponding holes in the fan housing 2 Push the fan shroud straight onto the fan housing 3 Complete the following procedures a See Install the power supply cover on page 172 b Reconnect the power and gas supply K...

Page 217: ...e 78 3 Pull the fan wire and connector through the left grommet from the fan side of the power supply See Figure 79 on page 218 4 Remove the 3 mounting screws located behind the fan flange 5 Remove the fan from the power supply 6 Orient the new fan so the wires extend from the top right of the fan see Figure 79 Tighten the 3 supplied mounting screws to 23 kg cm 20 inch pounds 7 Route the fan wire ...

Page 218: ...9 Complete the following procedures a See Install the fan shroud on page 216 b See Install the end panel bracket on page 175 c See Install the power supply cover on page 172 d Reconnect the power and gas supply 1 2 1 3 4 1 Mounting screw locations 2 Fan flange 3 Fan wire 4 Left grommet ...

Page 219: ...side of the power supply 4 Remove the pressure transducer from the solenoid valve by pushing to disconnect the plastic ring against the valve while pulling up on the pressure transducer 5 Insert the new pressure transducer into the valve and push down until fully seated 6 Route the pressure transducer connector and wires through the left grommet 7 Plug the pressure transducer connector into the J3...

Page 220: ...ual 808070 9 Power Supply Component Replacement Figure 80 J1 J2 J3 J5 J6 J1 J2 J3 J5 J6 1 2 3 4 5 6 1 Pressure transducer 2 Push to connect plastic ring 3 Solenoid valve 4 Transducer wires 5 Left grommet 6 Power board connectors ...

Page 221: ...gas filter housing 6 Lightly apply thread sealant to the threads of the new pressure switch If applied too heavily excess amounts of thread sealant can contaminate the gas line 7 Tighten the new pressure switch into the gas filter housing 8 Connect the wire terminals to the pressure switch blue wire closest to the center panel 9 Complete the following procedures a See Install the end panel bracket...

Page 222: ...222 Powermax125 Service Manual 808070 9 Power Supply Component Replacement Figure 81 Wire terminals Pressure switch Gas filter housing ...

Page 223: ...167 2 Disconnect the 2 wire terminals from the top of the pressure switch 3 Remove the screw securing the 2 ground wires to the gas filter housing 4 Push in the plastic ring on the push to connect fitting Gently pull the top of the rear panel away from the power supply until the gas tube pulls out of the push to connect fitting Figure 82 Kit number Description 228685 Kit Powermax65 85 105 125 gas ...

Page 224: ...n the 3 mounting screws in the rear panel to 23 kg cm 20 inch pounds 4 Lightly apply thread sealant to the gas fitting threads and tighten the gas fitting into the bracket on the rear panel If applied too heavily excess amounts of thread sealant can contaminate the gas line 5 Align the end of the gas tube with the push to connect fitting and gently push the rear panel toward the power supply until...

Page 225: ...the solenoid valve 1 Complete the following procedures a See Disconnect the power and gas supply on page 166 b See Remove the power supply cover on page 172 c See Remove the end panel bracket on page 174 d See Remove the fan shroud on page 216 2 Unplug the J6 connector from the back side of the power board Figure 84 3 Pull the solenoid valve power wires and connector through the left grommet from ...

Page 226: ...until fully seated See Figure 85 2 Secure the solenoid valve to the center panel by tightening the 2 supplied mounting screws to 23 kg cm 20 inch pounds 3 Push the long gas tube into the solenoid valve until fully seated 4 Push the pressure transducer into the solenoid valve until fully seated 5 Route the solenoid valve power wires and connector through the left grommet 6 Plug the solenoid valve c...

Page 227: ...he short gas tube out of the fitting 4 Push one end of the new short gas tube into the solenoid valve fitting until fully seated 5 Align the other end of the short gas tube with the straight push to connect fitting and gently push the top of the rear panel toward the power supply until the short gas tube is fully seated in the straight push to connect fitting 6 Push in the plastic ring on top of t...

Page 228: ...x125 Service Manual 808070 9 Power Supply Component Replacement Figure 86 1 2 3 4 5 6 1 Rear panel 2 Straight push to connect fitting 3 90 push to connect fitting 4 Long gas tube 5 Solenoid valve 6 Short gas tube ...

Page 229: ...ulling them straight out 4 Insert the new bulk capacitors from the fan side of the power supply noting the orientation of the polarity dot in regard to the viewing hole in the power board See Figure 88 on page 230 5 From the fan side rotate each capacitor until the polarity dot aligns with the viewing hole on the front side of the power board 6 Secure the inductor wire with the C152 top mounting s...

Page 230: ...mplete the following procedures a See Install the fan shroud on page 216 b See Install the component barrier on page 173 c See Install the power supply cover on page 172 d Reconnect the power and gas supply C151 C152 _ _ Bulk capacitor polarity dots Bulk capacitors Power board viewing holes ...

Page 231: ...Figure 89 4 From the fan side pull the torch interface cable through the center grommet See Figure 90 on page 232 5 From the fan side pull the nozzle wires through the protective sheathing that passes through the center panel 6 Disconnect the 90 push to connect fitting by pushing in the plastic ring closest to the brass nut and pulling the fitting away from the nut 7 Disconnect the electrode wire ...

Page 232: ...eptacle housing 10 Remove the quick disconnect receptacle by removing the 4 mounting screws that secure the quick disconnect receptacle to the front panel Figure 90 1 2 4 5 6 7 8 9 10 3 1 Torch interface cable 2 90 push to connect fitting 3 Brass nut 4 Electrode wire red 5 Protective sheathing 6 Nozzle wires 2 7 Output inductor wires 3 8 Plastic washer 9 Quick disconnect receptacle 10 Center gromm...

Page 233: ... fully seated 3 Install the plastic washer over the silver plated fitting and the plastic hub on the rear of the quick disconnect receptacle 4 Place the ring terminal over the silver plated fitting and tighten the brass nut onto the silver plated fitting Tighten the nut to 46 1 kg cm 40 inch pounds but do not overtighten the plastic washer should be able to spin when the brass nut is installed 5 P...

Page 234: ...ice Manual 808070 9 Power Supply Component Replacement Figure 91 1 2 5 6 7 4 3 1 Silver plated fitting 2 Ring terminal 3 Protective sheathing 4 Nozzle wires 2 5 Quick disconnect receptacle 6 Mounting screws 4 7 Plastic hub ...

Page 235: ...er board Align the orange wire in the connector with the ORG that is printed on the power board Figure 92 10 Complete the following procedures a See Install the fan shroud on page 216 b See Install the end panel bracket on page 175 c See Install the component barrier on page 173 d See Install the power supply cover on page 172 e Reconnect the power and gas supply J22 J27 WORK LEAD J26 _ RED J18 OR...

Page 236: ...n page 172 c See Remove the fan shroud on page 216 2 Remove the bolt securing the work cable to the work lead receptacle 3 Remove the nut and lock washer securing the work lead receptacle to the front panel 4 Push the work lead receptacle out through the front panel Figure 93 Kit number Description 228912 Kit Powermax105 125 work lead receptacle power supply side 1 2 3 4 5 1 Work lead receptacle 2...

Page 237: ...re 94 6 Place the lock washer over the work lead receptacle inside the power supply 7 Tighten the nut onto the work lead receptacle 8 Secure the work cable to the work lead receptacle by tightening the bolt Figure 94 9 Complete the following procedures a See Install the fan shroud on page 216 b See Install the power supply cover on page 172 c Reconnect the power and gas supply Front panel Work lea...

Page 238: ...the fan shroud on page 216 2 Remove the screw at J28 that secures the electrode wire to the power board 3 Remove the screw securing the output inductor wires to the power board The power board in Figure 95 is a CSA model The connections for the output inductor wires and the electrode wire are the same for all models Figure 95 Kit number Description 428125 Kit Powermax125 output inductor J22 J21 J2...

Page 239: ...ires by removing the brass nut that secures the ring terminal to the quick disconnect housing The electrode wire and short inductor wires are captured in the same wire connector 7 Pull the electrode wire through the protective sheathing that passes through the center panel 8 Carefully slide the front panel a short distance away from the base of the power supply 9 Remove the 2 mounting screws in th...

Page 240: ...placement Figure 96 1 5 6 7 8 10 3 9 2 4 11 1 90 push to connect fitting 2 Electrode wire red 3 Protective sheathing 4 Short inductor wires 3 5 Output inductor 6 Mounting screws 2 7 Front panel 8 Ring terminal 9 Plastic washer 10 Quick disconnect housing 11 Brass nut ...

Page 241: ... the protective sheathing that passes through the center panel 4 Tighten the 2 supplied mounting screws in the base of the output inductor to 69 1 kg cm 60 inch pounds 5 Verify that the plastic washer is installed over the plastic hub on the rear of the quick disconnect receptacle 6 Place the ring terminal over the silver plated fitting and tighten the nut onto the fitting Tighten the nut to 46 1 ...

Page 242: ...er Supply Component Replacement Figure 97 1 2 3 4 5 6 7 8 9 1 90 push to connect fitting 2 Protective sheathing 3 Slots in base 4 Long inductor wires 3 5 Electrode wire red 6 Output inductor 7 Ring terminal 8 Plastic hub 9 Silver plated fitting ...

Page 243: ...ecure the output inductor wires to the power board by tightening the screw to 40 3 kg cm 35 inch pounds 12 Complete the following procedures a Install the fan shroud on page 216 b Install the end panel bracket on page 175 c Install the component barrier on page 173 d Install the power supply cover on page 172 e Reconnect the power and gas supply Figure 98 Front panel mounting screws J22 J21 J20 J1...

Page 244: ... screws securing the long transformer wires to the output diode bridge 3 Remove the screw and bolt securing the short transformer wires to the power board The power board in Figure 99 is a CSA model The connections for the transformer wires are the same for all models Figure 99 Kit number Description 428129 Kit Powermax125 transformer 480 V CSA 428130 Kit Powermax125 transformer 600 V CSA 428128 K...

Page 245: ... of the transformer 5 Remove the bottom 2 fan mounting screws The screws are located directly behind the bottom holes in the fan housing flange 6 Push the bottom of the fan to the left so that it will not interfere with the removal of the transformer Figure 100 J1 J2 J3 J5 J6 Bottom holes in fan housing flange Transformer mounting screws ...

Page 246: ...Replacement 7 Lift the transformer out of the power supply while carefully guiding the transformer wires through the opening in the bottom of the center panel Figure 101 1 4 3 5 2 1 Bottom of fan 2 Slots in base 3 Transformer tab 4 Transformer 5 Transformer wires 4 ...

Page 247: ...47 9 Power Supply Component Replacement 8 From the power board side remove the 2 ferrite cores installed over the long transformer wires while removing the transformer from the power supply Figure 102 Long transformer wires Ferrite cores ...

Page 248: ...power board side install the 2 ferrite cores over the long transformer wires 6 Secure the long transformer wires to the output diode bridge by tightening the screws to 40 3 kg cm 35 inch pounds 7 Secure the short transformer wires to the power board using the screw and bolt removed in step 3 on page 244 Tighten the screw to 40 3 kg cm 35 inch pounds and the bolt at J26 to 63 4 kg cm 55 inch pounds...

Page 249: ...n page 172 c See Remove the component barrier on page 173 d See Remove the fan shroud on page 216 2 Remove the screw and bolt securing the PFC inductor wires to the power board Figure 104 Kit number Description 428127 Kit Powermax125 PFC inductor 480 V 600 V CSA 428126 Kit Powermax125 PFC inductor 400 V CE 380 V CCC J22 J21 J20 J19 J27 WORK LEAD J26 J25 _ _ RED J18 ORG J17 RED J32 J11 B R J28 C152...

Page 250: ...Replacement 3 Remove the 2 mounting screws from the base of the PFC inductor Figure 105 4 Lift the PFC inductor out of the power supply while carefully guiding the PFC inductor wires through the opening in the bottom of the center panel PFC inductor mounting screws ...

Page 251: ...crews in the base of the PFC inductor to 69 1 kg cm 60 inch pounds 4 Secure the PFC inductor wires to the power board using the screw and bolt removed in step 2 on page 249 Tighten the screw to 40 3 kg cm 35 inch pounds and the bolt at J25 to 63 4 kg cm 55 inch pounds Figure 106 5 Complete the following procedures a See Install the fan shroud on page 216 b See Install the component barrier on page...

Page 252: ...107 on page 253 3 Carefully tilt the top of the front panel away from the power supply The front panel is still attached to the bottom of the power supply and can only move a short distance 4 Remove the 3 screws that secure the control board to the front panel Two screws are installed at the top of the control board one at each end The third screw not shown is installed in the middle of the contro...

Page 253: ... 808070 253 9 Power Supply Component Replacement Figure 107 2 3 4 5 6 7 1 1 Current adjustment knob 2 Operating mode knob 3 Power board 4 Ribbon cable 5 Top mounting screws for control board 6 Control board 7 Top of front panel ...

Page 254: ...ing screws 8 Remove the bolt securing the work cable to the work lead receptacle 9 Remove the nut and lock washer securing the work lead receptacle to the front panel 10 Push the work lead receptacle out through the front panel Figure 108 3 4 5 6 1 2 7 1 Work lead receptacle 2 Bolt 3 Work cable 4 Nut 5 Lock washer 6 Quick disconnect receptacle 7 Mounting screws 4 ...

Page 255: ...ce Manual 808070 255 9 Power Supply Component Replacement 11 Remove the 3 front panel mounting screws 12 Remove the front panel from the power supply Figure 109 Front panel mounting screws Work lead receptacle Keyway up ...

Page 256: ... mounting screws to 23 kg cm 20 inch pounds 6 Plug the ribbon cable into the J6 connector on the control board 7 Carefully tilt the top of the front panel away from the power supply and slide the control board into place Angle the bottom of the board into the correct position first then angle the top of the board into place 8 Secure the control board to the front panel using the 3 supplied mountin...

Page 257: ... Install the power supply cover on page 172 e Reconnect the power and gas supply Replacing the rear panel Kit number Description 428110 Kit Powermax125 480V CSA rear panel 428112 Kit Powermax125 600V CSA rear panel 428111 Kit Powermax125 400V CE rear panel 428113 Kit Powermax125 380V CCC rear panel 2 3 4 5 6 7 1 1 Current adjustment knob 2 Operating mode knob 3 Power board 4 Ribbon cable 5 Top mou...

Page 258: ...3 d See Remove the end panel bracket on page 174 e See Disconnect the gas tube on page 188 f See Remove the power cord and strain relief on page 190 2 Remove the screw securing the 2 ground wires to the gas filter housing 3 Unplug the 2 wire connectors from the terminals on top of the pressure switch 4 Remove the 2 mounting screws securing the CNC interface to the rear panel Figure 111 1 2 3 4 1 C...

Page 259: ...by unscrewing the plastic retaining nut 9 Remove the gas fitting from the gas filter assembly 10 Remove the 3 gas filter assembly mounting screws 11 Lift the gas filter assembly out of the power supply 12 If the optional RS 485 connector is installed remove it by unplugging the 5 wires from the connector terminals inside the power supply and removing the 2 mounting screws from the rear panel Figur...

Page 260: ... extends to the right side of the inlet gas fitting 16 Peel off the entire label to expose the 4 mounting screws that secure the power switch to the rear panel 17 Remove the power switch from the rear panel by removing the 4 mounting screws 18 Remove the 3 mounting screws from the base of the rear panel if they are not already removed 19 Remove the rear panel Figure 113 Rear panel with and without...

Page 261: ...abel and affix it to the rear panel being careful to align the hole in the label with the corresponding hole in the rear panel 5 Push the power switch handle straight onto the post and tighten the handle screw to 11 5 kg cm 10 inch pounds 6 If removed in step 12 on page 259 secure the RS 485 connector to the rear panel by tightening the 2 mounting screws to 11 5 kg cm 10 inch pounds Figure 114 Rea...

Page 262: ...the gas filter assembly by tightening the plastic retaining nut 10 Insert the filter bowl into the bottom of the gas filter assembly with the thumb latch positioned 45 degrees to the right of center 11 Vertically align and firmly push the filter bowl up until it is fully seated 12 Rotate the filter bowl to the left until the thumb latch clicks into place Figure 115 CAUTION Never use PTFE tape on a...

Page 263: ...63 9 Power Supply Component Replacement 13 If disconnected in step 12 on page 259 connect the wires to the RS 485 connector terminals starting from the top in the following order red black brown white green Figure 116 1 2 3 4 5 1 2 3 4 5 ...

Page 264: ...0 inch pounds 17 Reinstall the power cord See Install the power cord and strain relief on page 194 18 If needed secure the end panel to the power supply by tightening the 3 mounting screws at the base of the panel to 23 kg cm 20 inch pounds Figure 117 19 Complete the following procedures a See Connect the gas tube on page 189 b See Install the end panel bracket on page 175 c See Install the compon...

Page 265: ...Manual 808070 265 Section 10 Torch Component Replacement WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance See the Safety and Compliance Manual 80669C for more safety precautions ...

Page 266: ...nt Disconnect the power gas supply and torch Figure 118 1 Turn the plasma power supply switch to OFF O 2 Turn the line disconnect switch to OFF O 3 Disconnect the gas supply hose from the plasma power supply 4 Disconnect the torch from the plasma power supply 1 3 4 2 ...

Page 267: ... 119 85 hand torch and Figure 120 15 hand torch Figure 119 85 hand torch 2 4 5 6 8 3 1 7 9 10 11 12 13 14 1 Right side of the handle 2 Cap sensor switch 3 Start switch 4 Pilot terminal screw 5 Torch body 6 Consumables 7 Pilot arc wire 8 Trigger 9 Spring 10 Screws 6 11 Left side of the handle 12 Torch lead 13 Gas hose fitting s flange 14 Strain relief ...

Page 268: ...d torch 2 4 5 6 8 3 1 7 9 10 11 12 13 14 1 Right side of the handle 2 Cap sensor switch 3 Start switch 4 Pilot terminal screw 5 Torch body 6 Consumables 7 Pilot arc wire 8 Trigger 9 Spring 10 Screws 6 11 Left side of the handle 12 Torch lead 13 Gas hose fitting s flange 14 Strain relief ...

Page 269: ...ng up The left side of the handle is the side with the screws It may be helpful to clamp the lead in place to keep it from moving 4 Remove the screws from the left handle 5 Being careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Figure 121 For the 15 hand torch carefully lift up the right end of the handle Insert a blade screwd...

Page 270: ...the trigger and spring up and out of the handle Set them aside 7 The torch body fits snugly into the right side of the handle While holding the torch body gently press the right side of the handle away from the torch body to remove it Figure 123 8 Slide the cap sensor switch off its mounting post See Figure 125 on page 271 ...

Page 271: ...9 Using a blade screwdriver pry the start switch off the 2 mounting posts Figure 125 1 2 3 4 5 6 1 Cap sensor switch s post hole 2 Cap sensor switch s mounting post 3 Trigger s pivot hole 4 Start switch s mounting posts 5 Slot for the gas hose fitting s flange 6 Strain relief slot ...

Page 272: ...label to the right side of the torch handle and the Duramax label to the left side of the torch handle 3 Press the cap sensor switch into its post hole and onto its mounting posts See Figure 124 on page 271 Figure 126 4 Route the cap sensor wires as shown in Figure 127 Position the wires below the slot for the gas hose fitting s flange 5 Press the start switch onto the 2 mounting posts and positio...

Page 273: ...igger spring into the front half of the trigger Slide the trigger and spring into place Figure 128 9 Being careful that the handle and gas fitting flange do not pinch the wires align the left half of the handle with the right half Verify that the trigger pivots are both located in the trigger pivot holes See Figure 127 10 Install the handle screws loosely 1 2 3 4 5 Cap sensor switch wires Start sw...

Page 274: ...rch 3 Place the torch on a flat surface with the left handle facing up 4 Remove the screws from the left handle Set the screws aside 5 Being careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Figure 129 For the 15 hand torch carefully lift up the right end of the handle Insert a blade screwdriver between the handles on the left ...

Page 275: ... Figure 131 8 Making sure that the handle and gas fitting flange do not pinch the wires align the left half of the handle with the right half Verify that the trigger pivots are both located in the trigger pivot holes See Figure 127 on page 273 9 Install the handle screws loosely 10 Make sure the trigger is in its pivot holes by pulling it a few times 11 Tighten the handle screws to15 0 kg cm 13 in...

Page 276: ...2 3 Use a 3 8 inch and 1 2 inch wrench together or 2 adjustable wrenches to loosen the gas fitting that secures the torch body to the torch lead Kit Description 428157 Kit Duramax Hyamp 15 hand torch main body replacement 428158 Kit Duramax Hyamp 85 hand torch main body replacement CAUTION Always use 2 wrenches to properly loosen and tighten the hex nuts and bolts mentioned in these procedures A s...

Page 277: ...hten the gas fitting that secures the torch body to the torch lead to 69 1 kg cm 60 inch pounds 7 Tighten the pilot terminal screw to 17 3 kg cm 15 inch pounds The wire should go down into the left handle Bend the terminal slightly if necessary 8 Complete the following procedures a Install all of the torch components that you removed See Install the handle on page 272 b Reconnect the torch and gas...

Page 278: ... from the left handle 5 Being careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Figure 134 For the 15 hand torch carefully lift up the right end of the handle Insert a blade screwdriver between the handles on the left end Gently twist the screwdriver to pry up the handle Figure 135 Kit Description 428162 Kit Duramax Hyamp start...

Page 279: ...nds 12 Press the torch body into the torch handle with the gas hose fitting s flange aligned with the slot in the handle 13 Align the strain relief with the strain relief slot in the handle 14 Compress the trigger spring into the front half of the trigger Slide the trigger and spring into place 15 Making sure that the handle and gas fitting flange do not pinch the wires align the left half of the ...

Page 280: ...itch by pressing the tab on the connector and pulling the connector apart Figure 137 3 Connect the new cap sensor switch to the torch lead by pushing the mating plug on the torch lead wires into the socket 4 Complete the following procedures a Install all of the components that you removed See Install the handle on page 272 b Reconnect the torch and gas supply and turn ON I the power Kit Descripti...

Page 281: ...ts from the torch See Remove the handle on page 269 2 Disconnect the cap sensor switch and start switch Figure 138 3 Remove the pilot terminal screw Figure 139 Kit Description 428159 Kit Duramax Hyamp hand torch lead replacement 7 6 m 25 foot 428160 Kit Duramax Hyamp hand torch lead replacement 15 m 50 foot 428161 Kit Duramax Hyamp hand torch lead replacement 23 m 75 foot Cap sensor switch Tab Tab...

Page 282: ...body Be very careful not to get any threadlocker on the conical surface of the gas tube fitting to avoid damage to the torch See Figure 140 Figure 140 CAUTION Always use 2 wrenches to properly loosen and tighten the hex nuts and bolts mentioned in these procedures CAUTION Do not get any threadlocker on the conical surface of the gas tube fitting to avoid causing damage to the torch If any threadlo...

Page 283: ...o tighten the gas fitting that secures the torch body to the torch lead to 69 1 kg cm 60 inch pounds 8 Tighten the pilot terminal screw to 17 3 kg cm 15 inch pounds 9 Connect the cap sensor switch and start switch Figure 141 10 Complete the following procedures a Install all of the components that you removed See Install the handle on page 272 b Reconnect the torch and gas supply and turn ON I the...

Page 284: ...ine torches Figure 142 6 7 1 4 2 5 3 8 10 11 12 9 1 Mounting sleeve screws 2 Mounting sleeve 3 Cap sensor switch and screw 4 Torch body 5 Coupler 6 Positioning sleeve 7 Adapter 8 Pilot arc wire and screw 9 Torch lead 10 Strain relief 11 Strain relief nut 12 Quick disconnect ...

Page 285: ... from the strain relief and slide the strain relief nut back along the torch lead 4 Unscrew the strain relief from the positioning sleeve full length only or adapter mini only and slide the nut back along the torch lead See Figure 143 on page 285 5 Unscrew the positioning sleeve full length only or adapter mini only from the coupler 6 Unscrew the coupler from the mounting sleeve 7 Remove the screw...

Page 286: ...he mounting sleeve 3 Reinstall the consumables 4 Screw the coupler onto the mounting sleeve 5 Screw the positioning sleeve full length only or adapter mini only onto the coupler 6 Screw the strain relief onto the positioning sleeve full length only or adapter mini only 7 Screw the strain relief nut onto the strain relief 8 Reconnect the torch and gas supply and turn ON I the power ...

Page 287: ...e tab on the connector and pulling the connector apart Figure 144 3 Remove the screw from the cap sensor switch and remove the switch from the torch body Figure 145 Install the cap sensor switch 1 Install the cap sensor switch and screw 2 Connect the cap sensor switch to the torch lead 3 Complete the following procedures a See Install the mounting sleeve on page 286 b Reconnect the torch and gas s...

Page 288: ... See Remove the mounting sleeve on page 285 c See Remove the cap sensor switch on page 287 2 Remove the pilot terminal screw and wire Set the screw aside Figure 146 3 Using a 3 8 inch and 1 2 inch wrench together or 2 adjustable wrenches loosen the nut that secures the gas supply line to the torch to remove the torch body Figure 147 Kit Description 428147 Kit Duramax Hyamp 180 machine torch main b...

Page 289: ...llowing procedures a See Disconnect the power gas supply and torch on page 266 b See Remove the mounting sleeve on page 285 c See Remove the torch body on page 288 2 Slide the coupler off the torch lead 3 Slide the positioning sleeve full length only or adapter mini only off the torch lead 4 Slide the positioning sleeve full length only or adapter mini only onto the torch lead 5 Slide the coupler ...

Page 290: ...ull length only or adapter mini only on page 289 Install the coupler and positioning sleeve or adapter onto the new lead 5 See Install the torch body on page 289 6 See Install the mounting sleeve on page 286 7 Reconnect the torch and gas supply and turn ON I the power Kit Description 428149 Kit Duramax Hyamp 180 machine torch lead replacement 4 6 m 15 feet 428150 Kit Duramax Hyamp 180 machine torc...

Page 291: ...ng the tab down and out toward the lead 5 Pull the spring out of the quick disconnect housing Figure 148 6 Place the new latch into the quick disconnect housing 7 Hold up the end of the latch and insert the new spring under the latch 8 Use a blade screwdriver to push the spring into the recess until it clicks into place Kit Description 428260 Kit Duramax and Duramax Hyamp torch quick disconnect re...

Page 292: ...10 Torch Component Replacement 9 Install the new shell halves onto the torch lead making sure the strain relief fits in the slot of the shell and the wires are not pinched or do not interfere with the latch 10 Install and tighten the screws ...

Page 293: ...e torch You can find procedures explaining how to install these kits in Power Supply Component Replacement on page 165 and Torch Component Replacement on page 265 For instructions on installing the consumables in the hand torches see Install the hand torch consumables on page 54 For instructions on installing the consumables in the machine torches see Install the machine torch consumables on page ...

Page 294: ...t Powermax125 CCC power supply cover with labels 5 428142 Kit Operating mode knob 6 428110 Kit Powermax125 480V CSA rear panel 6 428112 Kit Powermax125 600V CSA rear panel 6 428111 Kit Powermax125 400V CE rear panel 6 428113 Kit Powermax125 380V CCC rear panel 7 Work lead See Accessory parts on page 307 8 228912 Kit Powermax105 125 work lead receptacle power supply side 9 428120 Kit Powermax125 qu...

Page 295: ...V CE Powermax125 power cord with strain relief 400 V CE 3 228539 Kit Serial interface port internal cables and RS 485 board 223236 RS 485 cable unterminated 7 6 m 25 feet 223237 RS 485 cable unterminated 15 m 50 feet 223239 RS 485 cable 9 pin D sub connector for Hypertherm controls 7 6 m 25 feet 223240 RS 485 cable 9 pin D sub connector for Hypertherm controls 15 m 50 feet 4 228884 Kit Powermax105...

Page 296: ...op arc transfer signals for divided arc voltage 6 1 m 20 feet D sub connector with screws 223048 External machine interface cable start stop arc transfer signals for divided arc voltage 7 6 m 25 feet D sub connector with screws 223356 External machine interface cable start stop arc transfer signals for divided arc voltage 10 7 m 35 feet D sub connector with screws 123896 External machine interface...

Page 297: ...ol board 141100 3 428119 Kit Powermax125 DSP board 141316 4 428123 Kit Powermax125 power board 480 V CSA 141204 4 428124 Kit Powermax125 power board 600 V CSA 141290 5 228880 Kit Powermax105 125 power switch 400 V CE 380 V CCC 480 V 600 V CSA 428114 Kit Powermax125 component barrier J22 J21 J20 J19 J27 WORK LEAD J26 J25 _ _ RED J18 ORG J17 RED J32 J11 B R J28 C152 C151 TP7 TP9 TP8 W R B 1 2 3 4 5 ...

Page 298: ...rmax65 105 125 control board 141100 3 428119 Kit Powermax125 DSP board 141316 4 428122 Kit Powermax125 power board 400 V CE 380 V CCC 141207 5 228880 Kit Powermax105 125 power switch 400 V CE 380 V CCC 480 V 600 V CSA 428114 Kit Powermax125 component barrier J22 J21 J20 J19 J27 WORK LEAD J26 J25 _ _ RED J18 ORG J17 J32 J11 J28 TP7 TP9 TP8 W R B 1 2 3 4 5 ...

Page 299: ...689 Kit Powermax65 85 105 125 pressure transducer 7 228882 Kit Powermax105 125 regulator solenoid valve 8 228688 Kit Powermax65 85 105 125 pressure switch 9 428129 Kit Powermax125 transformer 480 V CSA 9 428130 Kit Powermax125 transformer 600 V CSA 9 428128 Kit Powermax125 transformer 400 V CE 380 V CCC 10 228888 Kit Powermax105 bulk capacitor CSA 230 400 V CE Powermax125 bulk capacitor 600 V CSA ...

Page 300: ...00 V CE 380 V CCC 14 428125 Kit Powermax125 output inductor Part Number Description 1 428139 Kit Powermax125 output diode with thermal grease 2 428138 Kit Powermax125 pilot arc IGBT with thermal grease 3 228898 Kit Powermax105 125 snubber resistor 15 Ω with thermal grease 4 428137 Kit Powermax125 snubber resistor 7 5 Ω with thermal grease 5 428140 Kit Powermax125 inverter IGBT with thermal grease ...

Page 301: ...ment 2 075696 Pilot terminal screw 3 428158 Kit Duramax Hyamp 85 hand torch main body replacement 4 428253 Kit Duramax Hyamp O ring replacement 5 5 428156 Kit Duramax Hyamp hand torch trigger with spring replacement 6 428162 Kit Duramax Hyamp start switch replacement 7 428148 Kit Duramax Hyamp hand torch handle screws 8 428159 Kit Duramax Hyamp hand torch lead replacement 7 6 m 25 foot 8 428160 Ki...

Page 302: ...ment 2 075696 Pilot terminal screw 3 428157 Kit Duramax Hyamp 15 hand torch main body replacement 4 428253 Kit Duramax Hyamp O ring replacement 5 5 428156 Kit Duramax Hyamp hand torch trigger with spring replacement 6 428162 Kit Duramax Hyamp start switch replacement 7 428148 Kit Duramax Hyamp hand torch handle screws 8 428159 Kit Duramax Hyamp hand torch lead replacement 7 6 m 25 feet 8 428160 Ki...

Page 303: ...A 220975 Duramax Hyamp nozzle 105 125 A 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420112 Duramax Hyamp gouging shield 220977 Duramax Hyamp retaining cap 420001 Duramax Hyamp gouging nozzle 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Part Number Description 420152 Duramax Hyamp FineCut shield 220977 Duramax Hyamp retaining cap 420151 D...

Page 304: ...feet lead 059522 Duramax Hyamp 180 full length machine torch assembly with 15 m 50 feet lead 059523 Duramax Hyamp 180 full length machine torch assembly with 23 m 75 feet lead 1 428248 Kit Duramax Hyamp 180 machine torch coupler 2 428144 Kit Duramax Hyamp 180 full length machine torch positioning sleeve 3 428145 Kit Duramax Hyamp 180 machine torch mounting sleeve 4 428253 Kit Duramax Hyamp O ring ...

Page 305: ...Kit Duramax and Duramax Hyamp torch quick disconnect repair lead side The torch assembly does not include consumables See page 306 for a list of consumable part numbers Part Number Description 059514 Duramax Hyamp 180 mini machine torch assembly with 4 6 m 15 foot lead 059515 Duramax Hyamp 180 mini machine torch assembly with 7 6 m 25 foot lead 059516 Duramax Hyamp 180 mini machine torch assembly ...

Page 306: ...achine torch lead replacement 15 m 50 feet 428260 Kit Duramax and Duramax Hyamp torch quick disconnect repair lead side The torch assembly does not include consumables See page 306 for a list of consumable part numbers Part Number Description 420168 Duramax Hyamp shield 45 65 A 220976 Duramax Hyamp shield 105 125 A 220977 Duramax Hyamp retaining cap 420156 Duramax Hyamp Ohmic retaining cap 420158 ...

Page 307: ...e Powermax105 125 101215 Kit Eliminizer gas filter protective metal cover for the Powermax105 125 cover only 223292 Kit 125 A work lead with hand clamp 7 6 m 25 feet 223293 Kit 125 A work lead with hand clamp 15 m 50 feet 223294 Kit 125 A work lead with hand clamp 23 m 75 feet 223298 Kit 125 A work lead with C style clamp 7 6 m 25 feet 223299 Kit 125 A work lead with C style clamp 15 m 50 feet 223...

Page 308: ...5 labels The label kits include the consumables label appropriate safety labels display panel label power switch label and side decals Part Number Description 428117 Kit Powermax125 labels CSA 428118 Kit Powermax125 labels CE 428257 Kit Powermax125 labels CCC ...

Page 309: ... this label Replace if it is missing damaged or worn Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death PN 110673 Rev D AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l opérateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant d...

Page 310: ...genuine Hypertherm parts to maintain the warranty and system certifications including CE CSA and CCC certification Power supply power board side 480 V 600 V CSA Part Number Description 1 428123 Kit Powermax125 power board 480 V CSA 141204 1 428124 Kit Powermax125 power board 600 V CSA 141290 2 228880 Kit Powermax105 125 power switch 400 V CE 380 V CCC 480 V 600 V CSA 3 428121 Kit Powermax125 power...

Page 311: ...5 125 power switch 400 V CE 380 V CCC 480 V 600 V CSA 3 228913 Kit Powermax105 power cord strain relief 230 400 V CE Powermax125 power cord strain relief 400 V CE 4 228886 Kit Powermax105 power cord with strain relief 230 400 V CE Powermax125 power cord with strain relief 400 V CE J22 J21 J20 J19 J27 WORK LEAD J26 J25 _ _ RED J18 ORG J17 J32 J11 J28 TP7 TP9 TP8 W R B 1 2 3 4 ...

Page 312: ...r 4 428130 Kit Powermax125 transformer 600 V CSA 4 428128 Kit Powermax125 transformer 400 V CE 380 V CCC 5 228888 Kit Powermax105 bulk capacitor CSA 230 400 V CE Powermax125 bulk capacitor 600 V CSA 5 428136 Kit Powermax125 bulk capacitor 480 V CSA 5 428135 Kit Powermax125 bulk capacitor 400 V CE 380 V CCC 6 428127 Kit Powermax125 PFC inductor 480 V 600 V CSA 6 428126 Kit Powermax125 PFC inductor ...

Page 313: ... Powermax125 transformer 600 V CSA 428128 Kit Powermax125 transformer 400 V CE 380 V CCC 428136 Kit Powermax125 bulk capacitor 480 V CSA 428135 Kit Powermax125 bulk capacitor 400 V CE 380 V CCC 428127 Kit Powermax125 PFC inductor 480 V 600 V CSA 428126 Kit Powermax125 PFC inductor 400 V CE 380 V CCC 428125 Kit Powermax125 output inductor 228688 Kit Powermax65 85 105 125 pressure switch 228882 Kit ...

Page 314: ... Kit Duramax Hyamp 180 machine torch coupler 228720 Kit Duramax Hyamp MRT 180 machine torch cap sensor switch replacement 428149 Kit Duramax Hyamp 180 machine torch lead replacement 4 6 m 15 feet 428150 Kit Duramax Hyamp 180 machine torch lead replacement 7 6 m 25 feet 428151 Kit Duramax Hyamp 180 machine torch lead replacement 10 7 m 35 feet 428152 Kit Duramax Hyamp 180 machine torch lead replace...

Page 315: ...Powermax125 Service Manual 808070 315 Section 12 Wiring Diagrams This section contains the following diagrams Powermax generic timing chart Powermax125 schematic diagram ...

Page 316: ...conds User set current Transfer PA current Pilot arc current Transfer threshold 1 6 A Pilot arc Transfer Steady state Loss of start Inverter output on Transfer relay and LED on Idle Power off Post flow Power Aux switch closed Start LED on Pilot arc IGBT gated Gas control device LED on Power up Start ...

Page 317: ...Powermax125 Service Manual 808070 317 12 Wiring Diagrams Powermax125 schematic diagram 380V CCC 400V CE 480V CSA 600V CSA TO PILOT ARC IGBT Q13 ...

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