Hypertherm POWERMAX 800 Service Manual Download Page 7

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ABLE

ONTENTS

Service Manual

SECTION 5 PARTS LIST - CE ..................................................................................................... 5-1

SECTION 6 WIRING DIAGRAMS ................................................................................................ 6-1

APPENDIX A

AERATION MANIFOLD FOR CUTTING ALUMINUM ............................................

a-1

APPENDIX B

STANDARDS INDEX ...............................................................................................

a-2

ILLUSTRATIONS

Figure 2-1

Powermax800 Hand Plasma Cutting System ................................................................................ 2-2

Figure 2-2

Powermax800 Power Supply with Dimensions .............................................................................. 2-3

Figure 2-3

PAC121TS Torch with Dimensions ................................................................................................ 2-4

Figure 2-4

PAC121MS Torch with Dimensions ............................................................................................... 2-4

Figure 2-5

S Mark Label ................................................................................................................................. 2-5

Figure 3-1

Filter Assembly ............................................................................................................................... 3-2

Figure 3-2

Air Filter Removal ........................................................................................................................... 3-3

Figure 3-3

Inverter Links .................................................................................................................................. 3-4

Figure 3-4

Single-Phase, 240 or 208V Block Diagram .................................................................................... 3-5

Figure 3-5

Back Side of Power Board - Test Points ...................................................................................... 3-27

Figure 3-6

Control Board Test Points ............................................................................................................ 3-29

Figure 3-7

PAC121TS Torch Main Body Removal ........................................................................................ 3-32

Figure 3-8

PAC121TS Torch Switch Removal .............................................................................................. 3-33

Figure 3-9

PAC121MS Torch Assembly ........................................................................................................ 3-35

Figure 3-10 Quick Disconnect O-Ring Removal and Replacement ................................................................. 3-36
Figure 4-1

Powermax800 - Front ..................................................................................................................... 4-3

Figure 4-2

Powermax800 - Top and Right Side .............................................................................................. 4-5

Figure 4-3

Powermax800 - Bottom and Left Side ............................................................................................ 4-7

Figure 4-4

Powermax800 - Rear ..................................................................................................................... 4-9

Figure 4-5

PAC121TS Torch Assembly and Leads ....................................................................................... 4-10

Figure 4-6

PAC121MS Torch Assembly and Leads ...................................................................................... 4-11

Figure 4-7

Consumable Parts ........................................................................................................................ 4-12

Figure 5-1

Powermax800 CE - Front ............................................................................................................... 5-3

Figure 5-2

Powermax800 CE - Top and Right Side ........................................................................................ 5-5

Figure 5-3

Powermax800 CE - Bottom and Left Side ...................................................................................... 5-7

Figure 5-4

Powermax800 CE - Rear ............................................................................................................... 5-9

Figure 5-5

PAC121TS Torch Assembly and Leads ....................................................................................... 5-10

Figure 5-6

PAC121MS Torch Assembly and Leads ...................................................................................... 5-11

Figure 5-7

Consumable Parts - CE ................................................................................................................ 5-12

Figure a-1

Aeration Manifold ........................................................................................................................... a-1

9-96

Summary of Contents for POWERMAX 800

Page 1: ...EN50199 EN50192 Plasma Arc Cutting System Service Manual 802280 Revision 4 ...

Page 2: ...mpshire 03755 5010 Tel 603 643 3441 Fax 603 643 5352 Copyright 1997 Hypertherm Inc All Rights Reserved HYPERTHERM and POWERMAX are trademarks of Hypertherm Inc and may be registered in the United States and or other countries for systems beginning with serial number 800 010000 Revision 4 December 1997 ...

Page 3: ...anization ETSO Ohmstrasse 6 D 63477 Maintal Germany Tel 49 6181 94070 Fax 49 6181 940739 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm U K 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 Hypertherm France 10 Allée de I lsara F 95000 Cer...

Page 4: ...ake additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained betweentheconduitandthec...

Page 5: ...HERM not in strict conformity with HYPERTHERM s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by HYPERTHERM HYPERTHERM agrees to indemnify protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because of ...

Page 6: ... terre 1a 4 Rappels de sécurité 1a 4 Prothèses électroniques 1a 4 SECTION 2 DESCRIPTION SPECIFICATIONS 2 1 Introduction 2 2 Specifications 2 3 PAC121 50A Torches 2 4 IEC Symbols Used 2 6 SECTION 3 MAINTENANCE 3 1 Introduction 3 2 Routine Maintenance 3 2 Theory of Operation 3 4 Sequence of Operation 3 6 Troubleshooting 3 7 Power Board 3 26 Control Board 3 28 Torch Check 3 30 PAC121TS Torch Parts Re...

Page 7: ...PAC121MS Torch with Dimensions 2 4 Figure 2 5 S Mark Label 2 5 Figure 3 1 Filter Assembly 3 2 Figure 3 2 Air Filter Removal 3 3 Figure 3 3 Inverter Links 3 4 Figure 3 4 Single Phase 240 or 208V Block Diagram 3 5 Figure 3 5 Back Side of Power Board Test Points 3 27 Figure 3 6 Control Board Test Points 3 29 Figure 3 7 PAC121TS Torch Main Body Removal 3 32 Figure 3 8 PAC121TS Torch Switch Removal 3 3...

Page 8: ...body workpiece or the water in a water table when operating the plasma system When using a water table be sure that it is correctly connected to earth ground Operating the plasma system completes an electrical circuit between the torch and the workpiece and anything touching the workpiece The workpiece is part of the electrical circuit WARNING Instant On Torches Instant on torches produce a plasma...

Page 9: ...an air supplied helmet 01 97 Fire Prevention Make fire extinguishers available in the cutting area Remove all combustible materials from the immediate cutting area to a distance of at least 35 feet 10 m Quench freshly cut metal or allow metal to cool before handling it or bringing it into contact with combustible materials Never use a plasma system to cut containers with potentially flammable mate...

Page 10: ...amine hoses at regular intervals for leaks wear loose connections or other hazard Replace hose that is damaged in any way Electric Shock Prevention continued Before changing the torch parts disconnect the main power or unplug the power supply After changing torch parts and replacing the retaining cap plug in the power supply again Never bypass or shortcut the safety interlocks Before removing a po...

Page 11: ...ose as possible to work cable Do not wrap the torch lead or work cable around your body Stay as far away from the power supply as possible Hoses continued Keep hose lengths to a minimum to prevent damage reduce pressure drop and to prevent possible flow restrictions Prevent kinking by laying out hoses as straight as possible between termination points Coil any excess hose and place it out of the w...

Page 12: ...s suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais couper de...

Page 13: ...et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du coupage Laisser la pièce à couper en place ou sur la table de travail le câble de retour connecté lors du coupage Avant de vérifier de nettoyer ou de remplacer les pièces de la torche couper l alimentation ou débrancher la prise de courant Ne jamais contourner ou court circuiter l...

Page 14: ...er le câble de retour à la partie de la pièce qui doit se détacher Table de travail Raccorder la table de travail à la terre conformément aux codes de sécurité locaux ou nationaux appropriés MISE À LA MASSE ET À LA TERRE Alimentation S assurer que le fil de terre du cordon d alimentation est connecté à la terre dans le coffret du sectionneur S il est nécessaire de brancher le cordon d alimentation...

Page 15: ...à tout prix le contact électrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs Utiliser un casque de prote...

Page 16: ...2 1 Service Manual DESCRIPTION SPECIFICATIONS Section 2 DESCRIPTION SPECIFICATIONS 9 96 In this section INTRODUCTION 2 2 SPECIFICATIONS 2 3 PAC121 50A Torches 2 4 IEC SYMBOLS USED 2 6 ...

Page 17: ...il free When properly set and maintained the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality The Powermax800 can also cut with nitrogen when extended electrode life is a priority This service manual provides information for qualified service technicians to troubleshoot and repair the p...

Page 18: ...in an ambient temperature above 86 F 30 C may show some decrease in duty cycle Apparent Input Power S1 10 4kVA U1 I1 Input Voltage U1 Input Current I1 6 kw Output 208V 50A 240V 43A 480V 25A 1φ 60 Hz 208V 29A 240V 25A 480V 13A 3φ 60 Hz 200V 52A 230V 45A 400V 30A 1φ 50 60 Hz 200V 30A 230V 26A 400V 16A 3φ 50 60 Hz 400V CE 16A 3φ 50 60 Hz 600V 11A 3φ 60 Hz Dimensions and Weight Depth 23 1 590 mm Width...

Page 19: ...3 scfm at 90 psi 150 l min at 6 2 bar supplied to power supply pressure regulator Power Supply pressure regulator setting 70 psi 4 8 bar flowing PAC121 50A TORCHES Maximum 50A Cutting Capacity PAC121TS 3 4 20 mm 50 duty cycle Maximum 50A Cutting Capacity PAC121MS 3 8 10 mm 50 duty cycle Maximum 35A Cutting Capacity PAC121MS 1 4 6 mm 100 duty cycle Maximum current at 50 duty cycle 50 amps Gas Flow ...

Page 20: ...held applications See Figure 2 5 below and also Section 5 Consumable Parts For CE Compliance for a list of CE consumable parts This requirement does not apply to machine torch applications S MARK The Powermax800 conforms to standard EN50192 The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The torches must have shiel...

Page 21: ...tting torch AC input power connection The terminal for the external protective earth conductor An inverter based power source Anode work clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle Power is on Power is off Volt amp curve drooping characteristic 9 96 ...

Page 22: ... External 3 7 Visual Inspection Internal 3 8 Initial Resistance Checks 3 9 Corrective Maintenance Checks 3 17 Power Board 3 26 Control Board 3 28 Control Board LEDs 3 28 Control Board Test Points 3 29 Torch Check 3 30 Cap Sensor Circuit Check 3 30 Start Circuit Check 3 31 PAC121TS Torch Parts Removal and Replacement 3 32 Torch Main Body Removal and Replacement 3 32 Torch Switch Removal and Replace...

Page 23: ... bowl of the filter at the rear of the power supply drain the bowl and clean the filter element 1 Shut the gas supply off and disconnect the gas supply hose from the filter assembly before proceeding 2 Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl 3 Unscrew the filter bowl 4 Unscrew the filter element See Powermax800 Fi...

Page 24: ... disconnect switch to OFF position In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures Air Filter 4 Clean the air filter with either soap and water or with low pressure compressed air 5 Replace the dry filter in the power unit with the wire mesh facing the fan 6 Replace and re fasten...

Page 25: ...onsists of several components an isolated gate bipolar transistor IGBT Q1 or Q2 a coil of the power transformer T2 a current sense transformer CS1 or CS2 and sections of the power board The inverters operate as a pulse width modulator controlled half bridge circuit The inverters are capacitor fed and transformer coupled switching at 20 KHZ The inverter outputs are connected in series and are recti...

Page 26: ...ion Push and hold GAS TEST switch to check air pressure Gas solenoid valve V1 opens to purge system and to allow setting of pressure Select cutting current with AMPS knob Power circuits ready Connect work cable to workpiece and position torch on workpiece Depress plasma start switch on hand torch or remote start switch for machine torch Gas solenoid valve V1 opens and gas flows Pilot arc relay CR1...

Page 27: ... 800 643 9878 Test Equipment Multimeter Troubleshooting Procedures Maintenance of the Powermax800 power supply consists of performing visual inspection and trouble shooting procedures Refer to the system wiring diagram when performing the checkout procedures To locate power supply and torch components refer to Section 4 for 208 240 480V and 200 230 400V power supplies and Section 5 for 400V CE pow...

Page 28: ...artment at 1 800 643 9878 Visual Inspection Internal WARNING The aluminum heatsink on the power PC board is electrically live when the plasma is on In case of an electrical failure of the inverter circuit the heatsink may be live when the power is off SHOCK HAZARD The large electrolytic capacitors blue cased cylinders located on the power PC board store large amounts of energy in the form of elect...

Page 29: ... 1 Set the Powermax800 power switch to O off unplug the power cord and disconnect the gas supply see warnings 2 Remove the cover of the power supply by removing 22 securing screws 3 Visually inspect the inside of the power supply especially on the side with the power board see Figures 4 2 and 4 3 Look for broken or loose wiring connections burn and char marks damaged components etc Repair or repla...

Page 30: ...tral on the plug of the power cord This reading is the resistance across the control transformer primary for the selected input voltage Meter indicates 18 ohms 200V 20 ohms 208V 22 ohms 230V 22 ohms 240V 56 ohms 400V 65 ohms 480V To page 3 13 Check 2 Indicates low ohms or short Indicates high ohms or infinity Isolate and check control transformer T1 power switch S1 input filter MOV1 capacitor C1 a...

Page 31: ...dicates an open No Set power switch S1 to ON 1 Measure resistance between the conductors on the plug of the power cord Do not use the ground pin on the plug as a measuring point The reading between TB1 1 TB1 2 is the resistance across the control transformer primary for the selected input voltage Yes Between TB1 1 TB1 2 does meter indicate 18 ohms 200V 20 ohms 208V 22 ohms 230V 22 ohms 240V 56 ohm...

Page 32: ...T1 power switch S1 input filter MOV1 capacitors C1 C2 and C3 contactor CR1 and all associated wiring for shorts Repair problem and repeat check From page 3 11 L Indicates low ohms or short Indicates high ohms or infinity No To page 3 11 Three Phase Check 1 From page 3 11 R No No Yes To page 3 13 Check 2 No Yes Isolate and check control transformer T1 power switch S1 fuses F1 and F2 and associated ...

Page 33: ...output diodes D2 and D3 Meter indicates infinity or high Kohms To page 3 14 Check 3 Place lead of ohm meter to upper bar spanning output diodes D2 and D3 Place lead of ohm meter to lower bar spanning output diodes D2 and D3 Yes Meter indicates 1 7K ohms Yes Replace diodes D2 and D3 No Replace diodes D2 and D3 No Upper bar spanning D2 D3 Lower bar spanning D2 D3 Location of Bars Spanning D2 and D3 ...

Page 34: ... a measuring point Meter indicates an open To page 3 15 Check 4 There is an internal short in the power supply Visually and with a meter inspect the unit for pinched broken and loose wires and wires with damaged insulation contacting the chassis Also check for loose hardware such as screws nuts and bolts No Problem found and repaired Yes Continue checking out unit until problem is found Then repea...

Page 35: ...n To page 3 16 Check 5 There is an internal short in the power supply Visually and with a meter inspect the unit for pinched broken and loose wires and wires with damaged insulation contacting the chassis Also check for loose hardware such as screws nuts and bolts No Problem found and repaired Yes Continue checking out unit until problem is found Then repeat check No Yes ...

Page 36: ...g point Meter indicates an open End of resistance checks To page 3 17 There is an internal short in the power supply Visually and with a meter inspect the unit for pinched broken and loose wires and wires with damaged insulation contacting the chassis Also check for loose hardware such as screws nuts and bolts No Problem found and repaired Yes Continue checking out unit until problem is found Then...

Page 37: ...therm Techni cal Services department at 1 800 643 9878 WARNING The aluminum heatsink on the power PC board is electrically live when the plasma is on In case of an electrical failure of the inverter circuit the heatsink may be live when the power is off SHOCK HAZARD The large electrolytic capacitors blue cased cylinders located on the power PC board store large amounts of energy in the form of ele...

Page 38: ...upply 4 Perform the corrective maintenance checks starting on the following page 5 After the problem has been located and repaired refer to the Sequence of Operation in this section for the normal operation of the power supply from power up to cutting WARNING SHOCK HAZARD Do not attempt repairs on the power board or control board Do not in any way cut away or remove the protective conformal coatin...

Page 39: ...ection Check connectors wires W94 and W95 and solder joints Repair as needed See also Torch Check Cap Sensor Circuit later in this section Replace torch main body and switch LINE VOLTAGE LED lights briefly before shutdown Yes No Power supply linked for proper line voltage Correct voltage links See label in linkbox and Powermax800 Operator Manual IM227 Section 3 Note 400V CE power supplies have no ...

Page 40: ...ins 12 14 Replace M1 No Yes Check wiring between T1 and control board If wiring is OK replace T1 Measure input line voltage at power switch S1 Single phase units between P1 P2 Three phase units between P1 P2 P2 P3 and P1 P3 No Voltage correct Check main power coming into power supply No Measure input line voltage at control board connector JP2 pins 1 2 for 24VAC JP2 pins 6 7 for 27VAC JP2 pins 9 1...

Page 41: ...408V 600V 510V Correct supply voltage Yes Check to see if D27 is illuminated No D27 illuminated Replace control board No Check control board JP2 24VAC at pins 1 2 27VAC at pins 6 7 Voltages correct Replace control board Meter indicates 0 ohms Unplug power cord Measure resistances of fuses F1 F2 Replace F1 and or F2 Check connectors wires between fuses and T1 Repair as needed No Yes Yes No Yes No Y...

Page 42: ... power cord Reconnect wires W92 W93 to PS1 Disconnect JP8 from control PCB Measure resistance between JP8 sockets 7 8 Yes Yes Check inlet gas supply pressure to pressure regulator It should be a minimum of 90 psi 6 2 bar No Adjust inlet pressure for 90 psi 6 2bar No Check hose from supply to regulator pressure regulator filter element and pressure regulator Replace as required Yes No 0 ohms Replac...

Page 43: ...mperature Disconnect JP8 from control PCB Measure resistance between JP8 sockets 1 2 and 3 4 No 0 ohms 0 ohms Disconnect temperature switch TS2 wires W88 W99 at power transformer T2 Measure resistance across wires coming from transformer Replace temperature switch TS1 If TS1 opens again after replacement replace heat sink SA Yes Temperature switches are functioning Problem is either with transform...

Page 44: ...lenoid V1 pressure regulator If no problems are found replace control PCB 70 psi 4 8 bar dynamic No Yes Check regulator hoses for leaks Ensure GAS TEST switch S2 has been released Press torch start switch to fire pilot arc Yes Yes Check regulator hoses for leaks No No Yes 12V Relay CR2 closes when torch start switch is pressed 0 ohms See Torch Check Start Circuit later in this section Check JP4 so...

Page 45: ...o transfer arc to workpiece to see if cutting current is adjustable Yes Replace AMPS control pot P1 If new pot does not fix problem replace control board Check TP1 of control board for 12V No 12V Check that work clamp is making good metal to metal contact Work clamp OK No Repair or replace work cable and clamp No No Replace control board Yes Replace consumables If arc does not transfer after chang...

Page 46: ... capacitors If questions or problems arise during servicing call Hypertherm Technical Services at 1 800 643 9878 Use extreme caution when taking the voltage readings on the back of the power PCB see warning above Use an isolated or floating digital volt meter since high voltages are present The following table lists the test points their descriptions and values Refer also to Figure 3 5 to locate t...

Page 47: ...ower supply and PC boards are subjected to dielectric and insula tion resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty If questions or problems arise during servicing call the Hypertherm Technical Services department at 1 80...

Page 48: ...en plasma start is pressed D27 MAIN CONTACTOR Illuminates when contactor CR1 is energized following soft start D29 TEMP LED Remains off when temperature is within operating limits It Illuminates when the thermostat in the power transformer opens over 110 C 230 F or if the heatsink becomes too hot over 85 C 185 F Overheating can be caused by exceeding the duty cycle rate D35 GAS PRESSURE Illuminate...

Page 49: ...s are OK TP10 Continuous PA threshold voltage Set to 3 55V by P3 TP11 7 0V TP15 Error amplifier reference voltage During inverter operation this signal is 1 915V at 50A current setting and 75V at 20A current setting TP16 Error amplifier output voltage TP17 Reference voltage 2 50V TP18 Output current value signal 38 3mv amp TP19 Wiper voltage 2 5V at 50A current setting and 1 00V at 20A current set...

Page 50: ... a problem with the torch cap sensor circuit 1 Disconnect power and gas See warning above 2 Remove the power supply cover 3 Locate fuses F1 and F2 on the control board See Fig 3 6 4 Check to see if the fuses are open If the fuses are open replace the torch the torch leads and the control board fuse s See Section 4 Parts List or Section 5 Parts List CE to order new components If the fuses are OK th...

Page 51: ...control board fuse s See Section 4 Parts List or Section 5 Parts List CE to order new components If the fuses are OK the gas supply is OK pressing the torch switch closes the connection between JP8 sockets 5 6 and the torch does not start replace the control board If the fuses are OK the gas supply is OK pressing the torch switch does not close connection between JP8 sockets 5 6 and the torch does...

Page 52: ...ding the plunger nut with a 1 4 6mm wrench or nut driver and removing the plunger screw Fig 3 7 6 Disconnect the torch main body and torch lead gas fittings using 5 16 8mm and 7 16 11mm open end wrenches 7 Replace with the new torch main body by reversing these instructions Note When connecting the plunger wire be certain to keep the plunger wire terminal at the proper angle as shown in Fig 3 7 in...

Page 53: ...ether 3 Remove the torch switch from the handle 4 Remove the torch switch by cutting the two splices at the torch lead violet wires 5 Replace the torch switch by crimping the switch wires and the violet wires from the torch lead together with the splices 6 Install the torch switch back into handle Be certain that torch switch slides into position above safety trigger and that trigger movement acti...

Page 54: ... Remove the screw securing the red wires from the torch lead to the torch main body Note for steps 7 and 8 Disconnect wires by pulling on terminals Do not pull on wires 7 Disconnect the two lead terminals four white wires in each terminal from the two black plunger wire terminals of the torch main body 8 Disconnect the two lead terminals blue wire in each terminal from the two white wires of the c...

Page 55: ...can be easily damaged Lightly coat with silicone 8 Screw the torch position sleeve and the torch sleeve together 9 When the nozzle electrode and swirl ring are properly in place replace the retaining cap with shield When the retaining cap is tightened the microswitch will click indicating that the torch main body has been replaced correctly 10 Align the connector plug key on torch lead with the co...

Page 56: ...r wear proceed as follows and refer to Figure 3 10 1 Turn the Powermax800 power switch OFF 0 2 Unplug the power cable or set line disconnect switch to off and disconnect gas supply 3 Unscrew and remove the torch lead quick disconnect plug from the receptacle on the power supply 4 Remove the O ring from the quick disconnect as shown in Figure 3 10 using needle nose pliers tweezers etc 5 Replace O r...

Page 57: ... 6 Rear 4 8 PAC121TS Torch Assembly 4 10 PAC121MS Torch Assembly 4 11 Consumable Parts 4 12 Powermax800 Field Upgrade Kits and Optional Parts 4 13 Power Supplies 208 240 480V 4 13 Power Supplies 200 230 400V 4 13 Recommended Spare Parts Powermax800 208 240 480V 4 14 Recommended Spare Parts Powermax800 200 230 400V 4 14 Section 4 PARTS LIST 6 96 ...

Page 58: ... Female Elbow 1 8NPTX1 4Push in tube 1 13 015283 Male Elbow 1 8NPX1 4Push in tube 1 14 015285 Male Conn 1 8NPTX1 4Push in tube 3 15 015517 Nip 1 8 X CL Hex Brass 1 16 015540 Tee 1 8 Brass 1 17 015588 Nip 1 8 X 2 L Brass 1 18 022027 Press Gauge 160 1 5 1 8CBM Panel 1 19 046077 Tubing 1 4 OD 04W Blue Nylon 2 3 ft 029956 Harness PMX800 Power Unit 1 20 009480 Pot 250 Ohm 1W 10 1T Cerm P1 1 21 029962 R...

Page 59: ...4 3 PARTS LIST Service Manual Figure 4 1 Powermax800 Front 1 2 3 4 5 8 9 10 6 12 13 14 14 15 16 17 18 19 19 21 22 24 23 11 7 19 25 20 7 97 POWER SUPPLY 208 240 480V 200 230 400V 4A ...

Page 60: ... fuse 4 17 041517 PCB Assy Pwrmx800 Control 200 230 400V 1 008989 Fuse 500ma 250V IEC 127 3 Fast F1 F4 pcb fuse 4 18 041532 PCB Assy Powermax800 ZB Power 1 19 014137 Current Sense Transformer 40A CS1 1 20 014137 Current Sense Transformer 40A CS2 1 21 008301 Fuse Holder 2P 30A 13 32 X 1 1 2 1 22 008809 Fuse 1A 600V 13 32 X 1 1 2 Slo F1 F2 2 22 008958 Fuse 1A 500V 10mmX38mm Slo F1 F2 2 029978 Heatsi...

Page 61: ...4 5 PARTS LIST Service Manual Figure 4 2 Powermax800 Top and Right Side POWER SUPPLY 208 240 480V 200 230 400V 9 96 1 2 3 4 6 7 8 10A 9 11 13 12 5 14 15 16 17 18 19 20 21 22 23 24 25 26 27 10 ...

Page 62: ...atsink SA Powermax800 Power Unit 1 8 004721 Heatsink Powermax800 Power Unit 1 9 041532 PCB Assy Powermax800 ZB Power 1 029978 Heatsink SA Pwrmx800 PA Cont PCB Q3 10 004673 Heatsink Powermax800 PA Cont 11 028908 Kit Powermax800 Cooling Fan Filter Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power suppl...

Page 63: ...4 7 PARTS LIST Service Manual Figure 4 3 Powermax800 Bottom and Left Side 1 3 2 4 9 10 6 11 5 7 8 9 96 POWER SUPPLY 208 240 480V 200 230 400V ...

Page 64: ...wermax800 200 230 400V 11 001500 Box Powermax800 Pwr Cord 1 12 008900 Terminal Board 4 Terminal with protector TB3 1 13 008926 Terminal Board 4 Terminal with protector TB2 1 14 008933 Terminal Board 3 Terminal with protector TB1 1 15 008279 Strain Relief PG9 5X 187 312 Nylon 16 123099 Cable Powermax800 Machine Interface 008201 Receptacle Shell 17 14 Reverse Sex 008186 Socket 24 20 AWG Type III Not...

Page 65: ...4 9 PARTS LIST Service Manual Figure 4 4 Powermax800 Rear 1 2 3 4 6 5 7 10 8 11 12 13 14 POWER SUPPLY 208 240 480V 200 230 400V 9 96 200 230 400V Three phase power cord not shown in Figure 4 4 15 9 16 ...

Page 66: ...d 120283 Shield PAC121 50A 120301 Cap Retaining 120556 Torch Main Body w Switch PAC121T 044016 O Ring BUNA 90Duro 614X 070 129001 Torch Lead 25 ft 7 6 m 129002 Torch Lead 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown Used only in 083003 Used only in 083004 Note See page 4 12 for detail of consumable parts Figure 4 5 PAC121TS Torch Assembly and Leads Handle 001288 Screw 5 075340 Gutcha Ring...

Page 67: ...o pigtail PAC121MS Torch Assembly and 35 ft 10 6 m Lead 083044 w pigtail 083057 no pigtail PAC121MS Torch Assembly and 50 ft 15 2 m Lead 083012 w pigtail 083058 no pigtail Part Number Description 020351 Electrode 020361 Ring Swirl 020559 Sleeve Machine Torch PAC121M 020620 Sleeve Torch Position PAC121M 028923 Torch Lead w pigtail 14 ft 4 3 m 028918 Torch Lead w pigtail 25 ft 7 6 m 028926 Torch Lea...

Page 68: ...A Shielded 3 120281 Nozzle 50A Gouging 1 120305 Nozzle Pipe Saddle Extended 1 120601 Shield T torch 1 120608 Shield Gouging 1 120303 Deflector 1 044016 O Ring 3 015152 Nipple 1 8 NPT QDisc Steel 1 015570 Bushing Reducer 1 4 X 1 8 Brass 1 015604 Reducer 1 4 FPT X 1 8 NPT Brass 1 027055 Lubricant Silicone 1 4 Oz Tube 1 Mach Consumable Spare Parts Kit 128030 Part Number Description Qty 001285 Box Con...

Page 69: ...o Used on 208 240 480V power supplies 008958 Fuse 1A 500V 10mm X 38mm Slo Used on 200 230 400V and 400V CE power supplies 023206 Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits POWER SUPPLIES 208 240 480V 1φ 3φ 60 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 083002 Hand No No 083015 Hand Yes ...

Page 70: ...32 PCB Assy Powermax800 ZB Power 4 5 4 7 129114 Cord Plug 42 1Phase 8 3SO 3Prong 7 3 4 9 029674 MOV Cap Assy MAX42 43 70 3PH 4 5 028908 Kit Powermax800 Cooling Fan Filter 4 7 RECOMMENDED SPARE PARTS POWERMAX800 200 230 400V Part Number Description Page Reference 003078 Relay 30A NO Mag Blwt QDisc Term 4 5 129068 Circuit Breaker SA 4Pole 480V W TC 4 9 129151 Contactor SA Powermax800 4 9 008958 Fuse...

Page 71: ... Right Side 5 4 Bottom and Left Side 5 6 Rear 5 8 PAC121TS Torch Assembly 5 10 PAC121MS Torch Assembly 5 11 Consumable Parts CE 5 12 Powermax800 Field Upgrade Kits and Optional Parts 5 13 Power Supplies 400V CE 5 13 Recommended Spare Parts Powermax800 400V CE 5 14 Section 5 PARTS LIST CE 6 96 ...

Page 72: ...male Elbow 1 8NPTX1 4Push in tube 1 13 015283 Male Elbow 1 8NPX1 4Push in tube 1 14 015285 Male Conn 1 8NPTX1 4Push in tube 3 15 015517 Nip 1 8 X CL Hex Brass 1 16 015540 Tee 1 8 Brass 1 17 015588 Nip 1 8 X 2 L Brass 1 18 022027 Press Gauge 160 1 5 1 8CBM Panel 1 19 046077 Tubing 1 4 OD 04W Blue Nylon 2 3 ft 029956 Harness PMX800 Power Unit 1 20 009480 Pot 250 Ohm 1W 10 1T Cerm P1 1 21 029962 Rece...

Page 73: ...5 3 PARTS LIST CE Service Manual Figure 5 1 Powermax800 CE Front 1 2 3 4 5 8 9 10 6 12 13 14 14 15 16 17 18 19 19 21 22 24 23 11 7 19 25 20 7 97 POWER SUPPLY 400V CE 4A ...

Page 74: ...y Powermax800 Control 1 008989 Fuse 500ma 250V IEC 127 3 Fast F1 F4 pcb fuse 4 17 041532 PCB Assy Powermax800 ZB Power 1 18 014137 Current Sense Transformer 40A CS1 1 19 014137 Current Sense Transformer 40A CS2 1 20 008301 Fuse Holder 2P 30A 13 32 X 1 1 2 1 21 008752 Fuse Block 3P 30A 600V 13 32X1 1 2 1 22 008958 Fuse 1A 500V 10mmX38mm Slo F1 F2 2 23 008959 Fuse 20A 500V 10mmX38mm Slo 3 029978 Hea...

Page 75: ...5 5 PARTS LIST CE Service Manual Figure 5 2 Powermax800 CE Top and Right Side 27 28 12 POWER SUPPLY 400V CE 2 3 1 5 6 4 7 8 9A 10 13 14 15 16 17 18 20 21 22 23 11 24 25 26 19 9 9 96 ...

Page 76: ...ermax800 Power Unit 1 9 041532 PCB Assy Powermax800 ZB Power 1 029978 Heatsink SA Pwrmx800 PA Cont PCB Q3 10 004673 Heatsink Powermax800 PA Cont 11 028908 Kit Powermax800 Cooling Fan Filter 12 129100 Capacitor SA Powermax800 CE 1 Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown...

Page 77: ...5 7 PARTS LIST CE Service Manual Figure 5 3 Powermax800 CE Bottom and Left Side 1 3 2 4 9 11 7 8 9 96 POWER SUPPLY 400V CE 10 12 6 5 ...

Page 78: ...500 1 10 047180 Cord 2 5mm PVC HD21 22 7 3 1 129049 Electric Line Filter SA Powermax800 CE 1 11 041505 PCB Assy Powermax800 CE Line Filter 1 12 004692 Bracket Powermax800 CE EMI 1 13 008949 Terminal Board 3 Term 1 14 008279 Strain Relief PG9 5X 187 312 Nylon 15 123099 Cable Powermax800 Machine Interface 008201 Receptacle Shell 17 14 Reverse Sex 008186 Socket 24 20 AWG Type III Notes Bold part numb...

Page 79: ...5 9 PARTS LIST CE Service Manual Figure 5 4 Powermax800 CE Rear POWER SUPPLY 400V CE 1 2 4 3 6 5 7 9 10 11 13 12 9 96 8 14 15 ...

Page 80: ...eld 120283 Shield PAC121 50A 120301 Cap Retaining 120556 Torch Main Body w Switch PAC121T 044016 O Ring BUNA 90Duro 614X 070 129001 Torch Lead 25 ft 7 6 m 129002 Torch Lead 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown Used only in 083003 Used only in 083004 Note See page 5 12 for detail of consumable parts Figure 5 5 PAC121TS Torch Assembly and Leads Handle 001288 Screw 5 075340 Handle 00...

Page 81: ...no pigtail PAC121MS Torch Assembly and 35 ft 10 6 m Lead 083044 w pigtail 083057 no pigtail PAC121MS Torch Assembly and 50 ft 15 2 m Lead 083012 w pigtail 083058 no pigtail Part Number Description 020351 Electrode 020361 Ring Swirl 020559 Sleeve Machine Torch PAC121M 020620 Sleeve Torch Position PAC121M 028923 Torch Lead w pigtail 14 ft 4 3 m 028918 Torch Lead w pigtail 25 ft 7 6 m 028926 Torch Le...

Page 82: ...art Number Description Quantity 001285 Box Consumable Parts 1 120573 Electrode 3 020361 Swirl Ring 1 120282 Nozzle 50A Shielded 3 120281 Nozzle 50A Gouging 1 120601 Shield T torch 1 120602 Shield M torch 1 120608 Shield Gouging 1 044016 O Ring 3 015152 Nipple 1 8 NPT QDisc Steel 1 015570 Bushing Reducer 1 4 X 1 8 Brass 1 015604 Reducer 1 4 FPT X 1 8 NPT Brass 1 027055 Lubricant Silicone 1 4 Oz Tub...

Page 83: ... Powermax800 011079 Gas Filter Element 129019 Jumper Powermax800 Link Box 008958 Fuse 1A 500V 10mm X 38mm Slo Used on 200 230 400V and 400V CE power supplies 023206 Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits POWER SUPPLIES 400V CE 3φ 50 HZ Part For With Pilot Arc With Machine Number Torch Type Control Interface 083018...

Page 84: ...0 125 Psig 1 8FPT 5 3 022027 Press Gauge 160 1 5 1 8CBM Panel 5 3 129046 Heatsink SA Powermax800 CE Power Unit 5 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 5 5 109043 008947 Diode 1600V 30A 3PH Bridge Thermal Pad AL 315 114 5 5 005178 Temp Switch Opens 85 Closes 75 C 5 5 009849 008903 Resistor 20 Ohm 50W 5 NON IND 4 Thermal Pad AL 197 114 4 5 5 009850 008902 Res...

Page 85: ...08 240 480V 6 2 Powermax800 Electrical Schematic 200 230 400V 6 3 Powermax800 Electrical Schematic 400V CE 6 4 Powermax800 Troubleshooting Schematic 1 of 2 6 5 Powermax800 Troubleshooting Schematic 2 of 2 6 6 Powermax800 CE Troubleshooting Schematic 1 of 2 6 7 Powermax800 CE Troubleshooting Schematic 2 of 2 6 8 ...

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Page 93: ...voiding free hydrogen buildup is to install an aeration manifold on the floor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Figure c 1 Make an Aeration Manifold with two inch 50 mm PVC tubing with one inch 25 mm Distribution Lines connected to it Drill 1 8 inch 3 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distributio...

Page 94: ...51 Oxygen Fuel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code obtainable from the National Fire Protection Associa tion 470 Atlantic Avenue Boston MA 02210 10 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 470 A...

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