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MAINTENANCE AND PARTS

powermax

1000

Operator Manual

5-11

Torch parts

083172

T60 Hand Torch Assembly, 25'

083171

T60 Hand Torch Assembly, 50'

083175

T60M Machine Torch Assembly, 15'

083174

T60M Machine Torch Assembly, 25'

083176

T60M Machine Torch Assembly, 35'

083177

T60M Machine Torch Assembly, 50'

027055

Silicon Lubricant, 1/4 Oz. Tube

015337

NIP: 1/4 NPT Qdisc STL (Non-CE)

015145

Adapter: 1/4 NPT x G1/4 BSPP RH BRS (CE)

058519

Torch O-Ring

128644

T60 Hand Torch Handle Replacement Kit (5 Screws included)

075586

T60 Hand Torch Handle Screw (5 Required)

220061

Shield Cap: T60M/T80M Ohmic Contact

Power Supply Parts

083178

Powermax 1000 Hand System, 200-600V, 1/3PH, 50/60Hz, CSA, Auto-
Voltage/Phase (Not CE Compliant), 25 Ft. Torch & Lead Assembly

083179

Powermax 1000 Hand System, 200-600V, 1/3PH, 50/60Hz, CSA, Auto-
Voltage/Phase (Not CE Compliant), 50 Ft. Torch & Lead Assembly

083182

Powermax 1000 Machine System, 200-600V, 1/3PH, 50/60Hz, CSA, Auto-
Voltage/Phase (Not CE Compliant), 25 Ft. Torch & Lead Assembly

083183

Powermax 1000 Machine System, 200-600V, 1/3PH, 50/60Hz, CSA, Auto-
Voltage/Phase (Not CE Compliant), 50 Ft. Torch & Lead Assembly

083192

Powermax 1000 Hand System, 230-400V, 3PH, 50/60Hz, CE, Auto-Voltage,
25 Ft. Torch & Lead Assembly

083193

Powermax 1000 Hand System, 230-400V, 3PH, 50/60Hz, CE, Auto-Voltage,
50 Ft. Torch & Lead Assembly

083194

Powermax 1000 Machine System, 230-400V, 3PH, 50/60Hz, CE, Auto-
Voltage, 25 Ft. Torch & Lead Assembly

083195

Powermax 1000 Machine System, 230-400V, 3PH, 50/60Hz, CE, Auto-
Voltage, 50 Ft. Torch & Lead Assembly

110394

Cover Assembly, Non-CE (12 Screws Included)

110395

Cover Assembly, CE (12 Screws included)

075533

Cover Screws (Individual Cover Screw)

128627

Filter Bowl w/ Fittings

129654

ETR Door Assembly

129405

Consumable Box

123645

Ground Clamp w/ Cable & Strain relief

129652

Power Cable, Standard 3PH

129726

Power Cable, CE, 3PH

Summary of Contents for powermax1000

Page 1: ... 120925 120978 120927 120928 120928 120929 120977 110378 Rev A 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ 15 50ft 4 5 15m 15 25ft 4 5 7 5m 35 50ft 12 15m 6 0 BAR 5 0 4 0 PSI 80 70 50 60 80 AMPS 80 AMPS Plasma Arc Cutting System Operator Manual 804290 Revision 0 powermax1000 ...

Page 2: ...mber 2001 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2001 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 powermax1000 ...

Page 3: ...90 Fax 65 6 841 2489 Technical Service Japan 1952 14 Yata Natsumegi Mishima City Shizuoka Pref 411 0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax Hypertherm UK Ltd 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax France 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S r l Via Torino 2 20123 M...

Page 4: ...ld be given to shielding the supply cable of per manently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous through out its length The shielding should be con nected to the cutting mains supply so that good electrical contact is maintained be tween the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting...

Page 5: ...herm PATENT INDEMNITY Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against...

Page 6: ...révention des incendies Prévention des explosions 1a 2 Risque d explosion argon hydrogène et méthane 1a 2 Détonation de l hydrogène lors du coupage de l aluminium 1a 2 Les chocs électriques peuvent être fatals 1a 3 Prévention des chocs électriques 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Torches à allumage instantané 1a ...

Page 7: ... Alignment 3 10 ON OFF Pendant Connection 3 11 Machine Interface Connection 3 11 Arc Voltage 3 12 Changing XFER start machine motion from dry contact closure to voltage signal 3 14 Section 4 Operation Controls and Indicators 4 2 Indicator LEDs 4 2 Torch Consumable Configurations 4 3 Installing Torch Consumables 4 4 Mode Switch 4 5 Turn Power ON 4 5 Check Indicator Lights 4 5 Adjust Gas Pressure an...

Page 8: ...00 Operator Manual v Controls and Indicators 5 4 Basic Troubleshooting 5 5 System Circuit Diagram 5 8 Technical Questions 5 9 Parts 5 10 Torch Consumable Configurations 5 10 Torch Parts 5 11 Power Supply Parts 5 11 Accessories 5 12 ...

Page 9: ...TABLE OF CONTENTS 0 vi powermax1000 Operator Manual ...

Page 10: ...n Kill 1 3 Cutting Can Produce Toxic Fumes 1 3 A Plasma Arc Can Cause Injury and Burns 1 4 Arc Rays Can Burn Eyes and Skin 1 4 Grounding Safety 1 4 Compressed Gas Equipment Safety 1 5 Gas Cylinders Can Explode If Damaged 1 5 Noise Can Damage Hearing 1 5 Pacemaker and Hearing Aid Operation 1 5 A Plasma Arc Can Damage Frozen Pipes 1 5 Additional Safety Information 1 5 Warning Label 1 6 ...

Page 11: ...e the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres bef...

Page 12: ...le you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the mai...

Page 13: ...ly Tighten all electrical connections to avoid excessive heating Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields and a welding helmet with appropriate lens shading to protect your eyes...

Page 14: ...g of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 5 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 6 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington ...

Page 15: ... path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced ve...

Page 16: ...vention des chocs électriques 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Torches à allumage instantané 1a 4 Les rayons de l arc peuvent brûler les yeux et la peau 1a 4 Protection des yeux Protection de la peau Zone de coupage 1a 4 Mise à la masse et à la terre 1a 4 Câble de retour Table de travail Alimentation 1a 4 Sécurit...

Page 17: ...ne sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais...

Page 18: ...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 les verrouillages de sécurité Avant d enlever le capot du système ou de la source de courant couper l alimentati...

Page 19: ... de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent brûler les yeux et la peau Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d écrans latéraux et encore masque de soudure avec des verres teintés appropriés pour protéger les yeux des rayons u...

Page 20: ...e jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs Utiliser un casque de protection homologué lors de l utilisation du système plasma Prévenir les pe...

Page 21: ...t être fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4 2 U...

Page 22: ...000 Operator Manual 2 1 Section 2 SPECIFICATIONS In this section Specifications Power Supply 2 2 Power Supply Dimensions and Weight 2 3 Specifications T60 Torches 2 4 Torch Dimensions 2 5 Symbols and Markings 2 6 ...

Page 23: ...0 19 I1eff I1 X used to determine 230 240 VAC 3PH 26 18 rating of power cord 380 415 VAC 3PH 15 10 5 480 VAC 3PH 12 8 5 600 VAC 3PH 11 8 Power Factor U1 Volts AC rms Harmonic Power Factor Displacement Power Factor 200 208 VAC 1PH 0 99 0 99 230 240 VAC 1PH 0 99 0 99 480 VAC 1PH 0 91 0 99 200 208 VAC 3PH 0 94 0 99 230 240 VAC 3PH 0 94 0 99 380 415 VAC 3PH 0 94 0 99 480 VAC 3PH 0 94 0 99 600 VAC 3PH ...

Page 24: ... powermax1000 Operator Manual 2 3 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ Power Supply Dimensions and Weight Weight of power supply without torch 76 lb 34 5 kg 23 1 in 586 mm 10 5 in 267 mm 19 5 in 495 mm ...

Page 25: ...inch 32 mm Gouging Capability 10 0 pounds 4 5 kg hour metal removal rate on mild steel Weight T60 6 9 pounds 3 1 kg with 25 ft 7 5 m lead 13 6 pounds 6 2 kg with 50 ft 15 m lead 4 5 pounds 2 0 kg with 15 ft 4 5 m lead T60M 8 3 pounds 3 8 kg with 25 ft 7 5 m lead 9 9 pounds 4 5 kg with 35 ft 10 7 m lead 15 0 pounds 6 8 kg with 50 ft 15 m lead Specifications T60 Torches ...

Page 26: ... Operator Manual 2 5 T60 Hand Torch Dimensions 8 9 226 mm 3 9 99 mm 1 5 38 mm 1 00 25 mm T60M T80M Machine Torch Dimensions 15 06 383 mm 1 00 25 mm 1 38 35 mm 1 13 29mm 8 203 mm 32 pitch 125 3 2 mm width 2 25 57 mm Torch Dimensions ...

Page 27: ...o maintain S mark compliance IEC Symbols Used The following symbols may appear on the power supply data plate control labels and switches O l Direct Current DC The terminal for the external protective earth conductor AC input power connection Plasma torch cutting and gouging Alternating current AC An inverter based power source Volt amp curve drooping characteristic Power is off Power is on Plasma...

Page 28: ...tallation 3 4 Single Phase Power Cord 3 5 Power Cord Installation 3 5 Plug Installation 3 5 Grounding 3 6 Extension Cords 3 6 Torch Installation 3 7 Plasma Gas Supply 3 9 Additional Gas Filtration 3 9 Gas Supply Installation 3 10 T60M Torch Alignment 3 10 ON OFF Pendant Connection 3 11 Machine Interface Connection 3 11 Arc Voltage 3 12 Changing XFER start machine motion from dry contact closure to...

Page 29: ... will furnish you with a copy of the bill of lading upon request If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor OEM If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Co...

Page 30: ...m weighs up to 83 lb 38 kg Always lift the power supply by TWO handles Do not lift the power supply by ONE handle The handle can break resulting in injury and damage Hoist Cover in place Approved hoisting strap Keep as vertical as possible Lifting Power Supply ...

Page 31: ...3PH for CE model Use a line disconnect switch for each power supply so that the operator can turn off the power supply quickly in an emergency Locate the switch so it is easily accessi ble to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses rated per local and national electrical codes Three Phase Power Cord Plug Insta...

Page 32: ...0mm2 3 wire power cord The power cord must be connected by a licensed electrician Single Phase Power Cord not for CE model Power Cord Installation Strip and prepare the power cord wires as shown below Plug Installation The plug must be connected to the power cord by a licensed electrician L1 10 Ground L2 4 102 mm 7 178 mm Route lead through strain relief and tighten Power Switch Ground L1 L2 ...

Page 33: ...requirements Refer to Grounding in the Safety section Extension Cords Use a cord that is certified by national or local codes The cord should be installed by a licensed electrician Refer to the length requirements listed below Recommended Extension Cord Gauge Size AWG mm2 10 ft 10 25 ft 25 50 ft 50 100 ft 100 150 ft 3 m 3 7 5 m 7 5 15 m 15 30 m 30 45 m Standard Model Input Voltage Phase AWG mm2 AW...

Page 34: ...SETUP 0 powermax1000 Operator Manual 3 7 Torch Installation Turn OFF power Remove power cord from power receptacle Open ETR door and route lead through the end cap OFF ON ETR Door End Cap ...

Page 35: ...uick Release collar and insert the lead s gas fitting Slide Quick Release collar foward to lock in the gas fitting Make sure that the gas fitting is secure Make sure that the red dot on the connector is on top then plug in the electrical connector Close ETR door Quick Release Collar ...

Page 36: ...as supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and parts life shortens Gas supply Powermax1000 Water particle filter Oil filter Oil vapor filter Additional Gas Filtration Use Hypertherm filter kit part 128647 when site conditions introduce moisture oil or other particulates into the air line A 3 stage coalescing filtration system as sh...

Page 37: ...ovides G1 4 adapter in CE kit Use liquid pipe sealant on threads Nipple Adapter is found in the consumables box located on the left side of the power supply cover 2 Air hose Use an inert gas hose with a 3 8 inch 9 5 mm internal diameter Connect it to the gas fitting installed in step 1 Adjust the air pressure according to the procedure in Operation section Torch CAUTION Never use Teflon tape when ...

Page 38: ...mally open 18VDC open circuit Normally open Dry contact closure when voltage at START terminals arc transfers 120VAC 1A maximum at Requires dry contact closure to activate machine interface relay or switching device supplied by customer Rear panel 3 4 12 14 sockets Cable wires Green Black Red Black of 023206 ON OFF Pendant Connection Inputs for arc start with machine torch T60M are available throu...

Page 39: ...llowing applicable national or local codes WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All work requiring removal of the power supply cover must be performed by a qualified technician 1 Disconnect power from the power supply 2 Remove screws that attach the power supply cover to the chassis Remove the cover 3 Feed the cable through the strain relief...

Page 40: ... 4 faston terminal ends to connect to J15 J16 Note 120VAC or 24 VAC must be sourced externally Signal Arc Voltage torch height control Type Output Notes Full arc voltage No voltage divider 300VDC maximum Signal not available on rear panel connector J15 VDC J16 VDC 5 Tighten strain relief 6 Replace cover ...

Page 41: ... VDC relay coil 240 ohms or greater or a Typical Industrial Input Isolation Module which has an opto coupler built in Shown below are typical connections for a high side drive arrangement Driving a Relay Coil Notes 1 24 VDC Relay Recoil 240 ohms 2 Must use suppression diode 1A 100V such as IN4002 through IN4004 type across coil Move Black wire and add Jumper as shown GND 24VDC BLK YEL RED WHT J19 ...

Page 42: ...rmax1000 Operator Manual 3 15 Driving an Industrial Isolated Input Module Move Black wire and add Jumper as shown GND 24VDC BLK YEL RED WHT J19 START SIGNAL BLK SHIELD ISOLATED INPUT MODULE XFER ST ART 4 3 14 12 13 ...

Page 43: ...SETUP 0 3 16 powermax1000 Operator Manual ...

Page 44: ...s 4 3 Installing Torch Consumables 4 4 Mode Switch 4 5 Turn Power ON 4 5 Check Indicator Lights 4 5 Adjust Gas Pressure and Current Setting 4 6 Hand Torch Operation 4 7 Safety Trigger Operation 4 7 Attach the Work Clamp 4 8 Starting a Cut from the Edge of the Workpiece 4 8 Hand Torch Cutting Technique 4 9 Piercing 4 10 Gouging 4 11 Cut Charts 4 12 ...

Page 45: ... 2 8 bar for gouging Green When illuminated indicates acceptable gas pressure for torch operation Yellow Torch Cap LED When illuminated indicates that the Retaining Cap is loose or not installed NOTE Condition must be corrected and power turned OFF then ON to clear LED Yellow Temp LED When illuminated indicates that the power supply temperature has exceeded its operating limit Red Fault LED When i...

Page 46: ...0928 120929 120931 120928 Mechanized Shielded 120930 120932 120928 120930 120931 120928 120979 220007 120928 Unshielded 120979 220006 120928 Gouging 120977 220059 120928 40A 60A 40A 60A 40A 60A 60A In CE countries unshielded consumables may only be used in mechanized torch applications 120925 120926 O Ring 058519 O Ring 058519 ...

Page 47: ...USE INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn through gloves and skin Make sure power is OFF before changing consumables Installing Torch Consumables Hand tighten only Retaining Cap Nozzle Electrode Swirl Ring Shield ...

Page 48: ...mum consumable life Use to gouge or for non transfered arc operation Turn ON Power Position the power switch to ON 1 as shown Check that the POWER ON lamp is illuminated Check Indicator Lights AC V Check that the remaining indicator lamps are NOT illuminated See Maintenance Section for details Check that the Gas Pressure LED is illuminated in Green ...

Page 49: ...PS 30 40 50 Set current knob to gas test Pull regulator knob to unlock 6 0 BAR 5 0 4 0 PSI 80 70 50 60 20 60 AMPS 30 40 50 Set pressure Cutting 70 75 psig 4 8 5 2 bar Gouging 50 60 psig 3 4 4 1 bar Push regulator knob to lock Turn current knob away from gas test to stop gas flow 20 amps minimum ...

Page 50: ... CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch switch is activated The plasma arc will quickly burn through gloves and skin Keep 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 Never use with Pendant Switch ...

Page 51: ...lamp to the portion that will fall away Starting a Cut from the Edge of the Workpiece Hold the torch nozzle vertical at the edge of the workpiece Start cutting from the edge of the workpiece Pause at the edge until the arc has completely cut through the workpiece Then proceed with the cut Attach the Work Clamp WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an a...

Page 52: ...le at a vertical position and watch the arc as it cuts along the line Shielded Consumables Do not push down on the torch when cutting Lightly drag the torch across the workpiece to maintain a steady cut Pulling the torch through the cut is easier than pushing it To cut thin material reduce the amps until you get the best quality cut For straight line cuts use a straight edge as a guide To cut circ...

Page 53: ... Point the torch away from yourself and others Piercing Hold the torch so that the nozzle is within 1 8 inch 3 mm from the workpiece before firing the torch Fire the torch at an angle to the workpiece then slowly rotate it to an upright position When sparks are exiting from the bottom of the workpiece the arc has pierced through the material When the pierce is complete proceed with the cut ...

Page 54: ...nd others Gouging Hold the torch so that the nozzle is within 1 16 inch 1 5 mm from the workpiece before firing the torch Hold the torch at a 45 degree angle to the work piece Pull the trigger to obtain a pilot arc Transfer the arc to the work piece Maintain a 45 angle approximately from the workpiece Feed into the gouge NOTE A heat shield is available for added hand and torch protection Part No 2...

Page 55: ...3 4 19 0 18 457 12 297 Aluminum Inches mm IPM mm min IPM mm min 135 0 1 16 1 6 666 16916 433 10995 138 1 8 3 2 400 10160 260 6604 141 1 4 6 4 145 3683 94 2388 146 0 75 3 8 9 5 74 1880 48 1219 149 1 2 12 7 51 1295 30 762 153 5 8 15 9 33 838 21 545 Optimum Travel Speeds Arc Voltage Material Thickness Arc Current Maximum Travel Speeds Arc Voltage Pierce Delay Material Thickness Maximum Travel Speeds ...

Page 56: ...149 0 75 3 16 4 7 67 1702 44 1118 149 1 00 1 4 6 4 47 1194 31 787 Aluminum Inches mm IPM mm min IPM mm min 150 1 32 0 8 610 15494 397 10084 152 1 16 1 5 268 6807 174 4420 146 0 25 3 32 2 4 293 7442 190 4826 149 0 50 1 8 3 2 204 5182 133 3378 151 1 00 1 4 6 4 76 1930 49 1245 25 40 0 Optimum Travel Speeds Optimum Travel Speeds Arc Current Maximum Travel Speeds Arc Current Arc Voltage Pierce Delay Ma...

Page 57: ...minum Inches mm IPM mm min IPM mm min 125 1 32 0 8 564 14326 366 9296 127 1 16 1 5 236 5994 153 3886 40 127 0 25 3 32 2 4 261 6629 170 4318 Arc Current Material Thickness 25 25 Arc Voltage Pierce Delay 0 Arc Current Optimum Travel Speeds Material Thickness Maximum Travel Speeds Optimum Travel Speeds Maximum Travel Speeds Material Thickness Optimum Travel Speeds 25 40 0 0 25 Arc Current Arc Voltage...

Page 58: ...this section Routine Maintenance 5 2 Inspect Consumables 5 3 Controls and Indicators 5 4 Basic Troubleshooting 5 5 System Circuit Diagram 5 8 Technical Questions 5 9 Parts 5 10 Torch Consumable Configurations 5 10 Torch Parts 5 11 Power Supply Parts 5 11 Accessories 5 12 ...

Page 59: ... air pressure or vacuum Replace damaged labels Check torch cap on safety switch observe that red fault LED and yellow torch cap LED illunimate when cap is loosened Check consumables for wear and proper installation Check trigger for damage Check torch body for cracks or exposed wires Each Week 6 Months 3 Months WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maint...

Page 60: ... Maximum pit depth Replace 1 32 inch 0 8 mm Electrode Part Check For Action External surfaces Damage or debris Replace Central bore I D Does electrode slide easily Replace Gas holes Blocked holes Replace Swirl Ring External surfaces Damage or wear Replace Dry surface Apply a thin film of Hypertherm grease Part No 027055 Torch O ring Max 1 32 inch 0 8 mm ...

Page 61: ...0 psig 2 8 bar for gouging Green When illuminated indicates acceptable gas pressure for torch operation Yellow Torch Cap LED When illuminated indicates that the Retaining Cap is loose or not installed NOTE Condition must be corrected and power turned OFF then ON to clear LED Yellow Temp LED When illuminated indicates that the power supply temperature has exceeded its operating limit Red Fault LED ...

Page 62: ...n and is connected to the power supply 2 2 The incoming gas pressure is too low Set incoming gas pressure to 90 120 psig 6 2 8 3 bar Check that there are no leaks in the gas supply line 2 3 Output gas pressure is set too low for selected mode Adjust gas pressure See page 4 6 item 3 for pressure settings 3 The POWER ON LINE VOLTAGE RANGE YELLOW and FAULT RED lamps are illuminated 3 1 Line voltage i...

Page 63: ...repair the work clamp 6 2 The work clamp is not making good metal to metal contact Clean the area where the clamp contacts the workpiece 6 3 The torch is too far away from the workpiece Move the torch head closer to the workpiece and start the torch again See Torch Operation Section 4 7 The arc blows out but re ignites when the torch switch is depressed again 7 1 The consumable parts are worn or d...

Page 64: ... if necessary 9 Cut quality is not good 9 1 Consumables are worn or the torch is being used incorrectly See Inspect Consumables in this section See Hand Torch Operation Section 4 10 The POWER ON GREEN and FAULT RED lamps are flashing 10 1 Self diagnostic failure System needs repair 11 The POWER ON GREEN and FAULT RED lamps are illuminated after power is turned on 11 1 Start signal ON when system p...

Page 65: ...MAINTENANCE AND PARTS 0 5 8 powermax1000 Operator Manual AC INPUT FILTER CE UNIT ONLY POWER BOARD ETR WORK LEAD TORCH 40 POSITION RIBBON CABLE CONTROL BOARD System Circuit Diagram ...

Page 66: ...s basic troubleshooting guide or if you need further assistance 1 Call your Hypertherm distributor or authorized Hypertherm repair facility 2 Call the nearest Hypertherm office listed in the front of this manual 3 Request a Powermax1000 Service Manual for wiring diagrams higher level troubleshooting and more parts list information ...

Page 67: ...058519 120926 120932 120928 120929 120931 120928 Mechanized Shielded 120930 120932 120928 120930 120931 120928 120979 220007 120928 Unshielded 120979 220006 120928 Gouging 120977 220059 120928 40A 60A 40A 60A 40A 60A 60A In CE countries unshielded consumables may only be used in mechanized torch applications 120925 120926 O Ring 058519 ...

Page 68: ...se Not CE Compliant 50 Ft Torch Lead Assembly 083182 Powermax 1000 Machine System 200 600V 1 3PH 50 60Hz CSA Auto Voltage Phase Not CE Compliant 25 Ft Torch Lead Assembly 083183 Powermax 1000 Machine System 200 600V 1 3PH 50 60Hz CSA Auto Voltage Phase Not CE Compliant 50 Ft Torch Lead Assembly 083192 Powermax 1000 Hand System 230 400V 3PH 50 60Hz CE Auto Voltage 25 Ft Torch Lead Assembly 083193 P...

Page 69: ...8 Circle Cutting Guide Assembly 027684 Replacement Bushing for Circle Cutting Guide Assembly 123646 50 Ft 15M Work Cable w clamp 128711 CE Stain Relief Inserts Standard Cord 128712 CE Strain Relief Inserts Non standard Cord 023206 CNC Interface Cable 220049 Hand Heat Shield Gouging 128650 On Off Pendant for Machine Torch 25 Ft 7 5M 128651 On Off Pendant for Machine Torch 50 Ft 15M 128652 On Off Pe...

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