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Plasma Arc
Cutting System

Service Manual
804300 – Revision 1

powermax1000

®

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Summary of Contents for powermax1000

Page 1: ...20925 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 _ 2 3 1 4 5 6 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 Service Manual 804300 Revision 1 powermax1000 ...

Page 2: ...Revision 1 May 2006 Copyright 2006 Hypertherm Inc All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Inc Hanover NH USA www hypertherm com ...

Page 3: ...vice Hypertherm Shanghai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 332...

Page 4: ...rect connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be au thorized by a person who is competent to assess whether the changes will increase ...

Page 5: ...ertherm 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 agai...

Page 6: ...2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Prévention 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 b...

Page 7: ... 4 Protección para los ojos Protección para la piel Área de corte 1b 4 Seguridad de toma a tierra 1b 4 Cable de trabajo Mesa de trabajo Potencia primaria de entrada 1b 4 Seguridad de los equipos de gas comprimido 1b 5 Los cilindros de gas pueden explotar si están dañados 1b 5 El ruido puede deteriorar la audición 1b 5 Operación de marcapasos y de audífonos 1b 5 Un arco plasma puede dañar tubos con...

Page 8: ... TSO 3 25 Test 8 plasma start 3 26 Test 9 torch cap sensor 3 26 Test 10 gas solenoid 3 27 Test 11 incoming line voltage VACR 3 27 Test 12 pressure switch 3 27 Test 13 fan 3 27 Test 14 AUX switch 3 28 Test 15 flyback circuit failure 3 28 T60 hand torch connector pinouts and assembly 3 29 T60M machine torch connector pinouts and assembly 3 30 Component replacement 3 31 Power cord replacement 3 31 To...

Page 9: ...F CONTENTS vi powermax1000 Service Manual T60 consumable configurations 5 6 T60M consumable configurations 5 7 Recommended spare parts 5 8 Section 6 Wiring diagrams Timing diagrams 6 2 Electrical schematic 6 5 ...

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

Page 12: ... on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge N...

Page 13: ...rdant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect...

Page 14: ...s possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible PACEMAKER AND HEARING AID OPERATION ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and...

Page 15: ... 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: ...e sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais ...

Page 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: ...sées du corps Pantalon sans revers pour éviter que des étincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette Peindre les murs et autres surfaces de couleur sombre pour réduire ...

Page 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: ...tre 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 Util...

Page 22: ...nte el electrochoque 1b 3 Los cortes pueden producir humos tóxicos 1b 3 El arco de plasma puede causar lesiones y quemaduras 1b 4 Antorchas de encendido instantáneo 1b 4 Los rayos del arco pueden producir quemaduras en los ojos y en la piel 1b 4 Protección para los ojos Protección para la piel Área de corte 1b 4 Seguridad de toma a tierra 1b 4 Cable de trabajo Mesa de trabajo Potencia primaria de ...

Page 23: ...r daños en el equipo Prevención ante el fuego Asegúrese de que el área sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables colocándolos a por lo menos 10 metros del área de corte Remoje los metales calientes o permita que se enfríen antes de que entren en contacto con materiales combustibles Nunca corte depósitos que contengan mate...

Page 24: ...ando se encuentren dañadas No toque la pieza ni los recortes cuando se está cortando Deje la pieza en su lugar o sobre la mesa de trabajo con el cable de trabajo conectado en todo momento Antes de inspeccionar limpiar o cambiar las piezas de la antorcha desconecte la potencia primaria o desenchufe la fuente de energía Nunca evite o descuide los bloqueos de seguridad Antes de retirar la cubierta de...

Page 25: ...nes sin dobladillos para impedir que recojan chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión Utilice pantallas o ba...

Page 26: ...or excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro La exposición prolongada al ruido propio de las operaciones de corte y ranurado puede dañar la audición Utilice un método de protección de los oídos aprobado al utilizar el sistema de plasma Advierta a las demás personas que se encuentren en las cercanías a...

Page 27: ...es provocados por la antorcha o el cableado pueden ser fatales Protéjase del electrochoque 3 1 Colóquese guantes aislantes No utilice guantes dañados o mojados 3 2 Aíslese de la pieza de trabajo y de la tierra 3 3 Antes de trabajar en una máquina desconecte el enchufe de entrada o la potencia primaria 4 La inhalación de los humos provenientes del área de corte puede ser nociva para la salud 4 1 Ma...

Page 28: ...powermax1000 Service Manual 2 1 1 Section 2 SPECIFICATIONS In this section Power supply 2 2 Dimensions and weight 2 3 T60 torches 2 4 Dimensions 2 5 Symbols and markings 2 6 S Mark 2 6 IEC symbols 2 6 ...

Page 29: ...determine 230 240 VAC 3PH 26 18 rating of power cord 380 400 415 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 99 380 400 415 VAC 3PH 0 94 0 99 480 VAC 3PH 0 94 0 99 600 VAC 3PH 0 80 0 99 Rsce s...

Page 30: ...ATIONS powermax1000 Service Manual 2 3 1 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ Dimensions and weight Weight of power supply without torch 76 lb 34 5 kg 23 in 584 mm 10 5 in 267 mm 19 5 in 495 mm ...

Page 31: ...m Maximum capacity 1 2 inch 12 mm Gouging capability 10 0 pounds 4 5 kg hour metal removal rate on mild steel Weight 6 9 pounds 3 1 kg with 25 ft 7 5 m lead T60 13 6 pounds 6 2 kg with 50 ft 15 m lead 20 6 pounds 9 4 kg with 75 ft 22 5 m lead 4 5 pounds 2 0 kg with 15 ft 4 5 m lead 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 1...

Page 32: ...ice Manual 2 5 T60 hand torch dimensions 8 9 226 mm 3 9 99 mm 1 5 38 mm 1 00 25 mm T60M machine torch dimensions 15 25 387 mm 1 00 25 mm 1 38 35 mm 2 03 52mm 8 203 mm 32 pitch 0 125 3 2 mm width 0 125 3 2 mm height 2 25 57 mm Dimensions ...

Page 33: ...to maintain S mark compliance IEC symbols 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 tor...

Page 34: ...tests 3 9 IGBT test preparation 3 10 IGBT device test using the Hypertherm tester 3 10 Troubleshoot the Hypertherm IGBT tester 3 11 Schematic for building an IGBT tester 3 11 IGBT device test using non Hypertherm tester 3 12 Troubleshooting guide 3 14 Control board LEDs 3 18 Test 1 voltage input 3 19 Test 2 voltage balance 3 20 Test 3 output diodes 3 21 Test 4 pilot arc IGBT Q8 3 22 Test 5 inverte...

Page 35: ... T60 hand torch connector pinouts and assembly 3 29 T60M machine torch connector pinouts and assembly 3 30 Component replacement 3 31 Power cord replacement 3 31 Torch replacement 3 32 Filter element replacement 3 34 Work cable replacement 3 35 Capacitor replacement 3 36 Heat sink component replacement 3 37 ...

Page 36: ...en illuminated indicates acceptable gas pressure for torch operation Note The LED should illuminate when the power is ON Yellow torch cap LED When illuminated indicates that the retaining cap is loose or not installed Note Turn the power OFF correct this fault condition then turn ON the power to extinguish the LED Yellow temp LED When illuminated indicates that the power supply s temperature is to...

Page 37: ...etween 170 and 540 VAC When the input voltage is above 540 VAC the bus voltage will rise to Vin 2 The inverter consists of an IGBT Q6 the power transformer T2 a current sense transformer and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit that is rectified by the output diode The output circuitry consists of 2 current transfer sensors located ...

Page 38: ...lenoid valve V1 opens The gas flow starts The cutting arc starts Position the torch above the workpiece Pull the plasma start trigger on the hand torch or press the remote start switch for the machine torch The power circuits are ready Gas solenoid valve V1 closes The gas flow stops Set the gas pressure see the Setup section in the Operator Manual Select the desired cutting amps with the current a...

Page 39: ...8883 Troubleshooting procedures and sequence When performing the troubleshooting procedures Refer to Section 6 for the system wiring diagram Refer to Section 4 to locate power supply components Refer to Section 5 for torch components After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power supply for proper operation External...

Page 40: ...EVERE BURNS Allow the power supply to cool before servicing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards Internal inspection 1 Set the ON OFF switch S1 to O OFF unplug the power cord and disconnect the gas supply 2 Remove the power supply s cover by removing the 12 securing scre...

Page 41: ...rical values shown are 25 2 4 MΩ 2 4 MΩ 2 4 MΩ 20 MΩ If no problems were found during the visual inspection or the initial resistance check and the power supply still does not operate correctly see the Troubleshooting guide Note The Troubleshooting guide provides most probable causes and solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before ...

Page 42: ...right or for a shorted IGBT when the switch is pressed to the left Red low battery LED When illuminated this LED indicates that the remaining voltage in the battery is insufficient to power the test circuitry Replace the battery Note The Hypertherm IGBT tester requires a minimum of 8V to properly power its circuitry Indicator LEDs and device tests Pass LED green Collector red Circuit diagram Fail ...

Page 43: ...GBT PFC Yellow lead Gate G Red lead Collector C Black lead Emitter E IGBT Pilot arc IGBT device test using the Hypertherm tester Using the Hypertherm IGBT tester press and hold the switch in the desired position to perform the tests described in the following table Switch LED position Fail Pass Battery This may mean Corrective action Left X IGBT is shorted Replace IGBT Left X IGBT passed short tes...

Page 44: ...e results do not match the table replace the lead connections Connect leads Short test Open test None Pass Fail Red to Black Fail Pass Legend 1 Collector 1 C1 2 Emitter 2 E2 3 Collector 2 Emitter 1 C2 E1 4 Gate 1 G1 5 Emitter 1 E1 6 Emitter 2 E2 7 Gate 2 G2 9 VDC battery R4 2 0K 009036 N O pushbutton switch Yellow Minigrabber test clip 4 5 Black Minigrabber test clip R1 3 01M 009464 3 7 6 2 1 D1 R...

Page 45: ... is performed 4 With the test leads connected and without pressing the pushbutton switch the LED should not illuminate If the LED is illuminated then the IGBT is shorted Replace the IGBT 5 With the test leads connected press the push button switch This time the LED should illuminate If the LED does not illuminate then the IGBT is open Replace the IGBT Yellow lead Gate 1 G1 Black lead Emitter 1 E1 ...

Page 46: ...ervice Manual 3 13 Control board PCB3 Board common TP1 PFC IGBT Q7 Flyback circuit Torch J18 Gas manifold Inverter circuit Power switch S1 Input diode Power factor circuit Inverter IGBT Q6 Output diodes Pilot arc IGBT Q8 Work lead ...

Page 47: ... test mode The current adjustment knob is in the gas test position Turn the knob clockwise until it is set at 20 amps or below Solenoid valve V1 stuck open or defective power board PCB2 Faulty valve power board PCB2 or control board PCB3 Perform Test 10 Voltage below proper operating limits or phase is lost Verify the incoming line voltage and the circuit size according to the Operator Manual Faul...

Page 48: ...c IGBT Q8 power board PCB2 or control board PCB3 Perform Test 4 No output from power board PCB2 Faulty inverter IGBT Q6 or power board PCB2 Perform Test 5 No air flow when trying to fire the torch and no fault LEDs are illuminated Air flows when in test Start signal not being received by power supply Start LED OFF on control board PCB3 See Control Board LEDs Damage to torch or lead assembly for ma...

Page 49: ... to fire the torch A voltage drop indicates an undersized electrical supply installation Inverter fault or interlock Power board PCB2 failure Check the fault LEDs on the back of the control board see Control Board LEDs If IF is illuminated disconnect J5 and place a jumper between pins 1 and 2 on power board PCB2 If the error clears replace the power switch S1 If not perform Test 5 If one of the tw...

Page 50: ...luminating see Control Board LEDs If both are true replace the control board PCB3 Fault LED on power up Start signal illuminated on control board CNC issuing plasma start in a machine application or the torch trigger is defective or engaged Remove the interface cable from the back of the power supply and check the Start LED see Control Board LEDs If the Start LED goes out the problem is either a s...

Page 51: ...k the LEDs on the rear of the control board PCB3 70 50 45 60 55 65 75 80 85 START START XFR SDF START IF START TSO START SP Diagnostic LEDS START XFR SDF IF TSO SP START SIGNAL VALID TRANSFER SELF DIAGNOSTICS FAILURE INVERTER INTERLOCK Blinking at 1 sec rate Visible for 10 sec after event TORCH STUCK OPEN Visible for 10 sec after event SPARE P1 UP MID DOWN CPA NORMAL GOUGE CURRENT GAS STATUS ...

Page 52: ...t diode replace the power switch For CE systems check the voltage at the CE filter If there is proper voltage to the CE filter and low voltage to the input diode replace the CE filter Check the output voltage of the input diode bridge Output VDC Line Voltage x 1 414 VDC Note All values can be 15 Line voltage Line voltage Line voltage Input diode bridge Power switch S1 Single phase Line voltage x 1...

Page 53: ...98 before and during torch operation Voltage across both capacitors should be 375 VDC On systems with serial numbers below 1000 016236 if the capacitors are not balanced at 375 VDC install the RCD resistor kit PN 128963 For systems with higher serial numbers replace the power board Note All values can be 15 750 VDC 375 VDC 375 VDC C94 375 VDC C98 375 VDC Bus bleed and soft start resistors for seri...

Page 54: ...pen with the meter leads in one direction and 0 1V to 1 0V with the meter leads reversed The diode is shorted if the value is less than 0 1V Replace the diode The diode is open if the value is greater than 1 0V in both directions Replace the diode Note In each case common black should be on 3 80 C100 3 3 2 1 3 2 1 2 1 Top 3 to 2 179V 3 to 1 1 8V Bottom 3 to 2 180V 3 to 1 1 8V ...

Page 55: ...cuit R108 R110 If the values are not 15 of the values shown below replace the power board PCB2 and the pilot arc IGBT Q8 If the values are correct check the pilot arc IGBT Q8 with an IGBT Tester If it fails replace the power board PCB2 and the pilot arc IGBT Q8 Pilot arc IGBT Q8 Gate drive resistors R108 1kΩ R110 10kΩ ...

Page 56: ...of the values shown below replace the power board PCB2 and the appropriate IGBT If the values are correct check both IGBTs with an IGBT tester If one IGBT fails replace the power board PCB2 and the failed IGBT 80 C100 Inverter IGBT Q6 PFC IGBT Q7 o o o o R65 R82 Inverter R82 994Ω R83 6 1Ω R65 995Ω R75 6 1Ω R84 10 4Ω R96 4Ω 80 C100 PFC R87 994Ω R56 4 1Ω R98 1Ω ...

Page 57: ...DC and 24 VDC R20 0 75Ω Verify that the diodes listed below are not short circuited by checking their resistance approximately 2kΩ Note Check voltage to ground TP1 D4 24 VDC R1 24 VDC D5 24 VDC R2 18 VDC D7 10 VDC R9 6 VDC D9 18 VDC R18 5 VDC D17 5 VDC R26 18 VDC R55 18 VDC 80 80 TP1 Visually inspect for damage ...

Page 58: ...ss than 100KΩ replace the pilot arc IGBT Q8 If the resistance is always greater than 100Ω then the electrode nozzle circuit is open Check the wiring to the torch Replace all consumables and verify that the torch will fire Note The retaining cap should be snug and not over tightened If the torch plunger does not move freely in the torch head replace the torch head Check to see if the pilot arc IGBT...

Page 59: ... If the Start LED is OFF verify continuity between the purple and orange wires on the Easy Torch Removal ETR connector of the torch lead If the Start LED is OFF and the trigger works correctly put a jumper wire between pins 3 and 4 of U22 If the Start LED illuminates replace the power board PCB2 If it does not illuminate replace the control board PCB3 80 Test 9 torch cap sensor Remove the ETR conn...

Page 60: ...f the air is continuously running disconnect the gas solenoid connector J20 from the power board PCB2 If the air does not shut off replace the valve If the air does shut off disconnect the ribbon cable J4 from the power board PCB2 and reconnect J20 If the air remains off replace the control board PCB3 If the air flow returns replace the power board PCB2 Test 13 fan Force the fan into an over tempe...

Page 61: ...al a failure in the flyback circuit Unplug the fan If the LEDs no longer flash replace the fan If the lights are still flashing plug the fan in again and perform the next step Unplug the solenoid valve If the LEDs no longer flash replace the solenoid valve If the lights are still flashing plug the solenoid valve in again and perform the next step Unplug the CNC interface cable or the ON OFF pendan...

Page 62: ...E NOZZLE CAP START KEY NOTE PIN 6 IS THE KEYING FEATURE FOR 60A AND 80A TORCHES X 1 2 3 4 5 6 7 8 9 10 11 12 Blue rubber seal White wires plunger Red dot Pin 1 Pin 10 violet wire trigger Orange wire cap sensor trigger Pin 12 blue wire cap sensor Pin 3 Not used Red wire nozzle Right handle Left handle Torch body Spring Trigger Screws 5 ...

Page 63: ...2 3 12 10 11 CAP 8 9 6 7 4 5 RED ORANGE ORANGE BLUE WHITE NOZZLE ELECTRODE Blue rubber seal White wires plunger Red dot Pin 1 Pin 10 not used Orange wire cap sensor Pin 12 blue wire cap sensor Pin 3 Red wires nozzle Screws 3 Mounting sleeve Torch body O ring Positioning sleeve Strain relief lock Strain relief ...

Page 64: ...ower supply cover 5 Reconnect the electrical power and the gas supply DANGER ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See warnings on page 3 7 before proceeding Component replacement Single phase Three phase Ground PE Ground PE L1 U L1 L2 L2 V L3 W Standard unit CE ...

Page 65: ... 32 powermax1000 Service Manual 1 Torch replacement Turn OFF O the power switch 1 Unplug the power cord from the power receptacle 2 Open the ETR door and route the lead through the end cap 3 OFF ON ETR door End cap ...

Page 66: ...p 4 Pull back the quick release collar and insert the lead s gas fitting 5 Slide the quick release collar forward to lock in the gas fitting Verify that the gas fitting is secure 6 Verify that the red dot on the connector is on top then plug in the electrical connector Close the ETR door 7 Quick release collar ...

Page 67: ...eeds replacement verify that you have the correct o ring for the filter Each filter has a label on the side of the filter body For AF30 filters use part number 011105 For NAF3000 filters use part number 011094 A B C Re install the filter bowl over the new filter element A Slide the filter bowl over the filter element B Align the marks on the filter bowl and the filter body C Rotate the filter bowl...

Page 68: ...ain relief on the power supply and secure it with a nut 2 Tighten the strain relief collar onto the cable 3 Connect the work cable to the power board at J14 Tighten the nut to 10 in lb 12 kg cm of torque 4 Install the ETR barrier 5 Install the power supply cover ETR barrier Strain relief Connect to J14 Work cable Caution This is a high current connection Proper torque is critical ...

Page 69: ...ove the fan assembly 4 Remove the capacitor from the fan side of the power supply Installation 1 Align the bleeder hole on the capacitor with the view hole on the power board 2 Install the new capacitor and secure it with 2 screws Tighten the screws to 20 in lb 24 kg cm of torque 3 Install the power supply cover Remove and install capacitors from fan side Correct installation Remove and install sc...

Page 70: ... 3 mils or a thickness equivalent to a sheet of paper to the component install with screws and tighten to required torque 4 Re torque after 2 minutes Repeat until torque is maintained 5 Clean the excess grease from the heat sink Notes Apply thermal grease and torque to 8 in lb 9 kg cm Apply thermal grease and torque to 20 in lb 23 kg cm Apply thermal grease and torque to 35 in lb 40 kg cm 3 3 3 3 ...

Page 71: ...MAINTENANCE 3 38 powermax1000 Service Manual 4 ...

Page 72: ...1000 Service Manual 4 1 1 Section 4 PARTS POWER SUPPLY In this section Exterior 4 2 Interior right side 4 3 Back interior right side 4 4 Interior fan side 4 5 Heat sink assembly 4 6 Recommended spare parts 4 7 ...

Page 73: ...stic 1 128687 Kit Front panel CE 1 2 008965 Current adjustment knob 1 3 128630 Kit End panel screws 8 4 123645 Ground clamp 1 5 011096 Regulator knob 1 6 128629 Kit Cover screws 12 7 128690 Kit Power supply cover with labels domestic 1 128688 Kit Power supply cover with labels CE 1 8 128973 Kit Rear panel 1 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ 1 8 7 6 5 2 3 4 ...

Page 74: ... 3 128801 Kit Pressure regulator 1 4 123604 Pilot arc IGBT cable 1 5 128622 Kit Gas manifold with solenoid valve V1 1 6 128628 Kit ETR Box 1 7 046116 Tubing 8mm OD 6mm ID nylon 3 ft 8 128963 Kit RCD resistor replacement S N 1000 013717 1 9 108211 On Off Knob 1 10 128662 Kit Machine interface 1 11 128665 Kit Strain relief arc voltage 1 12 128695 Kit Power board PCB2 1 13 123602 Gate drive cables 3 ...

Page 75: ...ide Part Item number Description Designator Qty 1 128672 Kit Power switch S1 1 2 128706 Kit EMI filter PCB CE only PCB1 1 3 128666 Kit 8 ft 2 5 m power cable domestic 3PH 1 128705 Kit 8 ft 2 5 m power cable CE 3PH 1 6 0 BAR 5 0 4 0 PSI 80 70 50 60 AC _ 60 40 AMPS 80 25 1 2 3 ...

Page 76: ...esignator Qty 1 128627 Kit Filter 1 011093 Air filter element 1 011094 O ring NAF3000 filter 1 011105 O ring AF30 filter 1 2 128707 Kit Fan M1 1 3 128693 Kit Inductor input choke L2 1 4 128691 Kit Capacitor C94 C98 2 5 128692 Kit Power transformer T2 1 6 128694 Kit Inductor output choke L1 1 1 2 6 5 3 4 ...

Page 77: ...utput diode bridge D25 1 2 128697 Kit Inverter IGBT Q6 1 3 128700 Kit Temperature Sensor PCB4 1 4 128708 Kit PFC IGBT Q7 1 5 128696 Kit Input diode bridge D24 1 6 128670 Kit Snubber resister 7 5 Ω 1 7 128699 Kit Pilot arc IGBT Q8 1 8 128669 Kit Snubber resister 20 Ω 1 Reference Section 3 Heat sink component replacement for torque specifications 1 8 7 6 5 2 3 4 ...

Page 78: ... ft 4 6 m 4 3 128695 Kit Power board 4 3 128963 Kit RCD resistor replacement S N 1000 013717 4 3 128672 Kit Power switch 4 4 128706 Kit EMI Filter PCB CE only 4 4 128627 Kit Filter 4 5 011093 Air filter element 4 5 011094 O ring NAF3000 filter 4 5 011105 O ring AF30 filter 4 5 128707 Kit Fan 4 5 128691 Kit Capacitor 4 5 127128 Thermal grease 10 cc 4 6 128677 Kit Output diode bridge 4 6 128697 Kit ...

Page 79: ...PARTS POWER SUPPLY 4 8 powermax1000 Service Manual ...

Page 80: ...Manual 5 1 1 Section 5 PARTS TORCH AND CONSUMABLES In this section T60 hand torch assembly 5 2 T60M machine torch assembly 5 4 T60 consumable configurations 5 6 T60M consumable configurations 5 7 Recommended spare parts 5 8 ...

Page 81: ...sor screws 2 6 128521 Kit T60 T60M torch head repair kit 1 7 128644 Kit T60 torch handle replacement 1 8 075586 Handle screws 5 9 002244 Safety trigger 1 10 027254 Spring 1 11 128681 Kit T60 25 ft 7 6 m torch lead replacement 1 12 128682 Kit T60 50 ft 15 2 m torch lead replacement 1 13 128893 Kit T60 75 ft 22 5 m torch lead replacement 1 14 128638 Kit ETR connector replacement 1 15 128642 Kit T60 ...

Page 82: ...PARTS TORCH AND CONSUMABLES powermax1000 Service Manual 5 3 1 8 7 10 9 12 11 15 14 2 1 6 5 3 4 13 ...

Page 83: ...sensor screws 2 6 128521 Kit T60 T60M torch head repair 1 7 128643 Kit T60M Torch Mounting Sleeve Replacement 1 8 075004 Torch mounting screws 3 9 128710 Torch positioning sleeve 1 10 128634 Kit 15 ft 4 6 m torch lead replacement 1 11 128633 Kit 25 ft 7 6 m torch lead replacement 1 12 128635 Kit 35 ft 10 7 m torch lead replacement 1 13 128641 Kit 50 ft 15 2 m torch lead replacement 1 14 128894 Kit...

Page 84: ...PARTS TORCH AND CONSUMABLES powermax1000 Service Manual 5 5 9 14 10 12 11 13 1 8 7 6 2 3 5 4 15 ...

Page 85: ...umable configurations 120929 120925 120926 120932 120928 40A O ring 058519 120929 120931 120928 60A Shield Nozzle Retaining cap Swirl ring Electrode 120925 120926 O ring 058519 120977 220059 120928 60A 220325 220329 120928 120926 120979 Hand held FineCut 220327 O ring 058519 For use with CE systems ...

Page 86: ...120928 60A 120925 120926 For use with CE systems In CE countries unshielded consumables may only be used in mechanized torch applications Maintain torch to work distance of approximately 3 16 inch 4 8 mm Use an ohmic sensing cap when a compatible torch height controller is installed 220061 Shield Nozzle Retaining cap Swirl ring Electrode Ohmic sensing retaining cap 220061 220404 O ring 058519 2203...

Page 87: ...le screw 5 required 002244 T60 torch trigger assembly with spring 027254 Replacement trigger spring T60 128642 Kit T60 start switch replacement 128564 Kit T60 hand torch main body replacement 128640 Kit T60M machine torch main body replacement 128639 Kit T60 T60M torch cap sensor replacement 128888 Kit FineCut consumables 128889 Kit FineCut consumables CE 083172 T60 hand torch assembly with 25 ft ...

Page 88: ...powermax1000 Service Manual 6 1 1 Section 6 WIRING DIAGRAMS In this section Timing diagrams 6 2 Electrical schematics 6 5 ...

Page 89: ...6 2 powermax1000 Service Manual 1 ...

Page 90: ...powermax1000 Service Manual 6 3 1 ...

Page 91: ...WIRING DIAGRAMS 6 4 powermax1000 Service Manual 1 ...

Page 92: ...B 6C 5C 5B 13 12 11 1C 1B 2B 2C 16 14 15 042188 ULN2003A U1 PREFLOW SSR PA t 60V 0 20A RT7 109024 BRIDGE D24 INPUT GND CONTROL 6 COMT 18REG 18T COMINV 18INV FLYBACK SUPPLY POWER SYSTEM T1 18PA COMPA 5 10 24 PE CKT PFC CONTROL POWER BD PCB2 SOFT START K1 VacR I Vbus 1 3 2 J8 PFC IGBT Q7 C94 2 1 J6 3 2 Vbus OR J10 J9 PFC CHOKE C98 J7 1 POWER TRANSFORMER 20 OHM YEL J13 YEL P2 50W BRN BRN INVERTER IGB...

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