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MAINTENANCE

3-6

powermax1250

Service Manual

Troubleshooting preparation

The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply
theory. In addition to being technically qualified, technicians must perform all testing with safety in mind.

If questions or problems arise during servicing, call the nearest Hypertherm Technical Services Department listed in
the front of this manual.

Test equipment

• Multimeter
• IGBT tester (part number 128883)

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 inspection

1. Inspect the exterior of the power supply for damage to the cover and external components.

2. Inspect the torch and the torch lead for damage.

Power OFF and

disconnected

External inspection

Power ON

Internal inspection

Resistance checks

Troubleshooting

guide

Troubleshooting

tests

Summary of Contents for powermax1250

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 803940 Revision 4 powermax1250 ...

Page 2: ...y 2006 Hypertherm Inc Hanover NH USA www hypertherm com 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 powermax1250 ...

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

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: ...n 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 blessures ou des brûlures 1a 4 Torches à allumage instan...

Page 7: ...os 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 congelados 1b 5 Etiqueta de advertencia 1b 6 Section 2 SPECIFICATIONS Power supply 2 2 Dimensions and weight 2 3 T80 torches 2 4 Dimensions 2 5 Symbols and markings 2 6 S Mark 2 6 IEC symbols 2 6 Section 3 MAINTENANCE Cont...

Page 8: ... and assembly 3 32 T60M machine torch connector pinout diagrams and assembly 3 33 Component replacement 3 34 Power cord replacement 3 34 Torch replacement 3 35 Filter element replacement 3 37 Work cable replacement 3 38 Capacitor replacement 3 39 Power board removal and replacement 3 40 Heat sink component replacement 3 43 Section 4 PARTS POWER SUPPLY Exterior 4 2 Interior right side 4 3 Back inte...

Page 9: ...TABLE OF CONTENTS vi powermax1250 Service 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: ... 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: ...powermax1250 Service Manual 2 1 4 Section 2 SPECIFICATIONS In this section Power supply 2 2 Dimensions and weight 2 3 T80 torches 2 4 Dimensions 2 5 Symbols and markings 2 6 S Mark 2 6 IEC symbols 2 6 ...

Page 29: ...mine 230 240 VAC 3PH 36 28 rating of power cord 380 400 415 VAC 3PH 21 16 480 VAC 3PH 17 13 600 VAC 3PH 16 5 13 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 short ...

Page 30: ...CATIONS 4 powermax1250 Service Manual 2 3 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 90 lb 41 kg 23 in 584 mm 10 5 in 267 mm 19 5 in 495 mm ...

Page 31: ... mm Maximum capacity 5 8 inch 16 mm Gouging capability 12 2 pounds 5 5 kg hour metal removal rate on mild steel Weight 7 2 pounds 3 3 kg with 25 ft 7 5 m lead T80 13 9 pounds 6 3 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 8 3 pounds 3 8 kg with 25 ft 7 5 m lead T80M 9 9 pounds 4 5 kg with 35 ft 10 7 m lead 15 0 pounds 6 8 kg with 50 ft...

Page 32: ...ice Manual 2 5 T80 hand torch dimensions 8 9 226 mm 3 9 99 mm 1 5 38 mm 1 00 25 mm T80M 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 to...

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 a non Hypertherm tester 3 12 Troubleshooting guide 3 14 Control board LEDs 3 20 Test 1 voltage input 3 22 Test 2 voltage balance 3 23 Test 3 output diodes 3 24 Test 4 pilot arc IGBT Q8 3 25 Test 5 inver...

Page 35: ...out diagrams and assembly 3 32 T60M machine torch connector pinout diagrams and assembly 3 33 Component replacement 3 34 Power cord replacement 3 34 Torch replacement 3 35 Filter element replacement 3 37 Work cable replacement 3 38 Capacitor replacement 3 39 Power board removal and replacement 3 40 Heat sink component replacement 3 43 ...

Page 36: ...s pressure for torch operation Note This LED should illuminate when the power is ON I Yellow torch cap LED When illuminated indicates that the retaining cap is loose or not installed Note Turn OFF O the power correct this fault condition then turn ON I the power to extinguish the LED Yellow temperature LED When illuminated indicates that the power supply s temperature is too hot Red fault LED When...

Page 37: ...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 on the ...

Page 38: ...h The gas solenoid valve V1 opens The gas flow starts The torch nozzle and electrode separate The pilot 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 The gas solenoid valve V1 closes The gas flow stops Set the gas pressure see the Setup section in the Operator Man...

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: ...cing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Use proper precautions when handling printed circuit boards Wear a grounded wrist strap when handling PC boards Store PC boards in anti static containers Internal inspection 1 Set the ON OFF switch S1 to O OFF unplug the power cord and disconnect the gas supply 2 Remove the cover of t...

Page 41: ... All electrical values shown are 25 2 4 MΩ 2 4 MΩ 2 4 MΩ 20 MΩ If no problems were found during the 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 Befo...

Page 42: ... a short circuited IGBT when 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 power its circuitry properly Indicator LEDs and device tests Pass LED green Collector red Circuit diagram Fail LED red ...

Page 43: ... 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 each test described in the following table Switch LED position Fail Pass Battery This may mean Corrective action Left X IGBT is short circuited Replace IGBT Left X IGBT passed the shor...

Page 44: ...voltage is greater than 8V 3 Test the IGBT Tester itself as shown below If the results do not match the table replace the lead connections Connect leads Short test Open test None Pass Fail Red to Black Fail Pass 9 VDC battery R4 2 0K 009036 Normally open N O pushbutton switch Yellow Minigrabber test clip 4 R1 3 01M 009464 Black Minigrabber test clip Q1 150A 1400V 109125 R3 2 0K 009036 Red LED lamp...

Page 45: ...ttery reads greater than 8 0v 3 Connect the test leads as shown below 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 pushbutton switch This time the LED should illuminate If the LED does not illuminate then the IGBT is open Replace ...

Page 46: ...vice Manual 3 13 3 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 IGBT Pilot Arc Q8 Work lead ...

Page 47: ...4 MAINTENANCE 3 14 powermax1250 Service Manual Troubleshooting Guide ...

Page 48: ...4 MAINTENANCE powermax1250 Service Manual 3 15 ...

Page 49: ...4 MAINTENANCE 3 16 powermax1250 Service Manual ...

Page 50: ...4 MAINTENANCE powermax1250 Service Manual 3 17 ...

Page 51: ...4 MAINTENANCE 3 18 powermax1250 Service Manual ...

Page 52: ...4 MAINTENANCE powermax1250 Service Manual 3 19 ...

Page 53: ...f control board PCB3 70 50 45 60 55 65 75 80 85 CURRENT P1 UP MID DOWN CPA NORMAL GOUGE GAS STATUS START XFR SDF IF TSO SP START SIGNAL VALID TRANSFER SELF DIAGNOSTICS FAILURE Blinking at 1 sec rate INVERTER INTERLOCK Visible for 10 sec after event TORCH STUCK OPEN Visible for 10 sec after event SPARE Diagnostic LEDs 4 MAINTENANCE 3 20 powermax1250 Service Manual ...

Page 54: ...MAINTENANCE powermax1250 Service Manual 3 21 4 ...

Page 55: ... input diode replace the power switch For CE systems check the voltage at the CE filter If there is proper voltage to 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 ...

Page 56: ...94 and C98 before measuring the resistors listed below Check the voltage across the inverter IGBT Q6 Check the voltage across the capacitors C94 C98 before and during torch operation Voltage across both capacitors should be 375 VDC On systems with serial numbers below 1250 008720 if the capacitors are not balanced at 375 VDC install the RCD resistor kit part number 128963 For systems with higher s...

Page 57: ...For each diode the value should be open with 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 3 3 2 1 3 2 1 2 1 ...

Page 58: ...uit R108 R110 If the values are not 15 of the values listed 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 59: ...of the values shown below replace the power board PCB2 and the appropriate IGBT If 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 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 PFC R87 994Ω R56 4 1Ω R98 1Ω ...

Page 60: ...8 VDC and 24 VDC Verify that the diodes listed below are not short circuited by checking their resistance approximately 2kΩ Note Check the voltage to TP1 Inspect the circuit for damage 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 R20 0 75Ω R26 18 VDC R55 18 VDC 80 80 TP1 ...

Page 61: ... less than 100kΩ replace the pilot arc IGBT Q8 If the resistance is always greater than 100Ω then the electrode nozzle circuit is open Inspect the wiring to the torch Replace all consumables and verify that the torch will fire Note The retaining cap should be snug but not over tightened If the torch plunger does not move freely in the torch head replace the torch head Verify that the pilot arc IGB...

Page 62: ...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 place 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 Test 9 torch cap sensor Remove the ETR connec...

Page 63: ... the PFC IGBT Q7 Test 12 pressure switch Verify that the voltage from the right side of R50 to ground TP1 reads approximately 0 0463 VDC multiplied by psi For example when the air regulator is set to 80 psi the voltage should be approximately 3 7 VDC If the value is correct replace the control board PCB3 If not replace the pressure switch Test 13 fan Force the fan into an over temperature conditio...

Page 64: ...the LEDs no longer flash replace the fan If the LEDs are still flashing plug in the fan again and perform the next step Unplug the solenoid valve If the LEDs no longer flash replace the solenoid valve If the LEDS are still flashing plug in the solenoid valve again and perform the next step Unplug the CNC interface cable or the ON OFF pendant on the back of the machine If the LEDS are still flashin...

Page 65: ...nnector pinout diagrams and assembly RED Blue rubber seal White wires plunger Red dot Pin 1 Pin 10 violet wire trigger Orange wire cap sense trigger Pin 12 blue wire cap sense Pin 3 Not used Red wire nozzle Right handle Left handle Torch body Spring Trigger Screws 5 ...

Page 66: ...e rubber seal White wires plunger Red dot Pin 1 Pin 10 not used Orange wire cap sense Pin 12 blue wire cap sense Pin 3 Red wires nozzle Screws 3 Mounting sleeve Torch body O ring Positioning sleeve Strain relief lock Strain relief J18 1 2 3 4 5 6 7 8 9 10 11 12 WHITE WHITE RED ORANGE NOZZLE ELECTRODE CAP BLUE ...

Page 67: ...rd 5 Install the power supply cover 6 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 L2 V L3 W L1 L2...

Page 68: ...50 Service Manual 3 35 4 Torch replacement Turn OFF O the power switch Unplug the power cord from the power receptacle Open the Easy Torch Removal ETR door and route the lead through the end cap OFF ON ETR Door End Cap 1 2 3 ...

Page 69: ...ap 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 70: ...ows signs of wear or otherwise needs replacement verify that you have the correct o ring for the filter Each filter has a label on one 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 A Hold the black tab down and slide the filter bowl over the filter element B Align the marks on the filter bowl and the filt...

Page 71: ... Install the strain relief to the power supply and secure it with a nut 3 Tighten the strain relief collar onto the cable 4 Connect the work cable to the power board at J14 Tighten the nut to 10 in lb 12 kg cm of torque 5 Install the ETR barrier 6 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 72: ...move 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 s...

Page 73: ...ap when handling PC boards Removal 1 Disconnect the electrical power and the gas supply 2 Remove the cover from the power supply by removing the 12 screws and then lifting off the cover 3 Remove the insulation panel by removing the screws on the right edge and bottom edge 4 Disconnect the torch lead and then remove the ETR barrier 5 Disconnect the pilot arc gate drive and the IGBT gate drives from...

Page 74: ...w Pilot arc IGBT screws 2 Capacitor C94 screws 2 Capacitor C98 screws 2 yellow cable and black wire attached with the left screw Current sensor cable J9 7 Remove the screws that secure the power board to the capacitors the input diode bridge and the IGBTs Remove any cables connected at those points Then remove the retaining screws from the power board 8 Lift the power board out of the power supply...

Page 75: ... red black J2 3 pin yellow black J3 2 pin yellow black J5 3 pin red yellow black Ribbon cable Black wire Black cable Pilot arc gate drive J12 J20 3 pin red black J21 2 pin red black Yellow cable and black wire Yellow cable Black cable Current sensor cable J9 IGBT gate drives J6 J7 and J8 J13 black wire through the hole in the board J11 3 Reattach the work lead and power cord ground cable 4 Re inst...

Page 76: ...w thermal pads on the temperature sensor 4 Use thermal grease on all components Apply a thin coat 3 mils or paper equivalent to the component install with screws and tighten to the required torque 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 k...

Page 77: ...MAINTENANCE 3 44 powermax1250 Service Manual ...

Page 78: ...x1250 Service Manual 4 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 79: ...8624 Kit Front panel Domestic 1 128625 Kit Front panel CE 1 3 128974 Kit Rear panel 1 4 128620 Kit Power supply cover with labels domestic 1 128621 Kit Power supply cover with labels CE 1 5 123645 Work cable with clip 20 ft 6 1 m 1 6 128629 Kit Cover screws 12 7 128630 Kit End panel screws 8 8 011096 Regulator knob 1 6 0 BAR 5 0 4 0 PSI 80 70 50 60 60 40 AMPS 80 25 AC _ 1 2 3 4 6 8 7 5 ...

Page 80: ... 128659 Kit Pressure Sensor 1 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 123602 Gate Drive Cables 3 9 128663 Kit Power board PCB2 1 10 108211 On Off Knob 1 11 128662 Kit Machine Interface 1 12 128665 Kit Strain relief arc voltage 1 1 2 3 4 6 8 9 10 7 5 11 12 ...

Page 81: ...anual Back interior right side Part Item number Description Designator Qty 1 128672 Kit Power switch S1 1 2 128671 Kit EMI filter PCB CE only PCB1 1 3 128666 Kit 8 ft 2 5 m power cable domestic 3PH 1 128667 Kit 8 ft 2 5 m power cable CE 3PH 1 1 2 3 ...

Page 82: ...signator Qty 1 128627 Kit Filter 1 011093 Air filter element 1 011094 O ring NAF3000 filter 1 011105 O ring AF30 filter 1 2 228021 Kit Fan M1 1 3 128680 Kit Inductor input choke L2 1 4 128673 Kit Capacitor C94 C98 2 5 128664 Kit Power transformer T2 1 6 128679 Kit Inductor output choke L1 1 1 3 4 6 5 2 ...

Page 83: ...28676 Kit Inverter IGBT Q6 1 3 128684 Kit Temperature Sensor PCB4 1 4 228071 Kit PFC IGBT Q7 1 128675 Kit PFC IGBT For serial numbers below 1250 014785 or 1250014795 CE 5 128678 Kit Input diode bridge D24 1 6 128670 Kit Snubber resister 7 5 Ω 1 7 128674 Kit pilot arc IGBT Q8 1 8 128669 Snubber resister 20 Ω 1 Reference Section 3 Heat sink component replacement for torque specifications 1 2 3 4 6 8...

Page 84: ...128672 Kit Power switch 4 4 128671 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 228021 Kit Fan 4 5 128673 Kit Capacitor 4 5 127128 Thermal grease 10 cc T grease 2500 4 6 128677 Kit Output diode bridge 4 6 128676 Kit Inverter IGBT 4 6 228071 Kit PFC IGBT 4 6 128675 Kit PFC IGBT 4 6 For serial number...

Page 85: ...PARTS POWER SUPPLY 4 8 powermax1250 Service Manual ...

Page 86: ...Manual 5 1 4 Section 5 PARTS TORCH AND CONSUMABLES In this section T80 hand torch assembly 5 2 T80M machine torch assembly 5 4 T80 consumable configurations 5 6 T80M consumable configurations 5 7 Recommended spare parts 5 8 ...

Page 87: ...sor screws 2 6 128521 Kit T80 T80M torch head replacement 1 7 128644 Kit Handle replacement 1 8 075586 Handle screws 5 9 002244 Safety trigger assembly 1 10 027254 Spring 1 11 128637 Kit T80 25 ft 7 6 m torch lead replacement 1 12 128636 Kit T80 50 ft 15 2 m torch lead replacement 1 13 128893 Kit T80 75 ft 22 5 m torch lead replacement 1 14 128638 Kit ETR connector replacement 1 15 128642 Kit T80 ...

Page 88: ...PARTS TORCH AND CONSUMABLES 2 powermax1250 Service Manual 5 3 14 11 12 13 15 1 2 3 4 6 8 9 10 7 5 ...

Page 89: ...1 5 075571 Cap off sensor screws 2 6 128521 Kit T80 T80M torch head repair 1 7 128643 Kit 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...

Page 90: ...PARTS TORCH AND CONSUMABLES 2 powermax1250 Service Manual 5 5 1 2 3 4 6 8 9 15 10 11 12 13 14 7 5 ...

Page 91: ...rations 120929 120925 120926 120932 120928 40A O ring 058519 120929 120931 120928 60A 120929 120927 120928 80A Shield Nozzle Retaining cap Swirl ring Electrode 120925 120926 O ring 058519 120977 220059 120928 60 80A 220325 220329 120928 120926 120979 Hand held FineCut 220327 O ring 058519 For use with CE systems ...

Page 92: ...120928 80A 120979 220007 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 ...

Page 93: ...andle screw 5 required 002244 T80 torch trigger assembly with spring 027254 Replacement trigger spring T80 128642 Kit T80 start switch replacement 128564 Kit T80 hand torch main body replacement 128640 Kit T80M machine torch main body replacement 128639 Kit T80 T80M torch cap sensor replacement 128888 Kit FineCut consumables 128889 Kit FineCut consumables CE 087001 T80 hand torch assembly with 25 ...

Page 94: ...powermax1250 Service Manual 6 1 3 Section 6 WIRING DIAGRAMS In this section Timing diagrams 6 2 Electrical schematics 6 5 ...

Page 95: ... 2 CURRENT I VALUES SHOWN FOR 80A UNIT I cut max 60A UNIT 80A UNIT 80 60 I cut min 25 20 I pilot 16 25 14 20 REQUIREMENTS PER HYPERTHERM P N 048266 3 RoHS WEEE COMPLIANT AND OTHER REGULATORY D 15365 6 1 06 6 5 06 APPROVED DATE DRAWN DATE ECN REV REVISIONS DESCRIPTION ITEM NO DRAWN BY PURPOSES WITHOUT PERMISSION FOR MANUFACTURING OR FABRICATION FROM HYPERTHERM INC THIS DRAWING AND ALL INFORMATION P...

Page 96: ...SED THIS DRAWING AND ALL INFORMATION FROM HYPERTHERM INC FOR MANUFACTURING OR FABRICATION PURPOSES WITHOUT PERMISSION FILE NAME Box 5010 Hanover NH 03755 5010 603 643 3441 013341 013341B2 ELEC SCHEM PMX1250 60 80A TMG NTS 2 OF 2 3 9 01 WITH CHAMFER OR RADIUS 015 MAX EDGES BREAK SHARP EDGES IF NECESSARY PART MUST BE FREE OF BURRS AND SHARP 3 PL DECIMAL 005 DIMENSIONS ARE IN INCHES ANGULAR 2 FRACTIO...

Page 97: ...WIRING DIAGRAMS 3 6 4 powermax1250 Service Manual ...

Page 98: ...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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