Hypertherm powermax1250, Service Manual

Page: 8 / 98

TABLE OF CONTENTS
4
powermax1250
Service Manual v
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 – inverter IGBT (Q6) and PFC IGBT (Q7) ...........................................................................................3-26
Test 6 – flyback circuit ....................................................................................................................................3-27
Test 7 – torch stuck open (TSO) ....................................................................................................................3-28
Test 8 – plasma start ......................................................................................................................................3-29
Test 9 – torch cap sensor ...............................................................................................................................3-29
Test 10 – gas solenoid ...................................................................................................................................3-30
Test 11 – incoming line voltage (VACR) .........................................................................................................3-30
Test 12 – pressure switch...............................................................................................................................3-30
Test 13 – fan...................................................................................................................................................3-30
Test 14 – AUX switch .....................................................................................................................................3-31
Test 15 – flyback circuit failure .......................................................................................................................3-31
T60 hand torch connector pinout 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
Section 4 PARTS – POWER SUPPLY
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
Section 5 PARTS – TORCH AND CONSUMABLES
T80 hand torch assembly .........................................................................................................................................5-2
T80M achine torch assembly ....................................................................................................................................5-4
T80 consumable configurations ................................................................................................................................5-6
T80M consumable configurations .............................................................................................................................5-7
Recommended spare parts ......................................................................................................................................5-8
Section 6 WIRING DIAGRAMS
Timing diagrams .......................................................................................................................................................6-2
Electrical schematics ................................................................................................................................................6-5