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MAINTENANCE

3-7

powermax

600

Service Manual

M1

Cap Switch

Start Switch

TS1

TS2

~

~

-

+

Board

Power

PCB2

S1

On Rear of Board

Start

LED6 LED7 LED8

Power

O.K.

Low Volt

Low Pres

Cap Off

Over Temp

Bridge

Input

D18

Diode

Regulator

Switch (gas)

Pressure

PS1

Valve (gas)

Soleniod

V1

Filter

Air/Gas
Source

Air/Gas

to

Torch

LEDs

Gas Test

Current Adjust

PCB3 Control Board

sensors

xfer

Nozzle

Work

IGBT

PA

Q3

xfmr

Power

T2

Diode

Output

D2

TB1

~

~

-

+

Workpiece

Electrode

Torch

Module

IGBT

Q2

L2

Pilot Arc

Switch

Designator

Component

D18 .................. Input diode bridge
D2 .................... Output diode
L2 ..................... Output choke inductor
M1 .................... Fan
PCB2 ................ Power board
PCB3 ................ Control board

PS1 .................. Pressure switch
Q2 .................... IGBT module
Q3 .................... Pilot arc IGBT
S1 ..................... Breaker
TB1 .................. Terminal block
TS1 .................. Heatsink temperature sensor

TS2 .................. Transformer temperature sensor
T2 ..................... Power transformer
V1 ..................... Solenoid valve

Figure 3-2.2 Powermax600 208-240/480 Volt Block Diagram

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Summary of Contents for powermax600

Page 1: ...Plasma Arc Cutting System Service Manual 803400 Revision 2 powermax600 ...

Page 2: ... 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 Revision 2 NOVEMBER 1999 Hypertherm Inc Hanover NH USA http www hypertherm com email info hypertherm com powermax600 ...

Page 3: ...al Support Organization ETSO Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm U K 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 5...

Page 4: ...uch as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enc...

Page 5: ...nfringes or alleges to infringe on WARNING Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty any patent or other right Distributors shall notify Hyper therm promptly upon learning of any action or threatened action in connection with any ...

Page 6: ...É 1a 2 LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION 1a 2 LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS 1a 3 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES 1a 4 LES RAYONS DE L ARC PEUVENT BRÛLER LES YEUX ET LA PEAU 1a 4 MISE À LA MASSE ET À LA TERRE 1a 4 SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ 1a 5 LES BOUTEILLES DE GAZ COMPRIMÉ P...

Page 7: ...COMPONENT REPLACEMENT 3 32 SECTION 4 PARTS LIST 400 230V CE POWER SUPPLY EXTERIOR 4 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE 4 3 POWER SUPPLY BACK INTERIOR RIGHT SIDE 4 4 POWER SUPPLY INTERIOR FAN SIDE 4 5 POWER SUPPLY HEAT SINK ASSEMBLY 4 6 RECOMMENDED SPARE PARTS POWERMAX600 230 400V 4 7 SECTION 5 PARTS LIST 208 240 480V POWER SUPPLY EXTERIOR 5 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE 5 3 POWER ...

Page 8: ...ion 1 2 Electric Shock Can Kill 1 3 Cutting Can Produce Toxic Fumes 1 3 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 Additional Safety Information 1 5 Warning Label 1 6 ...

Page 9: ...XPLOSION Fire Prevention Be 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 potent...

Page 10: ... clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the ...

Page 11: ...urfaces with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs GROUNDING SAFETY Input Power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connect ing the power cord to the power supply be sure to connect th...

Page 12: ...e away from your body Route the torch leads as close as 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 St...

Page 13: ...ing 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...

Page 14: ...T ÊTRE FATALS 1a 3 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES 1a 4 LES RAYONS DE L ARC PEUVENT BRÛLER LES YEUX ET LA PEAU 1a 4 MISE À LA MASSE ET À LA TERRE 1a 4 SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ 1a 5 LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES 1a 5 LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS 1a 5 PAC...

Page 15: ...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 16: ...er et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du coupage Laisser la pièce à couper en place ou sur la table de travail le câble de retour connecté lors du coupage Avant de vérifier de nettoyer ou de remplacer les pièces de la torche couper l alimentation ou débrancher la prise de courant Ne jamais contourner ou court circuite...

Page 17: ...fixer le câble de retour à la partie de la pièce qui doit se détacher Table de travail Raccorder la table de travail à la terre conformément aux codes de sécurité locaux ou nationaux appropriés MISE À LA MASSE ET À LA TERRE Alimentation S assurer que le fil de terre du cordon d alimentation est connecté à la terre dans le coffret du sectionneur S il est nécessaire de brancher le cordon d alimentat...

Page 18: ...ter à tout prix le contact électrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs Utiliser un casque de p...

Page 19: ...s peut 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 ...

Page 20: ...IFICATIONS POWER SUPPLY 2 2 SPECIFICATIONS PAC123 TORCHES 2 3 SETUP SPECIFICATIONS 2 4 INSTALL POWER CORD PLUG 2 4 CHECK REQUIRED INPUT VOLTAGE 2 4 S MARK 230 400 VOLT ONLY 2 4 GROUNDING REQUIREMENTS 2 5 POWER CORD EXTENSION CORD 2 5 GAS REQUIREMENTS 2 6 LINE VOLTAGE DISCONNECT BOX 2 6 10 99 ...

Page 21: ...5 2 U A 0 4 2 V 0 4 1 I 0 0 1 2 U A 8 2 2 V 0 4 1 e r u t a r e p m e t g n i t a r e p O 0 4 o t 0 1 4 0 1 o t 4 1 C F S r e w o P t u p n I t n e r a p p A 1 A V k 7 6 V 0 0 4 0 3 2 A V k 5 9 V 0 8 4 0 4 2 8 0 2 U e g a t l o V t u p n I 1 I t n e r r u C t u p n I 1 t a t u p t u O w k 6 5 E C z H 0 6 0 5 e s a h p 3 A 7 1 V 0 3 2 E C z H 0 6 0 5 e s a h p 3 A 7 9 V 0 0 4 L T R N A S C z H 0 6 ...

Page 22: ... 3 h c n i 8 1 y t i l i b a p a C g n i g u o G e t a r l a v o m e r l a t e m g k 5 2 s d n u o p 6 5 t h g i e W T 3 2 1 C A P d a e l m 5 4 t f 5 1 h t i w g k 6 1 s d n u o p 5 3 d a e l m 5 7 t f 5 2 h t i w g k 2 s d n u o p 5 4 d a e l m 5 1 t f 0 5 h t i w g k 2 3 s d n u o p 7 M 3 2 1 C A P d a e l m 5 4 t f 5 1 h t i w g k 7 2 s d n u o p 6 d a e l m 5 7 t f 5 2 h t i w g k 2 3 s d n u...

Page 23: ...mable parts to maintain S mark compliance SETUP SPECIFICATIONS Check Required Input Voltage Look at U1 on the data plate to check input voltage requirements The data plate is on the back of the power supply See Figure 2 4 Figure 2 4 Data Plate Input Voltage COMP 01 Install Power Cord Plug Use a power cord plug that is certified by national or local electrical codes The plug should be connected to ...

Page 24: ...service must use a 4 wire cord that includes a protective earth ground Also see Grounding Safety in Section 1 of this manual A PMX600 02 Power Cord Extension Cord 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 Input Voltage Phase Recommended Cord Gauge Size mm2 208 240 VAC 1 10 10 10 16 16...

Page 25: ...ted below PMX600 03 PMX600 04 Input Input Current Recommended Voltage Phase 5 6 kw Output Slow Blow Fuse Size 208 240 VAC 1 46 40A 100A 230 VAC 3 17A 40A 400 VAC 3 9 7A 25A 480 VAC 3 12A 25A Gas Requirements Air must be filtered to remove all dirt water and oil Contaminants can damage the power supply torch and consummables The power supply will not power up if the gas inlet pressure is below mini...

Page 26: ... 3 6 SEQUENCE OF OPERATION 3 8 TROUBLESHOOTING 3 9 TEST EQUIPMENT 3 9 TROUBLESHOOTING PROCEDURES AND SEQUENCE 3 9 VISUAL INSPECTION EXTERNAL 3 9 VISUAL INSPECTION INTERNAL 3 10 RESISTANCE CHECKS 3 11 TROUBLESHOOTING GUIDE 3 14 VOLTAGE CHECKS 3 21 COMPONENT REPLACEMENT 3 26 POWER CORD REPLACEMENT 3 26 TORCH LEAD REPLACEMENT MODELS WITHOUT QUICK DISCONNECT 3 27 AIR FILTER ELEMENT REPLACEMENT 3 28 WO...

Page 27: ...s are clear none of the yellow lamps are illuminated Yellow LOW LINE VOLTAGE When illuminated indicates that the AC line voltage is 1 below operating limits or 2 is missing 1 phase 230V and 400V systems only Yellow LOW GAS PRESSURE When illuminated indicates that the incoming gas pressure is below operat ing limits Yellow TORCH PARTS ARE LOOSE OR REMOVED When illuminated indicates that the torch c...

Page 28: ...MAINTENANCE 3 3 powermax600 Service Manual THEORY OF OPERATION General Refer to Functional Description Figures 3 2 1 and 3 2 2 Sequence of Operation and the system wiring diagram 10 99 ...

Page 29: ...or IGBT Q2 the power transformer T2 a current sense transformer LEM power factor choke and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit and is rectified by the output diode D2 The output circuitry consists of 2 current transfer sensors located on the power board the pilot arc IGBT Q3 and the output choke L2 The control board microprocessor ...

Page 30: ... PCB3 Control Board sensors xfer Nozzle Work IGBT PA Q3 xfmr Power T2 Diode Output D2 TB1 Workpiece Electrode Torch Module IGBT Q2 L1 L2 Designator Component D1 Input diode bridge D2 Output diode L1 Input choke inductor L2 Output choke inductor M1 Fan PCB1 Filter board PCB2 Power board PCB3 Control board PS1 Pressure switch Q2 IGBT module Q3 Pilot arc IGBT S1 Breaker TB1 Terminal block TS1 Heatsin...

Page 31: ...f the power board The inverter operates as a pulse width modulator controlled bridge circuit and is rectified by the output diode D2 The output circuitry consists of 2 current transfer sensors located on the power board the pilot arc IGBT Q3 and the output choke L2 The control board microprocessor monitors and regulates system operation and safety circuits The current is set to the desired value b...

Page 32: ...t PCB3 Control Board sensors xfer Nozzle Work IGBT PA Q3 xfmr Power T2 Diode Output D2 TB1 Workpiece Electrode Torch Module IGBT Q2 L2 Pilot Arc Switch Designator Component D18 Input diode bridge D2 Output diode L2 Output choke inductor M1 Fan PCB2 Power board PCB3 Control board PS1 Pressure switch Q2 IGBT module Q3 Pilot arc IGBT S1 Breaker TB1 Terminal block TS1 Heatsink temperature sensor TS2 T...

Page 33: ... torch on workpiece Depress plasma start switch on hand torch or remote start switch for machine torch Move torch to make cut Workpiece falls away after cut Release plasma start switch on hand torch or remote start switch for machine torch Arc extinguishes Post flow continues for 10 seconds System off Set gas pressure to 70 psi 4 5 bar Select cutting amps with current adjust knob Gas solenoid valv...

Page 34: ...ing Procedures and Sequence Refer to the system wiring diagram when performing the troubleshooting procedures To locate power supply components refer to Section 4 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 Visual Inspection External Visual Inspe...

Page 35: ...not attempt to repair the power board or control board Do not cut away or remove any protective conformal coating from either board To do so will risk a short circuit between the AC input circuit and the output circuit and may result serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING FAN CAN CAUSE INJURY Keep hands away from moving parts...

Page 36: ...re not close to the values given in this section isolate the problem by removing wires attached to the resistance check points or component until the problem is found After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power unit for proper operation Resistance Check 1 Figure 3 3 1 Turn switch ON power disconnected 2 Check res...

Page 37: ...wermax600 Service Manual Figure 3 4 Resistance Check 2 Power Board to Chassis Resistance Check 2 Figure 3 4 Check resistance from power board connection to chassis 10MΩ 10MΩ 230V and 400V 208 240V and 480V PMX600 20 10 99 ...

Page 38: ...powermax600 Service Manual 230V and 400V 208 240V and 480V PMX600 21 Resistance Check 3 Figure 3 5 Check resistance across output diode bridge Figure 3 5 Resistance Check 3 Output Diode Bridge 6 to 9 KΩ 4 to 7 KΩ 10 99 ...

Page 39: ...ystem wiring diagram and understand the theory of operation before troubleshooting Before purchasing a major replacement component verify the problem with Hypertherm Technical Service or the near est Hypertherm repair facility WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous volt ages exist inside the power supply that can cause serious injur...

Page 40: ...5 1 4 1 s e r i w n e e w t e b e g a t l o v t l o v 0 0 4 n o C D V 5 6 5 e b d l u o h s e g a t l o V e g d i r b s t i n u t l o v 0 3 2 n o 5 2 3 s t i n u m o r f 4 1 e r i w e v o m e r e g a t l o v o n r o t c e r r o c n i f I k c e h c e g a t l o v t a e p e r d n a d r a o b r e w o p n o 1 K e d o i d t u p n i e c a l p e r e g a t l o v o n r o t c e r r o c n i f I e g d i r b d ...

Page 41: ...t i w s t r a t s r e g g i r t h c r o t d e s s e r p t o n d e s s e r p t o n d e s s e r p t o n d e s s e r p t o n d e s s e r p t o n t s e t s a g n i s i m e t s y S e d o m n i s i b o n k t s u j d a t n e r r u C n o i t i s o p t s e t s a g p m a 0 2 e h t e v o b a l i t n u e s i w k c o l c b o n k n r u T 1 4 g n i t t e s 1 V e v l a v d i o n e l o S n e p o k c u t s e v l a ...

Page 42: ...r o s n e s p m e T d e i f s i t a s e l c y c y t u d d e d e e c x E s t i m i l e l c y c y t u d h t i w y a t S l o o c o t t i n u w o l l A 1 8 l a u n a m n i r o g n i t a r e p o t o n n a F g n i t a r e p o y l r e p o r p m i f I n a f o t d e i l p p u s g n i e b s i e g a t l o v y f i r e V 2 8 e g a t l o v o n f I n a f e c a l p e r t n e s e r p s i e g a t l o v d r a o b r ...

Page 43: ... l o v o n f I e v l a v e c a l p e r r o s e n i l r i a r a e l c e g a t l o v f I r o h c r o t d e g a m a D y l b m e s s a d a e l n e p o k c u t s r e g n u l p h c r o T s d a e l h c r o t n e k o r b r o 7 6 D E L d r a o b l o r t n o c t l u a f y f i r e V 3 9 y l b m e s s a d a e l h c r o t t c e p s n I d e t a n i m u l l i l o r t n o c d e g a m a D 3 B C P d r a o b d r a o...

Page 44: ...r u s s e r p k c e h c r a b 7 4 i s p 0 7 o t t s u j d a t o n n a c f I y l p p u s r i a l a n r e t x e r i a y t i l a u q r o o P s e t a n i m a t n o c r o e r u t s i o M e n i l r i a n i s e n i l e g r u p d n a n o i t a r t l i f e t a i r p o r p p a d d A 3 1 1 n e g o r t i N h t i w t u p n i t n e i c i f f u s n I r e w o p l a c i r t c e l e d e z i s r e d n U n o i t a l ...

Page 45: ... b k 5 n a h t s s e l s i e c n a t s i s e r f I d r a o b r e w o p n o C T B G I c r a t o l i p e c a l p e r s m h o y l p p u s r e w o p w o L t u p t u o o o t t e s t n e m t s u j d a t n e r r u C w o l r e p o r p t a s i b o n k t s u j d a t n e r r u c y f i r e V 1 1 1 e s i w k c o l c l l u f x a m o t n r u t g n i t t e s d r a o b r e w o p e v i t c e f e D r o s n e s t n e...

Page 46: ... line voltage disconnect switch box or plug into a properly grounded outlet Connect the gas supply to the power supply Switch the power supply on Voltage Checks WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous volt ages exist inside the power supply that can cause serious injury or death See warnings on page 3 6 before proceeding 10 99 ...

Page 47: ...Bridge Voltage Check 1 Figure 3 5 Check input voltage to the input diode bridge The AC voltage between any 2 input wires should equal the line voltage 230V and 400V 208 240V and 480V PMX600 22 8 10 9 Line Voltage Line Voltage Line Voltage Line Voltage Line Voltage Line Voltage 480V Only 10 99 ...

Page 48: ...re 3 6 Check output voltage of the input diode bridge Figure 3 6 Voltage Check 2 Output of Input Diode Bridge 230V and 400V 208 240V and 400V PMX600 23 15 14 230 VAC 400 VAC 208 240 VAC 480 VAC 325 VDC 565 VDC 300 330 VDC 660 VDC Line Voltage Output at Bridge 10 99 ...

Page 49: ...3 7 Check voltage across IGBT module Figure 3 7 Voltage Check 3 Across IGBT Module 230V and 400V 208 240V and 480V PMX600 24 A B C A B C A 160 280 165 330 C 325 565 330 660 B 160 280 165 330 230 VAC 400 VAC 208 240 VAC 480 VAC Line Voltage VDC Across Connections 10 99 ...

Page 50: ...heck 4 Across Power Supply Capacitors Voltage Check 4 Figure 3 8 Check voltage across power supply capacitors 230V and 400V 208 240V and 480V PMX600 25 230 VAC 400 VAC 208 240 VAC 480 VAC 290 VDC 290 VDC 165 165 VDC 330 VDC Line Voltage VDC Across Connections 10 99 ...

Page 51: ... power cord through the strain relief 2 Pass all 4 wires through the toroid as shown 230 and 400 volt only 3 Install the power cord connections where shown 4 Tighten the strain relief onto the power cord 5 Install the power supply cover 6 Reconnect electrical power and gas supply 208V 240V 230V and 400V PMX600 12 480V 230V 400V NOTE Toroid must be installed for power supply to be in compliance wit...

Page 52: ...orch lead until the gas fitting 3 is tight or the gas connection may leak Install the strain relief 1 and secure with nut 2 Connect and tighten the gas fitting 3 Tighten the strain relief collar 4 onto the lead Connect the electrical connections 5 6 and 7 Tighten terminal block screws to 10 in lb 12 kg cm of torque Install the power supply cover Figure 3 11 Torch Lead Replacement CAUTION These are...

Page 53: ...Figure 3 12 Figure 3 12 Air Filter Element Removal Unscrew the filter bowl Do not discard the O ring Remove the filter element from the filter housing NOTE Do not allow the filter element to turn when loosening the screw Compress the hose fitting collar and pull the gas hose from the hose fitting Pull the drain hose from the grommet in the floor of the power supply 10 99 ...

Page 54: ...r Connect gas supply Installation Refer to Figure 3 13 Install the new filter element into the filter housing Secure with screw and retainer Install the filter bowl and O ring into the filter housing Push the pressure line fully into the hose fitting Install the drain hose into the grommet Figure 3 13 Air Filter Element Installation 10 99 ...

Page 55: ...secure with nut 2 Install work cable 3 through the strain relief Tie a knot 4 in the end of the work cable Tighten the strain relief collar 5 onto the cable Connect the work cable to the terminal block 6 Tighten terminal block screw to 10 in lb 12 kg cm of torque Install the power supply cover Figure 3 14 Work Cable Replacement CAUTION This is a high current connection Proper torque is critical PM...

Page 56: ...ect Installation Positive Positive Capacitor Replacement Figure 3 15 Capacitor Replacement Remove and install capacitors from fan side Power Capacitor Supply Marking 208 240V 250V 6800uf 230V 250V 4700uf 400V 400V 1800uf 480V 450V 1500uf Capacitor Identification Removal Refer to Figure 3 15 Disconnect electrical power and gas supply before removing the power supply cover Remove screws securing cap...

Page 57: ...eplacement 11 99 Figure 3 16 Heat Sink Component Replacement Installation Refer to Figure 3 16 Install components to the heat sink as shown below Use a new thermal pad on components C Use thermal grease on components A and B Apply a thin coat to the component install with screws and tighten to required torque Re torque after 2 minutes Repeat until torque is maintained Clean excess grease from heat...

Page 58: ...on POWER SUPPLY EXTERIOR 4 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE 4 3 POWER SUPPLY BACK INTERIOR RIGHT SIDE 4 4 POWER SUPPLY INTERIOR FAN SIDE 4 5 POWER SUPPLY HEAT SINK ASSEMBLY 4 6 RECOMMENDED SPARE PARTS POWERMAX600 230 400V 4 7 11 99 Section 4 PARTS LIST 400 230V ...

Page 59: ...tion Designator Qty 1 001669 Rear end panel 1 2 001668 Front end panel Also order 110242 1 3 110242 Operation lable 1 4 129488 Power supply cover 1 5 008965 Knob 1 6 110261 Warning label 1 7 110258 Instruction label 1 8 110996 Pressure warning label 1 10 99 POWER SUPPLY EXTERIOR ...

Page 60: ...Part Item Number Description Designator Qty 1 041593 Control PCB assembly PCB3 1 2 108090 Terminal block 1 3 129374 Solenoid valve V1 1 4 123375 Work Cable with clamp 4 6 m 15 ft 1 POWER SUPPLY FRONT INTERIOR RIGHT SIDE PMX600 26 Early Configuration 10 99 ...

Page 61: ...ircuit breaker 400 V S1 1 003195 Circuit breaker 230 V S1 1 2 041566 EMI Filter PCB 400 V PCB1 1 041587 EMI Filter PCB 230 V PCB1 1 3 129368 Power cable 400 V 1 129410 Power cable 230 V 1 4 008389 Strain relief 400 V 1 108107 Strain relief 230 V 1 5 109070 Toroid 1 POWER SUPPLY BACK INTERIOR RIGHT SIDE 10 99 ...

Page 62: ... 1 4 014234 Power transformer 400V T2 1 014238 Power transformer 230V T2 1 5 009999 Capacitor 1800 1900UF 400V 2 109118 Capacitor 1800 1900UF 230V 2 6 014231 Inductor input choke 5MH 11A 400V L1 1 014241 Inductor input choke 5MH 11A 230V L1 1 7 011083 Filter regulator subassembly 1 8 011086 Air filter element 1 9 011087 O ring 1 10 129366 Fan subassembly M1 1 POWER SUPPLY INTERIOR FAN SIDE 10 99 ...

Page 63: ...HM 2 4 109080 IGBT pilot arc Q3 1 5 005222 Temp switch TS1 1 6 109079 IGBT module Q2 1 7 009849 Resistor 20 OHM 1 8 109067 MOV 1 9 109090 Input diode bridge 400V D1 1 109134 Input diode bridge 230V D1 1 10 041568 Power PCB 400V PCB2 1 041607 Power PCB 230V PCB2 1 11 008903 Thermal pad 3 12 027662 Thermal grease 5 oz tube 5 places 11 99 POWER SUPPLY HEAT SINK ASSEMBLY DC 120 PMX600 28 ...

Page 64: ... 4 4 005112 Pressure Switch 4 5 009999 Capacitor 1800 1900UF 400V 4 5 011083 Filter regulator subassembly 4 5 011086 Air filter element 4 5 011087 O ring Air filter element 4 5 014231 Inductor input choke 5MH 11A 400V 4 5 014232 Inductor output choke 80MH 40A 4 5 014234 Power transformer 400V 4 5 014238 Power transformer 230V 4 5 014241 Inductor input choke 5MH 11A 230V 4 5 022027 Pressure gauge 4...

Page 65: ...n POWER SUPPLY EXTERIOR 5 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE 5 3 POWER SUPPLY CIRCUIT BREAKER AND POWER CABLE 5 4 POWER SUPPLY INTERIOR FAN SIDE 5 5 POWER SUPPLY HEAT SINK ASSEMBLY 5 6 RECOMMENDED SPARE PARTS POWERMAX600 208 240 480V 5 7 Section 5 PARTS LIST 208 240 480V ...

Page 66: ...ption Designator Qty 1 001669 Rear end panel 1 2 001668 Front end panel also order 110271 1 3 110271 Operation lable 1 4 129594 Power supply cover 1 5 008965 Knob 1 6 010287 Warning label 1 7 110276 Instruction label 1 8 110996 Pressure warning label 1 10 99 POWER SUPPLY EXTERIOR ...

Page 67: ...m Number Description Designator Qty 1 041654 Control PCB assembly PCB3 1 2 108090 Terminal block 1 3 129534 Quick disconnect assembly 1 4 129533 Solenoid valve V1 1 5 123375 Work Cable with clamp 4 6 m 15 ft 1 POWER SUPPLY FRONT INTERIOR RIGHT SIDE PMX600 27 10 99 ...

Page 68: ...em Number Description Designator Qty 1 003193 Circuit breaker 480V S1 1 003202 Circuit breaker 208 230V S1 1 2 023519 Power cable 480V 1 129530 Power cable 208 230V 1 3 108124 Strain relief 480V 1 108122 Strain relief 208 230V 1 POWER SUPPLY CIRCUIT BREAKER AND POWER CABLE 10 99 ...

Page 69: ...ut choke 80MH 40A L2 1 4 014252 Power transformer 480V T2 1 014251 Power transformer 208 230V T2 1 5 109179 Capacitor 1800 1900UF 450V 480V 2 109187 Capacitor 1800 1900UF 250V 208 230V 2 6 011083 Filter regulator subassembly 1 7 011086 Air filter element 1 8 011087 O ring 1 9 129366 Fan subassembly 480V M1 1 027654 Fan assembly 208 230V M1 1 POWER SUPPLY INTERIOR FAN SIDE 10 99 ...

Page 70: ...05222 Temp switch TS1 1 5 109079 IGBT module 480V Q2 1 109183 IGBT module 208 240V Q2 1 6 009849 Resistor 20 OHM 1 7 109175 Input diode bridge 480V D18 1 109174 Input diode bridge 208 240V D18 1 8 041652 Power PCB 480V PCB2 1 041650 Power PCB 208 240V PCB2 1 9 008903 Thermal pad 3 10 027662 Thermal grease 5 oz tube 5 places 11 99 POWER SUPPLY HEAT SINK ASSEMBLY 129528 DC 120 PMX600 28 ...

Page 71: ...0V 5 4 005112 Pressure Switch 5 5 011083 Filter regulator subassembly 5 5 011086 Air filter element 5 5 011087 O ring Air filter element 5 5 014232 Inductor output choke 80MH 40A 5 5 014251 Power transformer 208 240V 5 5 022027 Pressure gauge 5 5 027654 Fan assembly 5 5 014252 Power transformer 480V 5 5 109179 Capacitor 1800 1900UF 450V 480V 5 5 109187 Capacitor 1800 1900UF 250V 208 230V 5 5 12936...

Page 72: ...ASSEMBLY NO QUICK DISCONNECT 6 2 PAC123T HAND TORCH ASSEMBLY WITH QUICK DISCONNECT 6 4 PAC123M MACHINE TORCH ASSEMBLY NO QUICK DISCONNECT 6 6 PAC123M MACHINE TORCH ASSEMBLY WITH QUICK DISCONNECT 6 8 TORCH CONSUMABLES 6 10 RECOMMENDED SPARE PARTS PAC123 TORCH 6 11 Section 6 PARTS LIST TORCH AND CONSUMABLES ...

Page 73: ... Handle 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch switch and wire splices 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring Gutcha 1 6 075339 Screws P S 4 X 1 2 PH RND S B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O Ring BUNA 90 Duro 614X 070 1 9 129475 Replacement Hand Torch Lead 15 ft 4 5 m 1 9 129476 Replacement Hand Torch Lead 25 ft 7 5 m 1 9 129477...

Page 74: ...6 3 powermax600 Service Manual PARTS LIST TORCH AND CONSUMABLES PAC123T 01 PAC123T Hand Torch and Lead Assembly No Quick Disconnect Included with replacement lead assembly 10 99 ...

Page 75: ...288 Handle 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch switch and wire splices 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring Gutcha 1 6 075339 Screws P S 4 X 1 2 PH RND S B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O Ring BUNA 90 Duro 614X 070 1 9 129599 Replacement Hand Torch Lead 15 ft 4 5 m 1 9 129600 Replacement Hand Torch Lead 25 ft 7 5 m 1 9 129...

Page 76: ...6 5 powermax600 Service Manual PARTS LIST TORCH AND CONSUMABLES PAC123T 02 PAC123T Hand Torch and Lead Assembly With Quick Disconnect Included with replacement lead assembly 10 99 ...

Page 77: ...120613 Sleeve Machine Torch 1 2 020620 Sleeve Torch Position 1 3 128374 Replacement Torch Lead 15 ft 4 5 m 1 3 128375 Replacement Torch Lead 25 ft 7 5 m 1 3 128376 Replacement Torch Lead 50 ft 15 m 1 4 027599 Snap Ring 1 5 120583 Torch Main Body with Safety Switch 1 6 044016 O Ring BUNA 90 Duro 0 614 X 0 070 inch 1 7 028714 On Off Pendant with Lead 25 ft 7 5 m 128061 On Off Pendant with Lead 50 ft...

Page 78: ...6 7 powermax600 Service Manual PARTS LIST TORCH AND CONSUMABLES PAC123M Machine Torch Assembly and Leads No Quick Disconnect P A C 1 2 3 M 0 3 Included with replacement lead assembly 10 99 ...

Page 79: ...h 1 2 020620 Sleeve Torch Position 1 3 128572 Replacement Torch Lead w Quick Disconnect 15 ft 4 5 m 1 3 128573 Replacement Torch Lead w Quick Disconnect 25 ft 7 5 m 1 3 128574 Replacement Torch Lead w Quick Disconnect 50 ft 15 m 1 4 027599 Snap Ring 1 5 120583 Torch Main Body with Safety Switch 1 6 044016 O Ring BUNA 90 Duro 0 614 X 0 070 inch 1 7 028714 On Off Pendant with Lead 25 ft 7 5 m 128061...

Page 80: ...6 9 powermax600 Service Manual PARTS LIST TORCH AND CONSUMABLES PAC123M Machine Torch Assembly and Leads With Quick Disconnect M 04 P A C 123 Included with replacement lead assembly 10 99 ...

Page 81: ...ctrode Swirl Ring Retaining Cap 120600 Shield 120828 Nozzle Gouging Machine Cutting Unshielded Hand Cutting 120600 120600 120826 120576 120573 120826 120831 120608 120827 Deflector 120303 120574 120606 120600 In CE countries unshielded consumables may only be used in machine torch applications ...

Page 82: ...d with Quick Disconnect 086027 PAC123M Machine Torch Assembly with 25 ft 7 5 m Lead with Quick Disconnect 086029 PAC123M Machine Torch Assembly with 50 ft 15 m Lead with Quick Disconnect 120570 Hand Torch Main Body with Safety Switch 120583 Machine Torch Main Body with Safety Switch 128374 Replacement Machine Torch Lead 15 ft 4 5 m No Quick Disconnect 128375 Replacement Machine Torch Lead 25 ft 7 ...

Page 83: ...7 1 powermax600 Service Manual WIRING DIAGRAMS In this section Electrical Schematic 230 400V 013335 Electrical Schematic 208 240 480V 013337 10 99 Section 7 WIRING DIAGRAMS ...

Page 84: ... 2 009999 2 BULK CAPS ON POWER BD 014238 014234 POWER XFR T2 014241 014231 POWER FACTOR CHOKE L1 041607 041568 POWER BOARD PCB2 109134 109090 INPUT BRIDGE D1 041587 041566 EMI FILTER BOARD PCB1 003195 003193 CIRCUIT BREAKER S1 ON TORROID 2 3 POWER CORD TURNS 230vac 3É 400vac 3É 086007 086000 INPUT VOLTAGE POWER SUPPLY PART J9 5 POWER BOARD PCB2 VIO ORG BLU J5 BREAKER CIRCUIT LED8 LED7 LED6 START 0...

Page 85: ...K VISIBLE FOR 15 SEC AFTER EVENT BLINKING 1 SEC RATE OFF ON SELF DIAGNOSTICS FAILURE OFF OFF SYSTEM OKAY STATUS LED6 LED7 FAULT CODES CONTROL BOARD PCB3 VDC 330 660 J4 1 C50 C51 CURRENT 013333 013333 TIMING DIAGRAM 109079 109183 IGBT MODULE Q2 109179 2 109187 2 BULK CAPS 014252 014251 POWER XFR T2 041652 041650 POWER BOARD PCB2 109175 109174 INPUT BRIDGE D18 003193 003202 CIRCUIT BREAKER S1 023519...

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