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Hypertherm powermax900, Service Manual

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Hypertherm powermax900 Service Manual Download Page 68

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ARTS

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IST

 - 208/240/480V

Service Manual

RECOMMENDED SPARE PARTS - POWERMAX900- 208/240/480V

Part Number

Description

     Page Reference

003078 ............................... Relay:30A NO Mag Blwt QDisc Term ........................................... 4-5
129068 ............................... Circuit Breaker SA:4Pole 480V W/TC .......................................... 4-9
128405 ............................... Contactor Replacement:Powermax800/900 ................................. 4-9
008809 ............................... Fuse:1A 600V 13/32X1-1/2Slo (2) ................................................ 4-4
014207 ............................... Xfmr:Powermax800/900 208-240-480 Control ............................. 4-7
014228 ............................... Xfmr:Powermax900 208-240-480 Power ...................................... 4-7
014230 ............................... Inductor:Powermax900 0.8MH 55A .............................................. 4-7
023922 ............................... Cable w/Clamp:PMX800/900 Work 20' ........................................ 4-3
027080 ............................... Fan:225CFM 120VAC 50-60HZ ................................................... 4-7
005112 ............................... Pressure Switch:39 Psi .013 Orifice ............................................. 4-3
006110 ............................... Sol. Valve:100# 1/8FPT 24VAC 3W ............................................. 4-3
011072 ............................... Filter:20 Micron 1/8FPT ................................................................ 4-9
011079 ............................... Filter Element for 011072 Filter .................................................... 4-9
011073 ............................... Regulator:0-125 Psig 1/8FPT ....................................................... 4-3
022027 ............................... Press. Gauge:160# 1.5" 1/8CBM Panel ....................................... 4-3
029957 ............................... Heatsink SA:Powermax800/900 Power Unit ................................ 4-5
109018/008906 .................. Diode:600V 100A UFast Recovery Dual (2)

/Thermal Pad:AL-380-100 (2) ....................................................... 4-5

109019/008904 .................. Diode:1600V 100A 3PH Module/Thermal Pad:AL-340-180 ......... 4-5
009849/008903 .................. Resistor:20-Ohm 50W 5% NON-IND (4)

/Thermal Pad: AL 197-114 (4) ...................................................... 4-5

009850/008902 .................. Resistor:20-Ohm 25W 5% NON-IND (4)

/Thermal Pad:AL 103-108 (4) ....................................................... 4-5

029998/008905 .................. IGBT Gate Drive SA:Powermax800/900 (2)

/Thermal Pad:AL-370-134 (2) ........................................................ 4-5

041668 ............................... PCB Assy:Powermax900 Micro Control ....................................... 4-5
041532 ............................... PCB Assy:Powermax800/900-ZB Power ...................................... 4-5, 4-7
129114 ............................... Cord/Plug:42 1Phase 8-3SO 3Prong 7'3" ..................................... 4-9
029674 ............................... MOV/Cap Assy:MAX42/43/70 3PH .............................................. 4-5
028908 ............................... Kit:Powermax800/900 Cooling Fan Filter ..................................... 4-7

9-99

Summary of Contents for powermax900

Page 1: ...EN50199 EN50192 Plasma Arc Cutting System Service Manual 803150 Revision 3 ...

Page 2: ...ial number 900 010000 Revision 3 June 2000 Copyright 2000 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 http www hypertherm com email info hypertherm com ...

Page 3: ...90 Hypertherm UK Ltd 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 France 15 Impasse des Rosiers 95610 Eragny France Tel 33 1 30 37 15 28 Fax 33 1 30 37 15 79 Hypertherm S r L Via Torino 2 20123 Milan Italy Tel 39 02 725 46 312 Customer Service Tel 39 02 725 46 314 Technical Service Fax 39 02 725 46 400 All Departments Hypertherm B V Burg Have...

Page 4: ... 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 enclosure Maintenance of Cutting Equipment The cutting equipment must be routinely maintained accordin...

Page 5: ...by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in co...

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

Page 7: ...ORCH PARTS REMOVAL AND REPLACEMENT 3 26 Torch Main Body Removal and Replacement 3 26 Torch Switch Removal and Replacement 3 27 PAC125M TORCH PARTS REMOVAL AND REPLACEMENT 3 28 Removal 3 28 Replacement 3 28 QUICK DISCONNECT O RING REMOVAL AND REPLACEMENT 3 30 Section 4 PARTS LIST 208 240 480V 4 1 POWER SUPPLY 208 240 480V 4 2 Front 4 2 Top and Right Side 4 4 Bottom and Left Side 4 6 Rear 4 8 Powerm...

Page 8: ... Torch Assembly and 14 ft 4 3 m Lead 083069 w pigtail 083073 no pigtail 7 3 PAC125M Torch Assembly and 25 ft 7 6 m Lead 083068 w pigtail 083072 no pigtail 7 3 PAC125M Torch Assembly and 35 ft 10 6 m Lead 083070 w pigtail 083074 no pigtail 7 3 PAC125M Torch Assembly and 50 ft 15 2 m Lead 083071 w pigtail 083075 no pigtail 7 3 Consumable Parts Kits 7 4 Consumable Spare Parts Kit CE 128289 7 4 Consum...

Page 9: ...TABLE OF CONTENTS Service Manual vi ...

Page 10: ...e or Explosion 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 ...

Page 11: ... OR EXPLOSION 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 p...

Page 12: ...y and 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...

Page 13: ...her surfaces 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 conne...

Page 14: ...ne side 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 A...

Page 15: ...SAFETY 1 6 Hypertherm Plasma Systems 8 99 ...

Page 16: ...TRIQUES 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 PEUVENT EXPLOSER EN CAS DE DOMMAGES 1a 5 LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUD...

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: ...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 19: ...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 20: ...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 21: ...SÉCURITÉ 1a 6 08 99 HYPERTHERM Systèmes plasma ...

Page 22: ...wer Supply 2 3 PAC125 Torches 2 4 PAC125T Hand Torch Assembly 2 4 PAC125M Machine Torch Assembly 2 4 S Mark 2 5 Setup Specifications 2 5 Power Cord Plugs 2 5 Power Cords 2 5 208 240 480 600V Power Supplies 2 5 200 230 400V Power Supplies 2 5 Power Requirements 2 6 Section 2 SPECIFICATIONS ...

Page 23: ...d as long as it is clean dry and oil free When properly set and maintained the pressure regulator and gas filter on the power supply ensure that the correct pressure and flow rate is supplied to the system at the proper quantity and quality The Powermax900 can also cut with nitrogen when extended electrode life is a priority This service manual provides information for qualified service technician...

Page 24: ...ted in an ambient temperature above 86 F 30 C may show some decrease in duty cycle Apparent Input Power S1 12 5kVA U1 I1 Input Voltage U1 Input Current I1 6 6 kw Output 208V 55A 240V 47A 480V 28A 1φ 50 60 Hz 208V 32A 240V 28A 480V 15A 3φ 50 60 Hz 200V 57A 230V 50A 400V 33A 1φ 50 60 Hz 200V 33A 230V 29A 400V 18A 3φ 50 60 Hz 230V CE 29A 400V CE 18A 3φ 50 60 Hz 600V 12A 3φ 60 Hz Dimensions and Weight...

Page 25: ...ting 70 psi 4 8 bar flowing PAC125 TORCHES Maximum 55A Cutting Capacity PAC125T 7 8 22 mm 50 duty cycle Maximum 55A Cutting Capacity PAC125M 1 2 13 mm 50 duty cycle Maximum 39A Cutting Capacity PAC125M 3 8 9 5 mm 100 duty cycle Maximum current at 50 duty cycle 55 amps Gouging Capability metal removal rate 6 3 pounds 2 9 kg hr Weight PAC125T 4 5 pounds 2 kg with 25 ft 7 6 m lead 7 pounds 3 2 kg wit...

Page 26: ...he input current used to determine the cord size is I1eff In the U S use a 3 conductor SO type cord for single phase and a 4 conductor SO type cord for three phase power supplies In other countries use cords that are certified by national or local codes Prepare the power cord wires as shown in Fig 2 5 for non CE power supplies or Fig 2 6 for CE power supplies Note that all 4 wires must loop throug...

Page 27: ...e power supply and should be easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses Use slow blow fuses according to the power requirements listed below Input Input Current Recommended Voltage Phase 6 6 kw Output Slow Blow Fuse Size 200 VAC 1 57 amps 70 amp 208 VAC 1 55 amps 70 amp 230 VAC 1 50 amps 70 amp 240 VAC 1 47 amps...

Page 28: ...Equipment 3 8 Troubleshooting Procedures 3 8 Visual Inspection External 3 8 Visual Inspection Internal 3 9 Resistance Checks 3 10 Powermax900 Troubleshooting Guide 3 13 Voltage Checks 3 18 Power Board 3 22 Control Board 3 24 Control Board LEDs 3 24 PAC125T Torch Parts Removal and Replacement 3 26 Torch Main Body Removal and Replacement 3 26 Torch Switch Removal and Replacement 3 27 PAC125M Torch P...

Page 29: ... bowl of the filter at the rear of the power supply drain the bowl and clean the filter element 1 Shut the gas supply off and disconnect the gas supply hose from the filter assembly before proceeding 2 Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl 3 Unscrew the filter bowl 4 Unscrew the filter element See Powermax900 Fi...

Page 30: ...the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate local or national safety procedures Cooling Air Filter 4 Clean the air filter with either soap and water or with low pressure compressed air 5 Replace the dry filter in the power unit with the wire mesh facing the fan 6 Replace and re fasten the power supply cover with t...

Page 31: ...inated indicates that the power supply temperature has exceeded operating limits Green GAS PRESSURE LED When illuminated indicates that the gas pressure is within operating limits GAS TEST Switch When pushed in allows the operator to view and adjust the pressure setting AMPS Output Adjustment Knob Adjusts output current between 20 and 55 amps Pressure Regulator Regulates input gas pressure to powe...

Page 32: ...s for 480V on the 208 240 480V units and for 400V on the 200 230 400V units The inverter links are located in the link box behind the rear panel at TB3 See Figs 3 4 3 5 3 6 The 400V CE power supply does not have a link box Figure 3 4 200V or 208V Configuration Figure 3 5 230V or 240V Configuration TB2 Black White TB3 1φ 1φ 3φ 3φ 3φ Red White Black TB2 Black White TB3 1φ 1φ 3φ 3φ 3φ Red White Black...

Page 33: ...tified by output diodes D2 and D3 The output circuitry consists of a current sensor CS4 and transfer sensor CS3 located on the control board pilot arc relay CR2 and output inductor L1 The feedback loop operates as follows The amp adjust pot P1 is first set to the desired value Current sensor CS4 measures the actual output current and compares it at the error amplifier with the user set current set...

Page 34: ...k air pressure Gas solenoid valve V1 opens to purge system and to allow setting of pressure Select cutting current with AMPS knob Power circuits ready Connect work cable to workpiece and position torch on workpiece Depress plasma start switch on hand torch or remote start switch for machine torch Pilot arc relay CR2 closes and pilot arc current starts Move torch to make cut Workpiece falls away af...

Page 35: ...cal Services at service hypertherm com Test Equipment Multimeter Troubleshooting Procedures Maintenance of the Powermax900 power supply consists of performing visual inspection and trouble shooting procedures Refer to the system wiring diagram when performing the checkout procedures To locate power supply components refer to Sections 4 5 or 6 Refer to Section 7 for torch components After the probl...

Page 36: ...y If questions or problems arise during servicing call the Hypertherm Tech nical Services department at 1 800 643 9878 WARNING SHOCK HAZARD Always turn off power and unplug cord from wall and wait 5 minutes before removing any cover of the power supply If power supply is directly connected to a line disconnect box place line discon nect switch to OFF position In the U S use a lock out tag out proc...

Page 37: ...ternal power supply wires attached and with the torch unplugged Perform Visual Inspection Internal before continuing in this section If your resistance values are 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 ...

Page 38: ... Diode Bridge e r i W m o r F d a e l r e t e m d a e l r e t e m d a e l r e t e m d a e l r e t e m d a e l r e t e m e r i W o T d a e l r e t e m d a e l r e t e m d a e l r e t e m d a e l r e t e m d a e l r e t e m e c n a t s i s e R s m h O g e M n i s m h O g e M n i s m h O g e M n i s m h O g e M n i s m h O g e M n i 4 1 8 2 3 E C V 0 0 4 n o 9 0 7 0 4 1 1 1 9 0 7 0 4 1 2 1 9 0 7 0 3 ...

Page 39: ...ubleshooting Before purchasing a major replacement component check with Hypertherm s Technical Service group at 1 800 643 9878 or the nearest Hypertherm repair facility Resistance Check 3 Fig 3 10 Across Output DIode Bridge Take 2 output diode bridge measurements First place the multimeter lead on wire 29 and the multimeter lead on wire 30 Next place the multimeter lead on wire 29 and the multimet...

Page 40: ...t t c e n n o c s i D 4 2 d a e l e h t f o d n e t c e n n o c s i d k c i u q e h t n o 8 d n a 2 s n i p n e e w t e b e c a l p n i s e l b a m u s n o c e h t h t i w t i u c r i c n e p o n a s i e r e h t f I y l b m e s s a s d a e l d n a h c r o t e h t e c a l p e r B C P l o r t n o c e h t e c a l p e R 5 2 s d n o c e s 0 1 5 r e t f a s p i r t r e k a e r B 3 n o i t a c i f i c e ...

Page 41: ...n i e h t t a h t y f i r e V 4 5 B C P l o r t n o c e h t e c a l p e r t c e r r o c s i D E L e r u s s e r P s a G 6 d e h s i u g n i t x e e r u s s e r p r i a t c e r r o c n I e h T r a b 8 2 i s p 0 4 e v o b a s i e g u a g e r u s s e r p r i a e h t t a h t y f i r e V 1 6 t c e r r o C e c n a m r o f r e p m u m i t p o r o f r a b 8 4 i s p 0 7 e b d l u o h s e r u s s e r p e c ...

Page 42: ...n o c y t r i d r o d e g a m a D 1 R C r o t c a t n o c e c a l p e r r o n a e l C 1 9 l o r t n o c e h t m o r f t u p t u o r e p o r p m I d r a o b 1 1 s n i p 4 J 7 5 6 5 s e r i w d r a o b l o r t n o c m o r f t u p t u o e h t t a h t y f i r e V 2 9 d r a o b l o r t n o c e h t e c a l p e r 4 J t a C A V 7 2 o n s i e r e h t f I C A V 7 2 s i 2 1 e r o f e b h c r o t e h t m o r ...

Page 43: ...e s s a h c r o t e c a l p e r c r a o n t u b w o l f r i A 4 1 e r u l i a f y a l e r c r a t o l i P g n i s o l c t o n s i y a l e r f I g n i s o l c s i y a l e r c r a t o l i p f i e e s o t k c e h C 1 4 1 y a l e r e h t o t d e i l p p u s s i C A V 0 2 1 d n a g n i t a n i m u l l i s i 3 D E L y f i r e v B C P l o r t n o c e c a l p e r d e t a n i m u l l i t o n s i 3 D E L f ...

Page 44: ... d e t r e s n i s i r o t c e n n o c n i p 3 e h t t a h t y f i r e V 2 6 1 e c n a t s i s e r e h t g n i r u s a e m y b r e t e m o i t n e t o p e h t k c e h C l l u f n i s e r i w w o l l e y k c a l b n e e w t e b s m h o 0 e b d l u o h s e c n a t s i s e R n o i t i s o p e s i w k c o l c r e t n u o c w o l l e y k c a l b n e e w t e b s m h o 0 3 2 y l e t a m i x o r p p a e b...

Page 45: ...ch the power supply on Connect the gas supply to the pressure regulator at the rear of the power supply Voltage Check 1 Figure 3 11 Voltage at Input of Input Diode Bridge The AC voltage between any 2 input wires will equal the line voltage on 3φ systems On 1φ systems the AC voltage between the top 2 input wires will equal the line voltage Voltage Checks SHOCK HAZARD See warnings on page 3 9 before...

Page 46: ...Voltage X 1 414 See Table 14 13 Figure 3 12 Voltage Check 2 Output of Input Diode Bridge Voltage Check 3 Figure 3 13 Voltage Across Power Board Capacitors taken at Q1 and Q2 See the table in Figure 3 13 to find the correct voltage readings across the power board capacitors Figure 3 13 Voltage Check 3 Across Power Board Capacitors Line Voltage Voltage across Wires 21 22 and 15 16 200VAC 280VDC 208V...

Page 47: ... output diode bridge when the torch arc is transferred to the workpiece Take this reading across the two bars spanning output diodes D2 and D3 wires 29 and 30 If the torch is not working the voltage will be approximately 300VDC for 5 seconds and then drop to 0VDC 29 30 140VDC Figure 3 14 Voltage Check 4 Output Voltage with Transferred Arc ...

Page 48: ...3 21 MAINTENANCE Service Manual Notes ...

Page 49: ...l volt meter since high voltages are present The following table lists the test points their descriptions and values Refer also to Figure 3 15 to locate test points Power Board Test Points t n i o P t s e T n o i t p i r c s e D e u l a V 3 E o t 1 E r e t r e v n i t f e l r e w o p e g a t l o v h g i H C D V 0 0 3 3 E o t 4 1 E r e t r e v n i t f e l r e w o p e g a t l o v h g i h f o f l a h...

Page 50: ... power supply and PC boards are subjected to dielectric and insula tion resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians Removal of the protective conformal coatings and other unauthorized repairs to the PC boards will void the warranty If questions or problems arise during servicing call the Hypertherm Technical Services department at 1 ...

Page 51: ...cap has not engaged the cap sensor micro switch or There is an inverter imbalance or There is a micro controller failure LED5 blinking red There is an internal torch failure a short from electrode to START or CAP lines LED11 OVER TEMP LED Remains off when temperature is within operating limits It Illuminates when the thermostat in the power transformer T2 opens over 135 C 275 F or if the heatsink ...

Page 52: ...f if the torch blow back does not occur within 2 seconds Turns off the power supply when the retaining cap is loose or when line voltage is too high LED6 PLASMA START Illuminates when the torch start button is pushed or when start button is activated from the machine interface LED7 INVERTER ON Illuminates when the command to turn on the inverter modulator is given LED8 CURRENT Illuminates when cur...

Page 53: ...nnect wires by pulling on terminals Do not pull on wires 3 Disconnect the two lead terminals blue wire in each terminal from the two wires of the cap sensor microswitch Fig 3 17 4 Disconnect the plunger wire from the torch main body by holding the plunger nut with a 1 4 6 mm wrench or nut driver and removing the plunger screw Fig 3 17 5 Disconnect the torch main body and torch lead gas fittings us...

Page 54: ... and disconnect the gas supply 2 Remove the 5 screws that secure the handle halves together 3 Remove the torch switch from the handle 4 Remove the torch switch by cutting the 2 splices at the torch lead violet wires 5 Replace the torch switch by crimping the switch wires and the violet wires from the torch lead together with the splices 6 Install the torch switch back into the handle Be certain th...

Page 55: ... current pin and receptacle connection Disconnect the pin from the receptacle Note for step 6 Disconnect wires by pulling on terminals Do not pull on wires 6 Remove the heat shrink from the cap sensor microswitch connectors blue wires from the lead and white wires from the microswitch to expose the terminals Disconnect the terminals 7 Disconnect the torch main body and torch lead gas fitting using...

Page 56: ...eptacle Slide the heat shrink over the pin receptacle connection and apply heat 6 Loop the high current wire next to the torch lead and secure with 2 plastic ties Be certain that there is slack between the high current wire and the torch lead gas fitting 7 Slide the positioning sleeve back down over the torch lead and screw it into the torch sleeve Be certain not to pinch any wires when screwing s...

Page 57: ...e or wear proceed as follows and refer to Figure 3 20 1 Turn the Powermax900 power switch OFF 0 2 Unplug the power cable or set line disconnect switch to off and disconnect gas supply 3 Unscrew and remove the torch lead quick disconnect plug from the receptacle on the power supply 4 Remove the O ring from the quick disconnect as shown in Figure 3 20 using needle nose pliers tweezers etc 5 Replace ...

Page 58: ...r Supply 208 240 480V Front 4 2 Top and Right Side 4 4 Bottom and Left Side 4 6 Rear 4 8 Powermax900 Field Upgrade Kits and Optional Parts 4 10 Power Supplies 208 240 480V 4 10 Recommended Spare Parts Powermax900 208 240 480V 4 11 Section 4 PARTS LIST 208 240 480V ...

Page 59: ... PS1 1 6 006110 Sol Valve 100 1 8FPT 24VAC 3W V1 1 7 011073 Regulator 0 125 Psig 1 8FPT 1 8 022027 Press Gauge 160 1 5 1 8CBM Panel 1 129356 Harness PMX900 Power Unit 1 9 129325 Recept SA PMX900 Pwr Unit Quick Disc 1 10 129389 Current Control Assy PMX900 1 Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in ...

Page 60: ...4 3 PARTS LIST 208 240 480V Service Manual Figure 4 1 Powermax900 208 240 480V Front 1 2 3 5 6 7 4 8 9 POWER SUPPLY 208 240 480V Front 10 ...

Page 61: ...1 10 014137 Current Sense Transformer 40A CS1 1 11 014137 Current Sense Transformer 40A CS2 1 12 008809 Fuse 1A 600V 13 32 X 1 1 2 Slo F1 F2 2 13 029978 Heatsink SA Powermax800 900 PA Cont PCB Q3 14 041486 PCB Assy Powermax800 900 PA Cont 128241 Kit Powermax900 Machine Interface 208 240 480V 15 041494 PCB Assy Powermax800 900 Machine Interface Notes Bold part numbers and descriptions are subassemb...

Page 62: ...4 5 PARTS LIST 208 240 480V Service Manual Figure 4 2 Powermax900 208 240 480V Top and Right Side POWER SUPPLY 208 240 480V Top and Right Side 1 2 4 5 6 7 8 9 10 11 12 13 14 15 3 9 99 ...

Page 63: ...00 ZB Power 1 029978 Heatsink SA Pwrmx800 900 PA Cont PCB Q3 6 004673 Heatsink Powermax800 900 PA Cont 7 028908 Kit Powermax800 900 Cooling Fan Filter Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Available only on power supplies with the pilot arc control...

Page 64: ...4 7 PARTS LIST 208 240 480V Service Manual Figure 4 3 Powermax900 208 240 480V Bottom and Left Side 1 5 6 3 7 2 4 POWER SUPPLY 208 240 480V Bottom and Left Side ...

Page 65: ...max900 208 240 480V 1 7 001660 Panel Powermax900 Power Cord 1 8 008228 Cord Grip 1NPT 690 990 2Screws 1 9 129114 Power Cord SA Powermax800 900 1 10 123099 Cable Powermax800 900 Machine Interface Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Use 129332 to o...

Page 66: ...4 9 PARTS LIST 208 240 480V Service Manual Figure 4 4 Powermax900 208 240 480V Rear 1 2 3 5 4 6 9 7 8 10 POWER SUPPLY 208 240 480V Rear 5 99 ...

Page 67: ...n Off Pendant with Lead 75 ft 23 m 128316 Kit Powermax900 Power Unit Wheels 128317 Kit Powermax900 Pilot Arc Controller 128241 Kit Powermax900 Machine Interface 208 240 480V 028907 Work Cable 50 ft 15 2 m 028908 Kit Powermax900 Cooling Air Filter 011079 Filter Element 129019 Jumper Powermax900 Link Box 128312 Kit Powermax900 600V Conversion 008809 Fuse 1A 600V 13 32 X 1 1 2 Slo 023206 Cable Machin...

Page 68: ...72 Filter 20 Micron 1 8FPT 4 9 011079 Filter Element for 011072 Filter 4 9 011073 Regulator 0 125 Psig 1 8FPT 4 3 022027 Press Gauge 160 1 5 1 8CBM Panel 4 3 029957 Heatsink SA Powermax800 900 Power Unit 4 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 4 5 109019 008904 Diode 1600V 100A 3PH Module Thermal Pad AL 340 180 4 5 009849 008903 Resistor 20 Ohm 50W 5 NON IN...

Page 69: ...4 12 Service Manual PARTS LIST 208 240 480V ...

Page 70: ...Supply 200 230 400V 5 2 Front 5 2 Top and Right Side 5 4 Bottom and Left Side 5 6 Rear 5 8 Powermax900 Field Upgrade Kits and Optional Parts 5 10 Power Supplies 200 230 400V 5 10 Recommended Spare Parts Powermax900 200 230 400V 5 11 Section 5 PARTS LIST 200 230 400V ...

Page 71: ... PS1 1 6 006110 Sol Valve 100 1 8FPT 24VAC 3W V1 1 7 011073 Regulator 0 125 Psig 1 8FPT 1 8 022027 Press Gauge 160 1 5 1 8CBM Panel 1 129356 Harness PMX900 Power Unit 1 9 129325 Recept SA PMX900 Pwr Unit Quick Disc 1 10 129389 Current Control Assy PMX900 1 Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in ...

Page 72: ...5 3 PARTS LIST 200 230 400V Service Manual Figure 5 1 Powermax900 200 230 400V Front 1 2 3 5 6 7 4 8 9 POWER SUPPLY 200 230 400V Front 10 ...

Page 73: ...r 1 10 014137 Current Sense Transformer 40A CS1 1 11 014137 Current Sense Transformer 40A CS2 1 12 008958 Fuse 1A 500V 10mmX38mm Slo F1 F2 2 13 029978 Heatsink SA Powermax800 900 PA Cont PCB Q3 14 041486 PCB Assy Powermax800 900 PA Cont 128242 Kit Powermax900 Machine Interface 200 230 400V 15 041494 PCB Assy Powermax800 900 Machine Interface Notes Bold part numbers and descriptions are subassembli...

Page 74: ...5 5 PARTS LIST 200 230 400V Service Manual Figure 5 2 Powermax900 200 230 400V Top and Right Side 1 2 4 5 6 7 8 9 10 11 12 13 14 15 POWER SUPPLY 200 230 400V Top and Right Side 3 9 99 ...

Page 75: ...0 ZB Power 1 029978 Heatsink SA Pwrmx800 900 PA Cont PCB Q3 6 004673 Heatsink Powermax800 900 PA Cont 7 028908 Kit Powermax800 900 Cooling Fan Filter Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Available only on power supplies with the pilot arc control ...

Page 76: ...5 7 PARTS LIST 200 230 400V Service Manual Figure 5 3 Powermax900 200 230 400V Bottom and Left Side 1 5 6 3 7 2 4 POWER SUPPLY 200 230 400V Bottom and Left Side ...

Page 77: ...900 200 230 400V 1 7 001660 Panel Powermax900 Power Cord 1 8 008228 Cord Grip 1NPT 690 990 2Screws 1 9 129115 Power Cord SA Powermax800 900 200V 1 10 123099 Cable Powermax800 900 Machine Interface Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Use 129333 to...

Page 78: ...5 9 PARTS LIST 200 230 400V Service Manual Figure 5 4 Powermax900 200 230 400V Rear 1 2 3 5 4 6 9 7 8 10 POWER SUPPLY 200 230 400V Rear 5 99 ...

Page 79: ...Optional Parts Part Number Description 028714 On Off Pendant with Lead 25 ft 7 6 m Also comes standard with most machine torch system configurations See note below 128061 On Off Pendant with Lead 50 ft 15 2 m 128062 On Off Pendant with Lead 75 ft 23 m 128316 Kit Powermax900 Power Unit Wheels 128317 Kit Powermax900 Pilot Arc Controller 128242 Kit Powermax900 Machine Interface 200 230 400V 028907 Wo...

Page 80: ... 3 011072 Filter 20 Micron 1 8FPT 5 9 011079 Filter Element for 011072 Filter 5 9 011073 Regulator 0 125 Psig 1 8FPT 5 3 022027 Press Gauge 160 1 5 1 8CBM Panel 5 3 029957 Heatsink SA Powermax800 900 Power Unit 5 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 5 5 109019 008904 Diode 1600V 100A 3PH Module Thermal Pad AL 340 180 5 5 009849 008903 Resistor 20 Ohm 50W 5...

Page 81: ...5 12 Service Manual PARTS LIST 200 230 400V ...

Page 82: ...n Power Supply 400V CE 6 2 Front 6 2 Top and Right Side 6 4 Bottom and Left Side 6 6 Rear 6 8 Powermax900 Field Upgrade Kits and Optional Parts 6 10 Power Supplies 400V CE 6 10 Recommended Spare Parts Powermax900 400V CE 6 11 Section 6 PARTS LIST 400V CE ...

Page 83: ... 006110 Sol Valve 100 1 8FPT 24VAC 3W V1 1 7 011073 Regulator 0 125 Psig 1 8FPT 1 8 022027 Press Gauge 160 1 5 1 8CBM Panel 1 129356 Harness PMX900 Power Unit 1 9 129325 Recept SA PMX900 Pwr Unit Quick Disc 1 10 129389 Current Control Assy PMX900 1 Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power su...

Page 84: ...6 3 PARTS LIST 400V CE Service Manual Figure 6 1 Powermax900 400V CE Front POWER SUPPLY 400V CE Front 1 2 3 5 6 7 4 17 8 9 10 ...

Page 85: ... 40A CS1 1 10 014137 Current Sense Transformer 40A CS2 1 11 008958 Fuse 1A 500V 10mmX38mm Slo F1 F2 2 12 008959 Fuse 20A 500V 10mmX38mm Slo 3 13 029978 Heatsink SA Pwrmx800 900 PA Cont PCB Q3 14 041486 PCB Assy Pwermax800 900 PA Cont 128286 Kit Powermax900 Machine Interface 400V CE 15 041494 PCB Assy Powermax800 900 Machine Interface Notes Bold part numbers and descriptions are subassemblies Inden...

Page 86: ...6 5 PARTS LIST 400V CE Service Manual Figure 6 2 Powermax900 400V CE Top and Right Side 14 15 3 POWER SUPPLY 400V CE Top and Right Side 1 4 5 6 7 8 9 11 12 2 13 10 9 99 ...

Page 87: ...nk SA Pwrmx800 900 PA Cont PCB Q3 6 004673 Heatsink Powermax800 900 PA Cont 7 028908 Kit Powermax800 Cooling Fan Filter 8 129100 Capacitor SA Powermax800 900 CE 1 Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only Available only on power supplies with the pilot...

Page 88: ...6 7 PARTS LIST 400V CE Service Manual Figure 6 3 Powermax900 400V CE Bottom and Left Side POWER SUPPLY 400V CE Bottom and Left Side 1 4 5 6 3 7 2 8 ...

Page 89: ...00 Power Cord EMI 1 8 008782 Strain Relief 3 4NPT 375 500 1 109068 Toroid Powermax1100 900 1 9 129376 Power Cord SA PMX900 CE 200 230 1 10 041505 PCB Assy Powermax800 900 CE Line Filter 1 11 123099 Cable Powermax800 Machine Interface Notes Bold part numbers and descriptions are subassemblies Indented normal type items are components of subassemblies All mounting hardware in power supply drawings s...

Page 90: ...6 9 PARTS LIST 400V CE Service Manual Figure 6 4 Powermax900 400V CE Rear POWER SUPPLY 400V CE Rear 1 3 2 5 4 6 8 9 10 7 11 5 99 ...

Page 91: ...r 011079 Filter Element 129019 Jumper Powermax900 Link Box 008958 Fuse 1A 500V 10mm X 38mm Slo 023206 Cable Machine Interface 25 ft 7 6 m Comes standard with machine torch system configurations and with machine interface kits 024548 Leather Cable Covers 25 ft 7 6 m 109068 Toroid Used only on 400V CE power supply linecord assemblies POWER SUPPLIES 400V CE 3φ 50 HZ Part For With Pilot Arc With Machi...

Page 92: ...AC 3W 6 3 011072 Filter 20 Micron 1 8FPT 6 9 011079 Filter Element for 011072 Filter 6 9 011073 Regulator 0 125 Psig 1 8FPT 6 3 022027 Press Gauge 160 1 5 1 8CBM Panel 6 3 129046 Heatsink SA Powermax800 900 CE Power Unit 6 5 109018 008906 Diode 600V 100A UFast Recovery Dual 2 Thermal Pad AL 380 100 2 6 5 109043 008947 Diode 1600V 30A 3PH Bridge Thermal Pad AL 315 114 6 5 009849 008903 Resistor 20 ...

Page 93: ...6 12 Service Manual PARTS LIST 400V CE ...

Page 94: ...LIST TORCH AND CONSUMABLES Service Manual In this section PAC125T Torch Assembly 7 2 PAC125M Torch Assembly 7 3 Consumable Parts Kits 7 4 Consumable Configurations 7 5 Section 7 PARTS LIST TORCHES AND CONSUMABLES ...

Page 95: ...7 Part Number Description 001288 Handle PAC121 125T 002244 Safety Trigger PAC121 125T 128284 Kit Switch Repair 120573 Electrode Air 120576 Ring Swirl 027254 Trigger Spring PAC121 125T 004764 Ring Gutcha 075339 Screws P S 4 X 1 2 PH RND S B 120577 Nozzle PAC125 55A Shield 120601 Shield PAC121T 120600 Cap Retaining 120570 Torch Main Body with Switch PAC125T 044016 O Ring BUNA 90 Duro 614X 070 129352...

Page 96: ...ail 14 ft 4 3 m 129342 Torch Lead no pigtail 25 ft 7 6 m 129344 Torch Lead no pigtail 35 ft 10 6 m 129345 Torch Lead no pigtail 50 ft 15 2 m 044009 Quick Disconnect O Ring not shown 027599 Snap Ring 120577 Nozzle PAC125 55A Shield 120602 Shield PAC121M Machine Torch 120600 Cap Retaining 120583 Torch Main Body w Switch PAC125M 044016 O Ring BUNA 90 Duro 614X 070 Note See page 7 4 for detail of cons...

Page 97: ...3 120574 Electrode Extended 3 120577 Nozzle 55A Shielded 3 120606 Nozzle 35A Extended 3 120602 Shield PAC125M Machine Torch 1 120303 Deflector 1 044016 O Ring 3 015152 Nipple 1 8 NPT QDisc Steel 1 015604 Reducer 1 4 FPT X 1 8 NPT Brass 1 027055 Lubricant Silicone 1 4 Oz Tube 1 Machine Consumable Spare Parts Kit 128288 Hand Consumable Spare Parts Kit 128287 Consumable Spare Parts Kit CE 128289 Part...

Page 98: ...76 PAC125 Torch Nozzle 120577 Retaining Cap 120600 Shielded Machine Torch 55A Cutting Shield 120602 Shield 120608 Nozzle 120607 Retaining Cap 120600 Shielded 55A Gouging Unshielded 55A Cutting Deflector 120303 Nozzle 120578 55A Retaining Cap 120600 Electrode 120574 Deflector 120303 Nozzle 120606 35A Retaining Cap 120600 Unshielded 35A Cutting Consumable Configurations In CE countries use unshielde...

Page 99: ...7 6 Service Manual PARTS LIST TORCH AND CONSUMABLES ...

Page 100: ...nual 8 1 WIRING DIAGRAMS Section 8 WIRING DIAGRAMS In this section Powermax900 Electrical Schematic 208 240 480V 8 2 Powermax900 Electrical Schematic 200 230 400V 8 3 Powermax900 Electrical Schematic 400V CE 8 4 ...

Page 101: ...8 2 E ELEC SCHEM PMX900 208 240 480V 013 3 326 1 OF 1 ...

Page 102: ...8 3 E ELEC SCHEM PMX900 200 230 400V 013 3 328 1 OF 1 ...

Page 103: ...8 4 E ELEC SCHEM PMX900 CE 400V 013 3 327 1 OF 1 ...

Page 104: ...e hydrogen buildup is to install an aeration manifold on the floor of the water table to replenish the oxygen content of the water Making an Aeration Manifold Figure a 1 Make an Aeration Manifold with two inch 50 mm PVC tubing with one inch 25 mm Distribution Lines connected to it Drill 1 8 inch 3 mm holes every six inches 150 mm in the distribution lines Cap the ends of the distribution lines and...

Page 105: ...uel Gas Systems for Welding and Cutting obtainable from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code obtainable from the National Fire Protection Associa tion 470 Atlantic Avenue Boston MA 02210 10 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 470 Atlantic Ave...

Page 106: ... C D V 8 3 e c a f r e t n i e n i h c a m t n e r r u c t i u c r i c t r o h s T O H 1 1 J l a n i m r e t 4 9 4 1 4 0 B C P 0 5 t a g n i s l u p e v a w f l a h k a e p C D s p m a i l l i m 2 3 z H 0 6 r o 4 9 4 1 4 0 e t a v i t c a o t d e r i u q e r t n e r r u c L A N G I S 2 1 J l a n i m r e t k a e p C D s p m a o r c i m 0 5 6 4 9 4 1 4 0 e t a v i t c a o t d e r i u q e r e g a t l...

Page 107: ... o c s s e n r a h r o l o c s s e n r a h r o l o c s s e n r a h r o l o c s s e n r a h e c a f r e t n i e n i h c a M 6 0 2 3 2 0 e l b a C 6 0 2 3 2 0 e l b a C 6 0 2 3 2 0 e l b a C 6 0 2 3 2 0 e l b a C 6 0 2 3 2 0 e l b a C r o l o c e r i w r o l o c e r i w r o l o c e r i w r o l o c e r i w r o l o c e r i w 1 1 J T O H T R A T S 3 t e k c o S d e R n e e r G 2 1 J L A N G I S T R A T...

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