Hypertherm powermax 190c Service Manual Download

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Plasma Arc
Cutting System

Service Manual
803660 Revision 4

Summary of Contents for powermax 190c

Page 1: ...Plasma Arc Cutting System Service Manual 803660 Revision 4 ...

Page 2: ...n 4 June 2005 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2005 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 ...

Page 3: ... 841 2489 Technical Service Hypertherm Shanghai Consulting 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 15 Impasse des Rosiers 95610 Eragny France 00 800...

Page 4: ...nnection 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 the ris...

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: ... 1a 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Prévention des incendies Prévention des explosions 1a 2 Risque d explosion argon hydrogène et méthane 1a 2 Détonation de l hydrogène lors du coupage de l aluminium 1a 2 Les chocs électriques peuvent être fatals 1a 3 Prévention des chocs électriques 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer d...

Page 7: ...ntrols and Indicators 3 3 Theory of Operation 3 4 Troubleshooting 3 5 Test Equipment 3 5 Troubleshooting Procedures 3 5 Visual Inspection External 3 5 Visual Inspection Internal 3 6 Powermax190c Troubleshooting Guide 3 7 Section 4 PARTS LIST 4 1 Powermax190c 120V Power Supply 4 2 Powermax190c 230V Power Supply 4 3 PAC105 Torch Assembly and 20 ft 6 1 m Torch Lead 070065 4 4 Consumable O rings 4 5 C...

Page 8: ...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 9: ... 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 10: ... 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 11: ...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 12: ...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 13: ...cutting 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 fo...

Page 14: ...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 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: ...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 17: ...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 18: ...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 19: ... 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 4...

Page 20: ...ICATIONS In this section Introduction 2 2 Specifications 2 2 Power Supply 2 2 PAC105 Torch 2 3 IEC Symbols Used 2 4 Grounding Requirements 2 5 Power Cord Plugs 2 5 Power Hookup 2 6 System Circuit Recommendations 2 6 Extension Cord Recommendations 2 6 ...

Page 21: ...ed Output Current I2 12 amps Duty Cycle X at 104 F 40 C at rated output voltage U2 and at rated output current I2 using 20 amp service 35 U2 110 volts I2 12 amps See power supply data tag for more information on duty cycle Temperature Operating Range Power supplies will operate between 32 F 0 C and 104 F 40 C Input Voltage U1 Input Current I1max at 1 32 kw Output 120 VAC 20 3 amps 1 Ph 60 Hz Non C...

Page 22: ...C105 Torch Recommended Cutting Capacity 1 8 inch 3 mm 12A 35 duty cycle Maximum Cutting Capacity 3 16 inch 4 5 mm 12A 35 duty cycle Severance Cutting Capacity 1 4 inch 6 mm 12A 35 duty cycle Air Pressure and Flow rate 40 psi 2 8 bar 53 4 scfh 0 89 cfm 25 liters min Weight 3 pounds 1 4 kg Power Cord PAC105 Torch Work Lead ...

Page 23: ...ments with increased hazard of electrical shock Direct current DC Alternating current AC Plasma cutting torch AC input power connection The terminal for the external protective earthed conductor An inverter based power source Anode work clamp Temperature switch Pressure switch Plasma torch in the TEST position cooling and cutting gas exiting nozzle The power is on The power is off Volt amp curve ...

Page 24: ...e shipped without a plug on the power cord For the 230V machine obtain a plug that meets national or local electrical codes The plug should be connected to the power cord by a licensed electrician Also note that some 120V receptacles may require a plug that is different from the plug on the power cord To install the required plug refer to the figure below The installed 120V plug and cords must con...

Page 25: ... AWG 6 mm2 for up to 75 ft 23 m 8 AWG 10 mm2 for up to 140 ft 46 m 230V power supply 2 5 mm2 14 AWG for up to 23 m 75 ft 4 mm2 12 AWG for up to 46 m 140 ft Note Special installation may be required where gasoline or volatile liquids are present Consult national or local codes Plug power cord into a properly grounded wall receptacle Torch Work lead and clamp Power cord Power Hookup System Circuit R...

Page 26: ...aintenance 3 2 Before Each Use 3 2 Every Week 3 2 3 Months 3 2 6 Months 3 2 Controls and Indicators 3 3 Theory of Operation 3 4 Troubleshooting 3 5 Test Equipment 3 5 Troubleshooting Procedures 3 5 Visual Inspection External 3 5 Visual Inspection Internal 3 6 Powermax190c Troubleshooting Guide 3 7 ...

Page 27: ...formed more frequently Before Each Use Check the torch and consumables for wear See Inspecting and Replacing Consumable Parts in Section 4 of the Powermax190c Operator manual 803650 if necessary Every Week Check the torch cap on sensor system by listening for the micro switch to click when the retaining cap is loosened 3 Months Replace damaged or unreadable labels Replace any cracked parts Check t...

Page 28: ...turned on before operation can begin 2 The power supply overheats In this condition the fan will continue to run Wait 15 minutes for the unit to cool or until the FAULT lamp is extinguished 3 The input voltage is not within specification 120 VAC 20 or 230 VAC 20 After the input voltage has been corrected the power supply must be turned off and then turned on before operation can continue POWER ON ...

Page 29: ...GBT is controlled by a pulse width modulated signal set internally in the control circuitry on PC1 The control circuitry regulates the output current the air compressor and the safety circuits The output current is set internally in the control circuitry to 12 amps The air compressor operates during preflow cutting and post flow modes The compressor unit is set to output 40 psi 2 8 bar The safety ...

Page 30: ...x190c power supply consists of performing visual inspection and troubleshooting procedures Refer to the system wiring diagram when performing the troubleshooting procedures To locate power supply components refer to Section 4 After the problem has been located and repaired refer to the Powermax190c Operator Manual 803650 for proper operation Visual Inspection External 1 Inspect the outside of the ...

Page 31: ...board Do not in any way cut away or remove the protective conformal coating from the board To do so will risk a short between the AC input circuit to the output circuit and may cause serious injury or death The power supply and PC boards are subjected to dielectric and insulation resistance tests per applicable CSA and IEC standards for the safety of the operator and service technicians Removal of...

Page 32: ... e n 1 S d e l c y c e r e b o t s d e e n 1 S d e l c y c e r e b o t s d e e n 1 S d e l c y c e r e b o t s d e e n 1 S e t a r e p o o t r e d r o n i e t a r e p o o t r e d r o n i e t a r e p o o t r e d r o n i e t a r e p o o t r e d r o n i e t a r e p o o t r e d r o n i t c e r r o c s i e g a t l o v g n i m o c n i t a h t y f i r e V 3 1 t a h t y f i r e V T 2 d n a T 1 n e e w t e...

Page 33: ... T m o r f s e g a t l o v e r u s a e M 4 2 C A V 0 2 2 d n a 1 s n i p 1 C R C A V 0 2 6 d n a 3 s n i p 1 C R C A V 0 2 5 d n a 4 s n i p 1 C R C A V 4 2 2 d n a 1 s n i p 0 1 C R C A V 4 2 2 d n a 1 s n i p 0 1 C R f I 1 T e c a l p e r t n e s e r p t o n e r a s e g a t l o v l l a f I 1 C P e c a l p e r t n e s e r p e r a s e g a t l o v l l a r e g g i r t h c r o t y t l u a F h c t i w...

Page 34: ...l o v f I 2 d n a 1 s n i p 2 C R n i 0 0 0 0 1 r o s s e r p m o c e c a l p e r t n e s e r p t u b g n i r e t t u p s c r A 4 t u c o t s e u n i t n o c t u c o t s e u n i t n o c t u c o t s e u n i t n o c t u c o t s e u n i t n o c t u c o t s e u n i t n o c s d a e l h c r o t n i r e t a W t n e m n o r i v n e d i m u H o t e l b i s s o p s i t i l i t n u e t a r e p o o t e u n i ...

Page 35: ...f a n i t o n f I n o i t i d n o c t l u a f 1 C P d r a o b r e w o p e c a l p e r r i a d e t a e h r e v O r o s s e r p m o c t a e c n a t s i s e r k c e h c d n a F F O r e w o p n r u T 6 5 2 n a h t r e t a e r g f I 2 d n a 1 s n i p n e e w t e b 2 C R r e w o p n r u T d e t a e h r e v o s a h r o s s e r p m o c e h t r o f g n i n n u r n a f h t i w e l d i m e t s y s e v a e l ...

Page 36: ...s section Powermax190c 120V Power Supply 070068 4 2 Powermax190c 230V Power Supply 070070 4 3 PAC105 Torch Assembly and 20 ft 6 1 m Torch Lead 070065 4 4 Consumable O rings 4 5 Consumable Parts 4 5 Powermax190c Labels 4 6 Optional Parts 4 6 Powermax190c Systems 4 6 ...

Page 37: ... 1 5 060135 Relay Powermax190c CR1 1 6 060138 Linecord Powermax190c 120V 1 7 060134 Shock Absorber Powermax190c 3 8 060131 Compressor AC1 1 9 011088 Filter Powermax190c Compressor 1 8 NPT 1 10 060144 PCB Assy Powermax190c 120V PC1 1 060155 Thermostat PMX190C 120V NC 180F 1 11 070065 PAC105 Hand Torch Assembly See page 4 4 1 12 060133 Cable with clamp Powermax190c work 1 13 060132 Switch Powermax19...

Page 38: ... 060135 Relay Powermax190c CR1 1 6 060145 Linecord Powermax190c 230V 1 7 060134 Shock Absorber Powermax190c 3 8 060131 Compressor AC1 1 9 011088 Filter Powermax190c Compressor 1 8 NPT 1 10 060144 PCB Assy Powermax190c 230V PC1 1 060154 Thermostat PMX190C 230V CE NC 195F 1 11 070065 PAC105 Hand Torch Assembly See page 4 4 1 12 060133 Cable with clamp Powermax190c work 1 13 060151 Switch Powermax190...

Page 39: ... 5 060135 Relay Powermax190c CR1 1 6 060138 Linecord Powermax190c 120V 1 7 060134 Shock Absorber Powermax190c 3 8 060215 Compressor AC1 1 9 128862 Compressor Cooling Coil 1 10 011088 Filter Powermax190c Compressor 1 8 NPT 1 11 060216 PCB Assy Powermax190c 120V PC1 1 060155 Thermostat PMX190C 120V NC 180F 1 12 070065 PAC105 Hand Torch Assembly See page 4 4 1 13 060133 Cable with clamp Powermax190c ...

Page 40: ...1 6 060145 Linecord Powermax190c 230V 1 7 060134 Shock Absorber Powermax190c 3 8 060215 Compressor AC1 1 9 128862 Compressor Cooling Coil 1 10 011088 Filter Powermax190c Compressor 1 8 NPT 1 11 060218 PCB Assy Powermax190c 230V PC1 1 060154 Thermostat PMX190C 230V CE NC 195F 1 12 070065 PAC105 Hand Torch Assembly See page 4 4 1 13 060133 Cable with clamp Powermax190c work 1 14 060151 Switch Powerm...

Page 41: ...r Assembly 4 120874 Torch Main Body with Switch PAC105 5 058503 O Ring VITON 625 X 070 6 075339 Screws 5 P S 4 X 1 2 PH RND S B 7 128883 Torch Lead Replacement Kit 20 ft 6 1 m 8 004764 Retaining Ring Gutcha 9 005202 Switch Torch Pushbutton 120880 Swirl Ring 120881 Electrode 120882 Nozzle 120898 Shielded Retaining Cap 120884 Shield See page 4 5 for consumable parts 1 2 3 4 5 6 7 8 9 1 ...

Page 42: ...d Retaining Cap 120884 Shield Swirl Ring O ring rear view 058012 Retaining Cap O ring 058010 Consumable O rings Unshielded Consumables For CE compliance do not use the unshielded consumables Shielded Consumables Nozzle 120882 Electrode 120881 Swirl Ring 120880 Shield 120884 Shielded Retaining Cap 120898 Retaining Cap 120883 Nozzle 120882 Electrode 120881 Swirl Ring 120880 ...

Page 43: ...1 PH 60 Hz with torch and 20ft 6 m torch lead S N 10 000 070786 230VAC 1 PH 50 60 Hz with torch and 20ft 6 m torch lead S N 10 000 Optional Parts Part Number Description 060133 Work lead with clamp 060138 Power cord Pmx190c 120V 060145 Power cord Pmx190c 230V 110291 230V Data label for 070069 110290 120V Data label for 070067 110253 110124 Powermax190c Labels 110459 230V Data label for 070786 1104...

Page 44: ...powermax190c Service Manual 5 1 2 00 Section 5 WIRING DIAGRAMS In this section Powermax190c 120V Wiring Diagram 5 2 Powermax190c 230V Wiring Diagram 5 3 Powermax190c 120 230 VAC Wiring Diagram 5 4 ...

Page 45: ...e service or maintenance work is complete In other countries follow appropriate national or local safety procedures Voltage Readings a Tolerance 10 unless specified b Reference to circuit common lead 43 unless noted V1 120 VAC V7 24 VAC V2 120 VAC V8 12 VDC V3 227 VAC V9 335 VDC open circuit voltage V4 V5 V6 20 VAC Figure 5 1 Powermax190c 120 VAC Wiring Diagram Power Supply 070067 Refer to Powerma...

Page 46: ...7 PLG7 RC8 PLG8 TEST RC9 PLG9 RC10 PLG10 RC11 PLG11 RC3 2 RC1 1 RC1 2 RC10 2 RC7 TP TP L CR CR R C C FM S WARNING SHOCK HAZARD Always turn off the power and unplug the cord or set the line disconnect switch to Off before servicing the unit or changing consumable parts In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate...

Page 47: ...ance work is complete In other countries follow appropriate national or local safety procedures Voltage Readings a Tolerance 10 unless specified b Reference to circuit common lead 43 unless noted V1 120 VAC V7 24 VAC V2 120 VAC V8 14 VDC V3 227 VAC V9 320 VDC OCV on 070784 V4 V5 V6 20 VAC V9 335 VDC OCV on 070786 Figure 5 3 Powermax190c 120 230 VAC Wiring Diagram Power Supplies 070784 and 070786 R...

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