Hypertherm POWERMAX900 Service Manual
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Hypertherm POWERMAX900 Service Manual

Plasma arc cutting system
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Table of Contents

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    • Section 1A Sécurité
    • Danger Avertissement Précaution
    • Identifier Les Consignes de Sécurité
    • Le Coupage Peut Provoquer un Incendie Ou Une Explosion
    • Suivre Les Instructions de Sécurité
    • Le Coupage Peut Produire des Vapeurs Toxiques
    • Les Chocs Électriques Peuvent Être Fatals
    • L'arc Plasma Peut Provoquer des Blessures Ou des Brûlures
    • Les Rayons de L'arc Peuvent Brûler Les Yeux Et la Peau
    • Mise À la Masse Et À la Terre
    • Les Bouteilles de Gaz Comprimé Peuvent Exploser en Cas de Dommages
    • Pacemakers Et Prothèses Auditives
    • Sécurité des Bouteilles de Gaz Comprimé

    • Specifications
      • Section 2 SPECIFICATIONS
      • Introduction
      • Specifications
      • Specifications
        • Power Supply
      • Pac125 Torches
        • PAC125T Hand Torch Assembly
        • PAC125M Machine Torch Assembly
      • S Mark
      • Setup Specifications
        • Power Cord Plugs
        • Power Cords
        • 208/240/480/600V Power Supplies
        • 200/230/400V Power Supplies
        • Power Requirements
        • Service Manual

    • Section 3 MAINTENANCE
      • Introduction
      • Routine Maintenance
        • Bowl Draining/Filter Element Cleaning
        • Removal, Cleaning and Replacement of the Cooling Air Filter
      • Controls and Indicators
      • Theory of Operation
        • General
        • Functional Description
      • Sequence of Operation
      • Troubleshooting
        • Test Equipment
        • Troubleshooting Procedures
        • Visual Inspection - External
        • Visual Inspection - Internal
        • Resistance Checks
        • Voltage Checks
        • Power Board Test Points
      • Power Board
      • Control Board
        • Control Board Leds
      • Pac125T Torch Parts Removal and Replacement
        • Torch Main Body Removal and Replacement
        • Torch Switch Removal and Replacement
      • Pac125M Torch Parts Removal and Replacement
        • Removal
        • Replacement
      • Quick Disconnect O-Ring Removal and Replacement

    • Parts List - 208/240/480V
      • Power Supply - 208/240/480V
        • Front
      • Power Supply - 208/240/480V Front
        • Top and Right Side
        • Bottom and Left Side
        • Rear
        • Powermax900 Field Upgrade Kits and Optional Parts
      • Power Supplies - 208/240/480V
      • Recommended Spare Parts - Powermax900- 208/240/480V

    • Parts List - 200/230/400V
      • Power Supply - 200/230/400V
        • Front
        • Top and Right Side
        • Bottom and Left Side
        • Rear
        • Powermax900 Field Upgrade Kits and Optional Parts
      • Power Supplies - 200/230/400V
      • Recommended Spare Parts - Powermax900- 200/230/400V
      • Power Supply - 400V Ce
        • Front
        • Top and Right Side
        • Bottom and Left Side
        • Rear
        • Powermax900 Field Upgrade Kits and Optional Parts
      • Power Supplies - 400V Ce, 3F, 50 Hz
      • Recommended Spare Parts - Powermax900 400V Ce

    • Section 7 PARTS LIST - TORCHES and CONSUMABLES
      • PAC125T Torch Assembly and 25 Ft (7.6 M) Lead - 083066
      • PAC125T Torch Assembly and 50 Ft (15.2 M) Lead - 083067
      • PAC125M Torch Assembly and 14 Ft (4.3 M) Lead - 083069 W/Pigtail, 083073 no Pigtail
      • PAC125M Torch Assembly and 25 Ft (7.6 M) Lead - 083068 W/Pigtail, 083072 no Pigtail
      • PAC125M Torch Assembly and 35 Ft (10.6 M) Lead - 083070 W/Pigtail, 083074 no Pigtail
      • PAC125M Torch Assembly and 50 Ft (15.2 M) Lead - 083071 W/Pigtail, 083075 no Pigtail
      • Consumable Parts Kits
      • Consumable Spare Parts Kit - CE (128289)
      • Consumable Configurations

    • Section 8 Wiring Diagrams

    • Appendix A AERATION MANIFOLD for PLASMA CUTTING ALUMINUM
      • Introduction
      • Making an Aeration Manifold - Figure

    • Appendixa

    • Appendix B
      • Standards Index

    • Appendixb

    • Appendix C
      • Machine Interface Specifications

    • Appendixc

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See also: Operator's Manual , Installation Manual
Plasma Arc
Cutting System
Service Manual
803150 - Revision 3
EN50199
EN50192
®

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  • Page 1 ® Plasma Arc Cutting System Service Manual 803150 - Revision 3 EN50199 EN50192...
  • Page 2 900-010000 Revision 3 June, 2000 Hypertherm, Inc. Hanover, NH http://www.hypertherm.com email:info@hypertherm.com © 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...
  • Page 3 Fax: 31 315 655 886 European Technical Support Organization (ETSO) Edisonstraat 12 3281 NC Numansdorp, The Netherlands Tel.: 00 800 4973 7843 (00 800 Hypertherm) – (toll-free Technical Service) Tel.: 31 186 659494 Fax: 31 186 659495 Japan Shinjuku Park Tower...

  • Page 4: Electromagnetic Compatibility

    Immunity of other equipment in the Equipotential Bonding environment. User shall ensure that Bonding of all metallic components in the Hypertherm's CE-marked equipment is other equipment being used in the cutting installation and adjacent to it built in compliance with standard environment is compatible.

  • Page 5: Warranty

    LIMITATION OF LIABILITY GENERAL In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or Hypertherm, Inc. warrants that its Products shall be free punitive damages (including but not limited to lost...

  • Page 6: Table Of Contents

    ABLE OF ONTENTS ELECTROMAGNETIC COMPATIBILITY ....................i WARRANTY ............................ii Section 1 Safety ....................1-1 RECOGNIZE SAFETY INFORMATION ..................... 1-2 FOLLOW SAFETY INSTRUCTIONS ....................1-2 CUTTING CAN CAUSE FIRE OR EXPLOSION ................1-2 ELECTRIC SHOCK CAN KILL ......................1-2 CUTTING CAN PRODUCE TOXIC FUMES ..................1-3 ARC RAYS CAN BURN EYES AND SKIN ..................
  • Page 7 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, 1F/3F, 60 HZ ................. 4-10 RECOMMENDED SPARE PARTS - POWERMAX900- 208/240/480V ........... 4-11 Section 5 PARTS LIST - 200/230/400V ..............
  • Page 8 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, 3F, 50 HZ ..................6-10 RECOMMENDED SPARE PARTS - POWERMAX900 400V CE ............ 6-11 Section 7 PARTS LIST - TORCHES AND CONSUMABLES ......
  • Page 9 ABLE OF ONTENTS Service Manual...

  • Page 10: Safety

    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 Hypertherm Plasma Systems 8-99...

  • Page 11: Recognize Safety Information

    Do not cut pressurized cylinders, pipes, or any table to eliminate the possibility of hydrogen deto- closed container. nation. Refer to the Appendix section of this manual • Do not cut containers that have held combustible for aeration manifold details. materials. Hypertherm Plasma Systems 8-99...

  • Page 12: Electric Shock Can Kill

    • Provide a disconnect switch close to the power grounding conductor first. supply with properly sized fuses. This switch allows • Each Hypertherm plasma system is designed to be the operator to turn off the power supply quickly in an used only with specific Hypertherm torches. Do not emergency situation.

  • Page 13: Arc Rays Can Burn Eyes And Skin

    Fasten the retaining nut tightly. Work Table Connect the work table to an earth • Tighten all electrical connections to avoid excessive ground, in accordance with appropriate national or local heating. electrical codes. Hypertherm Plasma Systems 8-99...

  • Page 14: Compressed Gas Equipment Safety

    Protection Association, 470 Atlantic Avenue, Boston, MA 02210 Hazardous Substances , American Welding Society 10. OSHA, Safety and Health Standards , 29FR 1910 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 U.S. Government Printing Office, Washington, D.C. 20402. Hypertherm Plasma Systems 8-99...
  • Page 15 AFETY Hypertherm Plasma Systems 8-99...

  • Page 16: Section 1A Sécurité

    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 PACEMAKERS ET PROTHÈSES AUDITIVES ..........1a-5 HYPERTHERM Systèmes plasma 1a-1 08/99...

  • Page 17: Identifier Les Consignes De Sécurité

    • Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 HYPERTHERM Systèmes plasma 08/99...

  • Page 18: Le Coupage Peut Produire Des Vapeurs Toxiques

    • Installer un sectionneur avec fusibles appropriés, à la prise de terre appropriée. proximité de la source de courant. Ce dispositif permet à • Chaque système plasma Hypertherm est conçu pour être l’opérateur d’arrêter rapidement la source de courant en utilisé uniquement avec des torches Hypertherm cas d’urgence.

  • Page 19: L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures

    Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 HYPERTHERM Systèmes plasma 08/99...

  • Page 20: Sécurité Des Bouteilles De Gaz Comprimé

    • Faire passer le faisceau de la torche le plus près possible du câble de retour. • Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. • Se tenir le plus loin possible de la source de courant. HYPERTHERM Systèmes plasma 1a-5 08/99...
  • Page 21 ÉCURITÉ 1a-6 HYPERTHERM Systèmes plasma 08/99...

  • Page 22: Specifications

    PECIFICATIONS Section 2 SPECIFICATIONS In this section: Introduction ...................... 2-2 Specifications ....................2-3 Power 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 ....................

  • Page 23: Introduction

    Powermax900 power supply provides constant-current output variable from 20 to 55 amps, for optimum performance on all thicknesses of metal up to 5/8" (16 mm) thick. At 55 amps, the Powermax900 can also cut metals up to 7/8" (22 mm) thick and will sever metals up to 1-1/8"...

  • Page 24: Specifications

    Width ................10.4" (260 mm) without wheels 15.3" (390 mm) with wheels Height ................19.6" (500 mm) without wheels 23.7" (620 mm) with wheels 27.7" (700 mm) for 600V power supply 10.4" 23.1" 19.6" Figure 2-2 Powermax900 Power Supply with Dimensions Service Manual 10-98...

  • Page 25: Pac125 Torches

    PECIFICATIONS Weight ................65 pounds (30 kg) without wheels 72 pounds (33 kg) with wheels 128 pounds (58 kg) for 600V and 230V-CE power supplies Gas Type ............... Air or Nitrogen Gas Quality, Air ............. Clean, dry, oil-free Gas Quality, Nitrogen ............ 99.995% pure Gas Inlet Pressure ............

  • Page 26: S Mark

    PECIFICATIONS S MARK The Powermax900 conforms to standard EN50192. The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. The hand torches must have shielded consumable parts to maintain S mark compliance.

  • Page 27: Power Requirements

    PECIFICATIONS 4.5" (114 mm) 4.75" (120 mm) 3.5" (89 mm) 3.75" (95 mm) 0.5" (13 mm) Ground All wires 1 turn Ground through 109068 toroid. Figure 2-5 Power Cord Preparation - Non-CE Figure 2-6 Power Cord Preparation - CE Power Requirements Line Voltage Disconnect Box Use a line disconnect box for each power supply.

  • Page 28: Section 3 Maintenance

    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 ......

  • Page 29: Introduction

    Figure 3-1 Filter Assembly 3. Unscrew the filter bowl. 4. Unscrew the filter element. See Powermax900 Field Upgrade Kits and Optional Parts in Section 4 for part number information. 5. Clean filter element with alcohol, then blow out with air from the inside of the filter element.

  • Page 30: Removal, Cleaning And Replacement Of The Cooling Air Filter

    3. Remove the cover, and remove the cooling air filter from the clips by sliding the filter to the left and then up - Fig. 3-2. See Powermax900 Field Upgrade Kits and Optional Parts in Section 4 for part number information.

  • Page 31: Controls And Indicators

    When illuminated green, indicates that the AC line voltage is within proper operating limits. If disabled, (white) or if illuminated or blinking any other color, see Basic Troubleshooting in Section 5 of Powermax900 Operator manual 803080. • Yellow TEMP LED When illuminated, indicates that the power supply temperature has exceeded operating limits.

  • Page 32: Theory Of Operation

    THEORY OF OPERATION General The Powermax900 is a multi-voltage, multi-phase power supply. The two inverter inputs are linked in parallel for 208 or 240V on the 208/240/480V units, and for 200 or 230V on the 200/230/400V units. The inverters are linked in series for 480V on the 208/240/480V units, and for 400V on the 200/230/ 400V units.

  • Page 33: Functional Description

    AINTENANCE Functional Description Refer to block diagram 3-7, and the system wiring diagram. See Parts List Sections 4, 5 or 6: to identify system components referenced in this description. AC power enters power switch S1 from terminal block TB1. The MOV and filter capacitor block MOV1 provides spike and noise suppression.

  • Page 34: Sequence Of Operation

    AINTENANCE SEQUENCE OF OPERATION Shaded boxes represent operator action. Clear boxes represent results from operator action. System off • Connect torch and lead assembly • Connect gas supply to filter-regulator on power unit • Apply power at line voltage disconnect box. •...

  • Page 35: Troubleshooting

    In addition to being technically qualified, technicians must perform all testing with safety in mind. If questions or problems arise during servicing, call the Hypertherm Technical Services Department at 1 800 643 9878, or email Technical Services at: - service@hypertherm.com.

  • Page 36: Visual Inspection - Internal

    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 Tech- nical Services department at 1-800-643-9878. Service Manual...

  • Page 37: Resistance Checks

    AINTENANCE 1. Set the Powermax900 power switch to O (off), unplug the power cord, and disconnect the gas supply. 2. Remove the cover of the power supply by removing the securing screws. 3. Visually inspect the inside of the power supply, especially on the side with the power board (see Figure 4-3).
  • Page 38 AINTENANCE Resistance Check #2 - Fig. 3-9 • Across Input DIode Bridge Take measurements placing the + multimeter lead to wire 14 or 13, and the – multimeter lead to all other wires. (32 on 400V CE) – ( – ( –...
  • Page 39 Note: In the Troubleshooting Guide are "best-guess" solutions. Study the system wiring diagram and understand the theory of operation before troubleshooting. Before purchasing a major replacement component, check with Hypertherm's Technical Service group at 1 800 643 9878 or the nearest Hypertherm repair facility.

  • Page 45: Voltage Checks

    AINTENANCE Voltage Checks SHOCK HAZARD - See warnings on page 3-9 before proceeding. Before switching on the power supply, perform Visual Checks - Internal, Resistance Checks and also review the warnings on page 3-9. • Verify that the torch is plugged into the power supply. •...
  • Page 46 AINTENANCE Voltage Check #2 - Figure 3-12 • Voltage at Output of Input Diode Bridge This DC voltage will approximately equal the line voltage X 1.414 - See table below. Line Voltage Output at Bridge ≈ 280VDC ≈ Line Voltage 200VAC ≈...
  • Page 47 AINTENANCE Voltage Check #4 - Figure 3-14 • Output Voltage With Transferred Arc The voltage is approximately 140VDC at the 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).
  • Page 48 AINTENANCE Notes Service Manual 3-21...

  • Page 49: Power Board Test Points

    Wait at least 5 minutes after turning the power supply off before handling the PC board or capacitors. If questions or problems arise during servicing, call Hypertherm Technical Services at 1-800-643-9878. Use extreme caution when taking the voltage readings on the back of the power PCB - see warning above.
  • Page 50 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 1-800-643-9878. E14 - YEL...

  • Page 51: Control Board

    AINTENANCE CONTROL BOARD Control Board LEDs Control Board LEDs Visible from the Powermax900 Front Panel • LED2 POWER ON: Illuminates when power is applied. • LED5 LINE VOLTAGE: Illuminates different colors for different conditions. • LED5 not illuminated (white) Extremely low AC line voltage or micro-controller failure.
  • Page 52 AINTENANCE • 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 current greater than 10 amps is detected in electrode circuit.

  • Page 53: Pac125T Torch Parts Removal And Replacement

    To remove and replace the torch main body, order the torch main body with cap-on sensor switch and refer to the following procedure and Figures 3-17 and 3-18. Set the Powermax900 power switch to O (off), unplug the power cable, and disconnect the gas supply. Disconnect the torch lead quick disconnect from the power supply.

  • Page 54: Torch Switch Removal And Replacement

    Figure 3-18. See Section 7 for a complete list of torch parts. 1. Ensure the Powermax900 power switch is positioned to O (off), unplug the power cable, and disconnect the gas supply.

  • Page 55: Pac125M Torch Parts Removal And Replacement

    See Section 7 for a complete list of the machine torch parts. Removal 1. Set the Powermax900 power switch to O (off), unplug the power cable, and disconnect the gas supply. Disconnect the torch lead quick disconnect from the power supply.
  • Page 56 AINTENANCE Torch Cap Sensor White Blue Main Body Microswitch Wires (2) Wires (2) Torch Torch Lead Torch Positioning Lead Snap Ring Terminals Gas Fitting Lead Sleeve Connector Loop these leads next High-Current Wire to the torch lead when reassembling Retaining Torch Sleeve Receptacle...

  • Page 57: Quick Disconnect O-Ring Removal And Replacement

    To remove and replace the O-ring in the event of damage 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.

  • Page 58: Parts List - 208/240/480V

    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 Service Manual...

  • Page 59: Power Supply - 208/240/480V

    Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only. See also Section 5 Parts List - 200/230/400V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual 2-99...
  • Page 60 - 208/240/480V ARTS POWER SUPPLY - 208/240/480V Front Figure 4-1 Powermax900 - 208/240/480V - Front Service Manual...

  • Page 61: Top And Right Side

    Available only on power supplies with the pilot arc control option ** Available only on power supplies with the machine interface option See also Section 5 Parts List - 200/230/400V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual 9-99...
  • Page 62 - 208/240/480V ARTS POWER SUPPLY - 208/240/480V Top and Right Side Figure 4-2 Powermax900 - 208/240/480V - Top and Right Side Service Manual 9-99...

  • Page 63: Bottom And Left Side

    Available only on power supplies with the pilot arc control option Available only as an option See also Section 5 Parts List - 200/230/400V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual...
  • Page 64 - 208/240/480V ARTS POWER SUPPLY - 208/240/480V Bottom and Left Side Figure 4-3 Powermax900 - 208/240/480V - Bottom and Left Side Service Manual...

  • Page 65: Rear

    Use 129332 to order power cord rear panel for 208/240/480V power supplies if you have the machine interface option. Available only with the machine interface option. See also Section 5 Parts List - 200/230/400V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual 5-99...
  • Page 66 - 208/240/480V ARTS POWER SUPPLY - 208/240/480V Rear Figure 4-4 Powermax900 - 208/240/480V - Rear Service Manual 5-99...

  • Page 67: Powermax900 Field Upgrade Kits And Optional Parts

    Machine 083078 Machine Notes: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations. See also Section 5 Parts List - 200/230/400V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies.

  • Page 68: Recommended Spare Parts - Powermax900- 208/240/480V

    /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 .......
  • Page 69 - 208/240/480V ARTS Service Manual 4-12...

  • Page 70: Parts List - 200/230/400V

    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 Service Manual...

  • Page 71: Power Supply - 200/230/400V

    Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only. See also Section 4 Parts List - 208/240/480V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual 2-99...
  • Page 72 - 200/230/400V ARTS POWER SUPPLY - 200/230/400V Front Figure 5-1 Powermax900 - 200/230/400V - Front Service Manual...

  • Page 73: Top And Right Side

    * Available only on power supplies with the pilot arc control option ** Available only on power supplies with the machine interface option See also Section 4 Parts List - 208/240/480V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual 9-99...
  • Page 74 - 200/230/400V ARTS POWER SUPPLY - 200/230/400V Top and Right Side Figure 5-2 Powermax900 - 200/230/400V - Top and Right Side Service Manual 9-99...

  • Page 75: Bottom And Left Side

    Available only on power supplies with the pilot arc control option Available only as an option See also Section 4 Parts List - 208/240/480V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual...
  • Page 76 - 200/230/400V ARTS POWER SUPPLY - 200/230/400V Bottom and Left Side Figure 5-3 Powermax900 - 200/230/400V - Bottom and Left Side Service Manual...

  • Page 77: Rear

    Use 129333 to order power cord rear panel for 200/230/400V power supplies if you have the machine interface option. Available only with the machine interface option. See also Section 4 Parts List - 208/240/480V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies. Service Manual 5-99...
  • Page 78 - 200/230/400V ARTS POWER SUPPLY - 200/230/400V Rear Figure 5-4 Powermax900 - 200/230/400V - Rear Service Manual 5-99...

  • Page 79: Powermax900 Field Upgrade Kits And Optional Parts

    Machine 083084 Machine Notes: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations. See also Section 4 Parts List - 208/240/480V, and Section 6 Parts List - 400V CE to identify parts for other Powermax900 power supplies.

  • Page 80: Recommended Spare Parts - Powermax900- 200/230/400V

    /Thermal Pad:AL 103-108 (4) ............5-5 029998/008905 ....IGBT Gate Drive SA:Powermax800/900 (2) /Thermal Pad:AL-370-134 (2) ............5-5 041668 ....... PCB Assy:Powermax900 Micro Control ........5-5 041532 ....... PCB Assy:Powermax800/900-ZB Power ........5-5, 5-7 129115 ....... Cord: 2.5mm PVC HD21/22 ............5-9 029674 .......
  • Page 81 - 200/230/400V ARTS Service Manual 5-12...
  • Page 82 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 Service Manual...

  • Page 83: Power Supply - 400V Ce

    Indented normal type items are components of subassemblies All mounting hardware in power supply drawings shown for reference only. See also Section 4 Parts List - 208/240/480V, and Section 5 Parts List - 200/230/400V to identify parts for other Powermax900 power supplies. Service Manual 2-99...
  • Page 84 - 400V CE ARTS POWER SUPPLY - 400V CE Front Figure 6-1 Powermax900 - 400V CE - Front Service Manual...

  • Page 85: Top And Right Side

    Available only on power supplies with the pilot arc control option ** Available only on power supplies with the machine interface option See also Section 4 Parts List - 208/240/480V, and Section 5 Parts List - 200/230/400V to identify parts for other Powermax900 power supplies. Service Manual 9-99...
  • Page 86 - 400V CE ARTS POWER SUPPLY - 400V CE Top and Right Side Figure 6-2 Powermax900 - 400V CE - Top and Right Side Service Manual 9-99...

  • Page 87: Bottom And Left Side

    Available only on power supplies with the pilot arc control option ** Available only as an option See also Section 4 Parts List - 208/240/480V, and Section 5 Parts List - 200/230/400V to identify parts for other Powermax900 power supplies. Service Manual...
  • Page 88 - 400V CE ARTS POWER SUPPLY - 400V CE Bottom and Left Side Figure 6-3 Powermax900 - 400V CE - Bottom and Left Side Service Manual...

  • Page 89: Rear

    ** Available only with the machine interface option *** Not shown in Figure 6-4 See also Section 4 Parts List - 208/240/480V, and Section 5 Parts List - 200/230/400V to identify parts for other Powermax900 power supplies. Service Manual 5-99...
  • Page 90 - 400V CE ARTS POWER SUPPLY - 400V CE Rear Figure 6-4 Powermax900 - 400V CE - Rear Service Manual 5-99...

  • Page 91: Powermax900 Field Upgrade Kits And Optional Parts

    Machine 083081 Machine Notes: Contact your distributor or call the nearest Hypertherm office for hand and machine torch system configurations. See also Section 4 Parts List - 208/240/480V, and Section 5 Parts List - 200/230/400V to identify parts for other Powermax900 power supplies.

  • Page 92: Recommended Spare Parts - Powermax900 400V Ce

    /Thermal Pad:AL-103-108 (4) ............. 6-5 029998/008905 ....IGBT Gate Drive SA:Powermax800/.900 (2) /Thermal Pad:AL-370-134 (2) ............. 6-5 041668 ....... PCB Assy:Powermax900 Micro Control ..........6-5 041532 ....... PCB Assy:Powermax800/900-ZB Power ........6-5, 6-7 129049 ....... Electric Line Filter SA:Powermax800/900-CE ........6-9 129376 .......
  • Page 93 - 400V CE ARTS Service Manual 6-12...

  • Page 94: Section 7 Parts List - Torches And Consumables

    ARTS ORCH AND ONSUMABLES Section 7 PARTS LIST - TORCHES AND CONSUMABLES In this section: PAC125T Torch Assembly ..............7-2 PAC125M Torch Assembly ..............7-3 Consumable Parts Kits ................ 7-4 Consumable Configurations ..............7-5 Service Manual...

  • Page 95: Pac125T Torch Assembly And 25 Ft (7.6 M) Lead - 083066

    ARTS ORCH AND ONSUMABLES PAC125T Torch Assembly and 25 ft (7.6 m) Lead - 083066 PAC125T Torch Assembly and 50 ft (15.2 m) Lead - 083067 Part Number Description 001288 ........Handle, PAC121/125T 002244 ........Safety Trigger, PAC121/125T 128284 ........Kit: Switch Repair 120573 ........

  • Page 96: Pac125M Torch Assembly And 14 Ft (4.3 M) Lead - 083069 W/Pigtail, 083073 No Pigtail

    Torch Sleeve O-Ring 120613 044016 On/Off Pendant (not part of machine torch assembly - See Powermax900 Field Upgrade Kits and Optional Parts in Pigtail Sections 4, 5 or 6 for part numbers) Figure 7-2 PAC125M Torch Assembly and Leads Service Manual...

  • Page 97: Consumable Parts Kits

    ARTS ORCH AND ONSUMABLES Consumable Parts Kits Hand Consumable Spare Parts Kit (128287) Part Number Description (Quantity) 001285 ....Box, Consumable Parts (1) 120573 ....Electrode (3) 120574 ....Electrode, Extended (1) 120577 ....Nozzle, 55A, Shielded (3) 120578 ....Nozzle, Pipe Saddle, Extended (1) 120607 ....

  • Page 98: Consumable Configurations

    ARTS ORCH AND ONSUMABLES Consumable Configurations Shield Swirl Ring Retaining Cap Nozzle Electrode PAC125 120601 120576 120600 120577 120573 Torch Shielded Hand Torch 55A Cutting Swirl Ring Shield Retaining Cap Electrode PAC125 Nozzle 120602 120576 120600 120577 120573 Torch Shielded Machine Torch 55A Cutting Swirl Ring...
  • Page 99 ARTS ORCH AND ONSUMABLES Service Manual...

  • Page 100: Section 8 Wiring Diagrams

    IRING IAGRAMS 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 Service Manual...
  • Page 101 ELEC SCHEM: PMX900 208–240–480V 013–3–326 1 OF 1...
  • Page 102 ELEC SCHEM: PMX900 200–230–400V 013–3–328 1 OF 1...
  • Page 103 ELEC SCHEM: PMX900–CE 400V 013–3–327 1 OF 1...

  • Page 104: Appendixa

    PPENDIX AERATION MANIFOLD FOR PLASMA CUTTING ALUMINUM Introduction When plasma arc cutting aluminum at the water table surface or below water, free hydrogen gas may be generated by the cutting process. The high temperature of the plasma process causes disassociation of oxygen and hydrogen from the water in the water table. The hot aluminum, which has a high affinity for oxygen, then combines with the oxygen leaving free hydrogen.

  • Page 105: Appendixb

    PPENDIX STANDARDS INDEX For further information concerning safety practices to be exercised with plasma arc cutting equipment, please refer to the following publications: ANSI Standard Z49.1, Safety in Welding and Cutting , obtainable from the American Welding Society, 550 LeJeune Road, P.O. Box 351020, Miami, FL 33135. NIOSH, Safety and Health in Arc Welding and Gas Welding and Cutting , obtainable from the Superinten- dent of Documents, U.S.

  • Page 106: Appendixc

    PPENDIX MACHINE INTERFACE SPECIFICATIONS See the following page for machine interface board and cable details. v l i o l l o l l µ t i c " " T - f l " " T - t r a i l - f l "...
  • Page 107 PPENDIX Machine Interface PCB 041494 o l l Green Black Black Machine Interface Cable 023206 Service Manual...

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