User Manuals: Hypertherm Powermax 125 Plasma Cutter

Manuals and User Guides for Hypertherm Powermax 125 Plasma Cutter. We have 4 Hypertherm Powermax 125 Plasma Cutter manuals available for free PDF download: Service Manual, Field Service Bulletin

Hypertherm Powermax 125 Service Manual (317 pages)

Plasma Arc Cutting System

Brand: Hypertherm | Category: Welding System | Size: 18.11 MB

Table of Contents
7
Electromagnetic Compatibility (EMC

15
- Assessment of Area
  15
- Installation and Use
  15
- Introduction
  15
- Methods of Reducing Emissions
  15
  - Mains Supply
    15
- Cutting Cables
  16
  - Earthing of the Workpiece
    16
  - Equipotential Bonding
    16
- Maintenance of Cutting Equipment
  16
- Screening and Shielding
  16
- Attention
  17
- General
  17
Warranty

17
- Insurance
  18
- Liability Cap
  18
- Limitation of Liability
  18
- National and Local Codes
  18
- Patent Indemnity
  18
- Transfer of Rights
  18
Specifications

19
Contents

23
Power Supply Setup

29
Basic System Operations

39
- Controls and Indicators
  39
  - Rear Controls
    39
  - Front Controls and Leds
    40
    
    Leds
    40
    
    Selectors
    40
    
    Amperage Adjustment Knob
    41
    
    Operating Mode Switch
    41
    
    Status Screen
    41
    
    Fault Codes and Icons
    42
    
    Gas Pressure Indicators
    42
    
    System Status Icons
    42
    
    Powermax125 Service Manual
    43
  - Operating the Powermax
    44
    
    Connect the Electrical Power, Gas Supply, and Torch Lead
    44
    
    Attach the Work Lead to the Power Supply
    45
    
    Attach the Ground Clamp to the Workpiece
    46
    
    Turn on the System
    46
    
    Check the Indicators
    47
    
    Set the Operating Mode Switch
    47
    
    Adjusting the Current (Amperage)
    48
    
    Manually Adjusting the Gas Pressure
    48
  - Electrode End-Of-Life Detection Feature
    49
  - Understanding Duty-Cycle Limitations
    50
Hand Torch Setup

51
- Introduction
  51
- Consumable Life
  51
- Hand Torch Components
  52
Hand Cutting

57
- Using the Hand Torch
  57
- Operate the Safety Trigger
  58
- Hand Torch Cutting Guidelines
  58
- Start a Cut from the Edge of the Workpiece
  59
- Pierce a Workpiece
  60
- Gouge a Workpiece
  62
  - Gouge Profile
    63
  - Varying the Gouge Profile
    64
  - 125 A Gouging Profile Chart
    64
  - Common Hand-Cutting Faults
    66
Contents

67
Machine Torch Setup

67
Mechanized Cutting

99
- Connecting an Optional Remote-Start pendant
  99
- Connecting the Machine Interface Cable
  100
  - Machine Interface Pinout
    102
  - Setting the Five-Position Voltage Divider
    103
  - Accessing Raw Arc Voltage
    104
  - Connecting an Optional RS-485 Serial Interface Cable
    104
    
    Serial Port Cables
    105
  - Using the Machine Torch
    105
  - Setting up the Torch and Table
    105
  - Understand and Optimize Cut Quality
    105
    
    Cut or Bevel Angle
    106
    
    Dross
    106
  - Piercing a Workpiece Using the Machine Torch
    107
  - Common Machine-Cutting Faults
    107
Troubleshooting and System Tests

109
- Controls and Indicators
  109
  - Rear Panel
    109
  - Front Panel
    110
  - Status Screen
    110
  - Theory of Operation
    111
    
    400 V CE, 380 V CCC 3-Phase Power Supply Functional Description
    111
    
    480 V and 600 V CSA 3-Phase Power Supply Functional Description
    111
    
    Sequence of Operation
    112
  - Troubleshooting Preparation
    113
    
    Test Equipment
    113
    
    Troubleshooting Procedures and Sequence
    113
    
    External Inspection
    115
    
    Internal Inspection
    115
  - Initial Resistance Check
    115
    
    Check the Power Switch
    115
    
    Hypertherm IGBT Tester
    118
    
    IGBT Test Preparation
    119
    
    Indicator Leds and Device Tests
    119
    
    IGBT Device Test Using the Hypertherm Tester
    121
    
    Troubleshoot the Hypertherm IGBT Tester
    121
Contents

122
- IGBT Device Test Using a Non-Hypertherm Tester
  122
- Fault Codes
  128
  - Important Fault Icons
    128
  - Displaying the Service Screen
    128
  - Run a Gas Test
    130
  - Perform a Cold Restart
    131
  - Fault Codes and Solutions
    131
    
    Fault Code Format - 0-00-0
    131
    
    Fault Code Format - 0-Nn-N
    132
    
    Fault Code Format - 1-Nn-N
    138
    
    Fault Code Format - 2-Nn-N
    138
    
    Fault Code Format - 3-Nn-N
    139
    
    Torch-Related Faults - Continuity Check
    142
- Troubleshooting Guide
  143
- System Tests
  149
  - Test 1 - Voltage Input
    150
  - Test 2 - DC Power Bus
    152
    
    Resistance Check
    152
    
    Voltage Check
    152
    
    Test 3 - Output Diodes
    154
    
    Test 4 - Inverter Temperature Sensor
    154
    
    For Operational Fault Codes 0-40-2 and 0-40-3 or Power Board Faults 2-10-0 and 2-10-1
    155
    
    Test 5 - Flyback Circuit (DC Minor Voltages)
    156
    
    Test 6 - Torch Stuck Open/Torch Stuck Closed
    158
    
    Test 7 - Start Signal
    160
    
    Test 8 - Torch Cap Switch
    161
    
    Test 9 - Electronic Regulator
    162
    
    Test 10 - Pressure Sensor
    163
    
    Test 11 - Fan
    164
    
    Test 12 - aux Switch
    164
Power Supply Component Replacement

165
- Installing a Machine Interface Cable for Raw Arc Voltage
  166
- Disconnect the Power and Gas Supply
  166
- Replacing the Gas Filter Element
  167
- Replacing the Work Lead Connector
  169
- Installing the Optional Filter Kit
  170
- Replacing the Power Supply Cover
  172
- Replacing the Component Barrier
  173
- Replacing the End Panel Bracket
  174
- Powermax125 Service Manual
  175
- Replacing the Machine Interface Cable with Voltage Divider Board
  176
  - Set the Voltage Divider Board
    181
- Installing the Machine Interface Cable
  182
- Installing the RS-485 Serial Interface Cable
  183
- Replacing the Power Cord and Strain Relief
  190
- Replacing the Power Switch
  197
- Replacing the Control Board
  201
- Replacing the DSP Board
  203
- Replacing the Power Board
  205
- Replacing the Input Diode Bridge
  209
- Replacing the Output Diode Bridge
  210
- Replacing the Pilot Arc IGBT
  211
- Replacing the Inverter IGBT Module
  212
- Replacing the Snubber Resistor
  213
- Replacing the Thermal Sensor
  214
- Replacing the Fan Shroud
  216
- Replacing the Fan
  217
- Replacing the Pressure Transducer
  219
- Replacing the Pressure Switch
  221
- Replacing the Gas Filter Assembly
  223
- Replacing the Solenoid Valve
  225
- Replacing the Gas Tubing
  227
- Replacing the Bulk Capacitors
  229
- Replacing the Torch Quick Disconnect Receptacle
  231
- Replacing the Work Lead Receptacle
  236
- Replacing the Output Inductor
  238
- Replacing the Transformer
  244
- Replacing the PFC Inductor
  249
- Replacing the Front Panel
  252
- Replacing the Rear Panel
  257
Torch Component Replacement

265
- Disconnect the Power, Gas Supply, and Torch
  266
- Hand Torches
  267
  - Replacing the Handle
    269
  - Replacing the Trigger Assembly
    274
  - Replacing the Torch Body
    276
  - Replacing the Start Switch
    278
  - Replacing the Cap-Sensor Switch
    280
  - Replacing the Torch Lead
    281
Contents

284
- Machine Torches
  284
- Replacing the Quick Disconnect Housing
  291
Parts

293
- Power Supply Parts
  294
  - Exterior, Front
    294
  - Exterior, Rear
    295
  - Interior, Power Board Side
    297
    
    480 V, 600 V Csa
    297
    
    400 V Ce/380 V CCC
    298
    
    Interior, Fan Side
    299
    
    Interior, Heatsink Assembly
    300
- Duramax Hyamp 85° Hand Torch Replacement Parts
  301
- Duramax Hyamp 15° Hand Torch Replacement Parts
  302
- Hand Torch Consumables
  303
  - Drag Cutting
    303
  - Gouging
    303
  - Finecut
    303
- Duramax Hyamp 180° Full-Length Machine Torch Replacement Parts
  304
- Duramax Hyamp 180° Mini Machine Torch Replacement Parts
  305
- Machine Torch Consumables
  306
  - Shielded
    306
  - Gouging
    306
  - Finecut
    307
- Accessory Parts
  307
- Powermax125 Labels
  308
- Safety-Critical Parts
  310
  - Power Supply, Power Board Side
    310
  - Power Supply, Fan Side
    312
- Recommended Spare Parts
  313
Wiring Diagrams

315
- Powermax Generic Timing Chart
  316
- Powermax125 Schematic Diagram
  317

Hypertherm Powermax 125 Field Service Bulletin (40 pages)

Machine Interface Receptacle with Voltage Divider PCB

Brand: Hypertherm | Category: Welding System | Size: 5.57 MB

Hypertherm Powermax 125 Field Service Bulletin (20 pages)

Brand: Hypertherm | Category: Welding System | Size: 1.43 MB

Hypertherm Powermax 125 Field Service Bulletin (13 pages)

Wheel Kit Operation

Brand: Hypertherm | Category: Welding System | Size: 1.05 MB

Hypertherm Categories

Welding System Cutter Flashlight Industrial Equipment Controller

More Hypertherm Manuals

User Manuals: Hypertherm Powermax 125 Plasma Cutter

Hypertherm Powermax 125 Service Manual (317 pages)

Table of Contents

Electromagnetic Compatibility (EMC

Warranty

Specifications

Contents

Power Supply Setup

Basic System Operations

Hand Torch Setup

Hand Cutting

Contents

Machine Torch Setup

Mechanized Cutting

Troubleshooting and System Tests

Contents

Power Supply Component Replacement

Torch Component Replacement

Contents

Parts

Wiring Diagrams

Hypertherm Powermax 125 Field Service Bulletin (40 pages)

Hypertherm Powermax 125 Field Service Bulletin (20 pages)

Hypertherm Powermax 125 Field Service Bulletin (13 pages)

Related Products

Hypertherm Categories