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powermax600 - Air

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1. 480 VAC 330 VDC 230 and 400 400 H L _ 5 Lal F EE au T F L __ LB 600 25 9 w Figure 3 8 Voltage Check 4 Across Power Supply Capacitors powermax600 Service Manual 3 25 10 99 MAINTENANCE COMPONENT REPLACEMENT WARNING ELECTRIC SHOCK CAN KILL e Disconnect electrical power before performing any maintenance See warnings on page 3 6 before proceeding Power Cord Replacement Disconnect electrical power and gas supply before removing the old power cord Installation See Figure 3 10 Insert the new power cord through the strain relief Pass all 4 wires through the toroid as shown 230 and 400 volt only Install the power cord connections where shown Tighten the strain relief onto the power cord Install the power supply cover Reconnect electrical power and gas supply 230V and 400V BROWN BLUE BLACK oo gt RZEZ NOTE Toroid must
2. CAP SWITCH 480 086022 208 240V 086021 POWER BOARD PCB2 Bi K1 K2 51 E E M J Ba w3 W7 T WHT w2 CMT e P OUTPUT BRIDGE m Wit din We BLK wi 5 1 0 9 018 P 018 INPUT INPUT R SOVER BLK Wi w5 m BRIDGE pp CPN wa CONTROL 2140 vg TRANSFORMER gau pg D Ti 310 P1 3 E BRN 7 YEL 4 SYSTEM J13 009849 277 SUPPLY COMPA l 4140 20 COMINV A gt y itid 20 OHM C50 IX 6 O 20 OHM J5 er 4 48 W18 4 O 208 240V UNIT ONLY W14 TRIP e MOV 4 49 TRANSFER SENSOR 5 TURNS a Lidia J18 we TB1 w W17 WORK LEAD ZE J1 Q3 NOZZLE RED 108071 Z 1 T IGBT wig Fe ELECTRODE WHT OUTPUT CHOKE 2 5 014232 WHT TP1 3 4 PCB3 5 U1 042188 CONTROL BOARD 218 1018 6 s 14 GAS 7 4B 4 O 9 5B 5 12 SPARE START 8 7 6B Ho 7B 7C C POWER O 9 OUTA sl 2 19 5 LED6 LED7 LED8 Bou
3. CAP SWITCH O START wi4 WHT A WHT pa J7 gt J6 CIRCUIT o4 SOFT START IGBT 02 109070 n X MODULE W3 BLK W7 m J9 w10 m OUTPUT BRIDGE 3 PHASE BLU W6 R w R BOARD de 2 Wi BRN W5 P ws BRIDGE h CONTR L 2 1 iR i GND L BAN GRNYEL s 16 d oo PE EL 009849 77 SUPPLY COMPA 4 E 20 I 0O 18INV 009849 2 6 2 um m 230V UNIT ONLY ee RC TRIP MOV W15 99 FAULT CODES T 12 LEM LED7 LED6 STATUS NEM TRANSFER SENSOR we tme EN OFF OFF SYSTEM OKAY H 109160 M OFF ON SELF DIAGNOSTICS FAILURE S nnus BLINKING 1 SEC RATE INVERTER SAFETY INTERLOCK J1 K NOZZLE VISIBLE FOR 15 SEC AFTER EVENT 198971 ARC T 1 48 IGBT wig nm ELECTRODE ON ON TORCH STUCK OPEN E OUTPUT CHOKE VISIBLE FOR 15 SEC AFTER EVENT 7 5 WE 4 008924 4 P C B3 U11 042188 CONTROL BOARD 218 7 89m 6 2 2215 14 GAS 7 4148 4c 18 o START Er SPARE x4 7B 7 30 POWER 0 9 OUTA sly ue 5 LED6 LED7 1 8 T DUE 24 ULN2003A iur C O K 11 lt 50V R3 009994 CAPON 12 lt S U4 IT L
4. e CD c 0 PMX600 23 Q T Figure 3 6 Voltage Check 2 Output of Input Diode Bridge powermax600 Service Manual 3 23 10 99 MAINTENANCE Voltage Check 3 Figure 3 7 e Check voltage across IGBT module VDC Across Connections Line Voltage 230 VAC 400 VAC 208 240 VAC 480 VAC id 7 1 a B 0 J ran m Te de H LG Ne e o zt O wu y Lj 208 240V and 480V 480 1 J 8 5 4 Rb TT Se J 3 24 10 99 T w w E Figure 3 7 Voltage Check 3 Across IGBT Module powermax600 Service Manual MAINTENANCE Voltage Check 4 Figure 3 8 e Check voltage across power supply capacitors Line Voltage VDC Across Connections 230 VAC 290 VDC 400 VAC 290 VDC 208 240 VAC 165 165 VDC
5. 3 21 COMPONENT REPLACEMENT c cccesseccocessescscessesceccsssesecceceeseesasusensaseesneasenten 3 26 POWER CORD REPLACEMENT eene nnne 3 26 TORCH LEAD REPLACEMENT MODELS WITHOUT QUICK DISCONNECT 3 27 AIR FILTER ELEMENT REPLACEMENT sisi 3 28 WORK CABLE REPLACEMENT eene 3 30 CAPACITOR REPLACEMENT eene nnne nnne tnn 3 31 powermax600 Service Manual 3 1 10 99 MAINTENANCE CONTROLS AND INDICATORS Indicator Lamps FO Green POWER IS ON When illuminated indicates that AC voltage is supplied to the power supply and that the ON OFF switch is in the ON position Green SYSTEM READY When illuminated indicates that circuits are activated and that all fault conditions are clear none of the yellow lamps are illuminated Yellow LOW LINE VOLTAGE When illuminated indicates that the AC line voltage is 1 below operating limits or 2 is missing 1 phase 230V and 400V systems only Yellow LOW GAS PRESSURE When illuminated indicates that the incoming gas pressure is below ing limits Yellow TORCH PARTS ARE LOOSE OR REMOVED When illuminated indicates that the torch consumables are loose or not installed Yellow HIGH TEMPERATURE When illuminated indicates that the power supply temperature has ex ceeded operating limits Controls See Figure 3 1 Pressure ED SS OFF Pilot Arc Control Sw
6. 5 7 powermax600 Service Manual 5 1 11 99 PARTS LIST 208 240 480V POWER SUPPLY EXTERIOR AIR 8 BAR MAX 2 120 PSI MAX SS 4 2 5 Part Item Number Description Designator Qty 1 001669 Rear end panel 1 2 001668 Front end panel also order 110271 1 3 110271 Operation lable 1 4 129594 Power supply cover 1 5 008965 Knob 1 6 010287 Warning label 1 110276 Instruction label 1 8 110996 Pressure warning label 1 5 2 powermax600 Service Manual 10 99 PARTS LIST 208 240 480V POWER SUPPLY FRONT INTERIOR RIGHT SIDE EN LAY C LS A V sy A N f A f AN VU Number Description Designator Qty 1 041654 Control PCB assembly PCB3 1 2 108090 Terminal block 1 3 129534 Quick disconnect assembly 1 4 129533 Solenoid valve V1 1 5 123375 Work Cable with clamp 4 6 m 15 ft 1 powermax600 Service Manual 9 3 10 99 PARTS LIST 208 240 480V POWER SUPPLY CIRCUIT BREAKER AND POWER CABLE 208V 240V Part Item Number Description Designator Qty 1 003193 Circuit breaker 480V 51 1 003202 Circuit breaker 208 230V S1 1 2 023519 Power cable 480V 1 129530 Power cable 208 230V 1 3 108124 Strain relief 480V 1 108122 Strain relief 208 230V 1 5 4 powermax600 Service Manual 10 99 PARTS LIST 208 240 480V
7. Inductor output choke 80MH 40A 5 5 ZE Power transformer 208 240V 5 5 022027 Pressure 5 5 02 054 NT CM Fan ie E A 5 5 014252 Power transformer 480V 5 5 Capacitor 1800 1900UF 450 480V 5 5 109187 Capacitor 1800 1900UF 250V 208 230V 5 5 129900 Fan subassembly 480V m 5 5 005222 Temp SWC Mr 5 6 009849 Resistor 20 OHM 5 6 041650 Power PCB 208 240V 5 6 041052 Power PCB 480V a 5 6 109079 IGBT module 480V 5 6 0 EU 5 6 109088 Output diode RER 5 6 16 a REA Input diode bridge 208 240 5 6 109175 Input diode bridge 480V 5 6 OS IGBT module 208 240V em nes 5 6 027662 Thermal grease 5 oz 0 340 5 6 006009
8. a 6 11 SECTION 7 WIRING DIAGRAMS iv powermax600 Service Manual Section 1 this section Recognize Safety 1 2 Follow Safety AS UGS a OAZA 1 2 Cutting Can Cause Fire or Explosion 1 2 Electric Shock Can 1 3 Cutting Can Produce Toxic 1 3 Plasma Arc Can Cause Injury and Burns VU 1 4 Arc Rays Can Burn Eyes and Skin 1 4 Grounding RETE 1 4 Compressed Gas Equipment Safety 1 5 Gas Cylinders Can Explode if 1 5 Noise Can Damage Hearing 1 5 Pacemaker and Hearing Aid Operation 1 5 Additional Safety Information 1 5 MEI 1 6 Hypertherm Plasma Systems 1 1 SAFETY A RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine understand the potential for personal injury and follow the related instructions to avoid the hazard FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety labels on your machine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use
9. 2 6 powermax600 Service Manual 2 1 10 99 Section 2 SPECIFICATIONS SPECIFICATIONS POWER SUPPLY Rated Open Circuit Voltage U 300 VDC Rated Output Current 20A 40A Rated Output Voltage U 140 VDC Duty Cycle at 40 C 50 L 240A U 140V See data tag on power supply for more information on duty cycle 100 1 28 U 140V Operating temperature 10 to 40 C 14 to 104 F 230 400V 6 7 KVA Apparent Input Power S 208 240 480V 9 5 kVA 230V 17A 3 phase 50 60 Hz CE Input Voltage U Input Current 1 at 400V 9 7A 3 phase 50 60 Hz CE 5 6 kw Output 208 240V 46 40A 1 phase 50 60 Hz CSA NRTL 480V 12A 3 phase 50 60 Hz CSA NRTL Gas Quality Clean dry oil free 99 995 pure Gas Inlet Pressure and Flow See Setup Specifications Powermax600 Power Supply Dimensions and Weight 20 in mm sd NAW AT 47 Ib 21 Weight with hand torch and 15 ft 4 5 m lead PMX600 14 Figure 2 1 Powermax600 Power Supply Dimensions 2 2 powermax600 Service Manual 11 99 SPECIFICATIONS SPECIFICATIONS PAC123 TORCHES Maximum Cutting Capacity 40A PAC123T 5 8 inch 16 mm 50 duty cycle 40A PAC123M 1 4 inch 6 mm 50 duty cycle 28A PAC123M 1 8 inch 3 mm 100 duty cycle Gouging Capability 5 6 pounds 2 5 kg metal removal rate PAC123T PAC123M Dimensions 25 Figure 2 2 PAC123T Hand Torch Dimensio
10. 5 2 881222 Rear end panel 5 2 8 8 5 575 m 5 2 010287 Warning label nnne 5 2 10020 1 853118 219127 5 2 129594 Power supply Rad Eod 5 2 15 oy 2 Control POB assembly satus SO Z aur 5 3 108090 Terminal block 5 3 123370 Work Cable with clamp 4 6 1 15 5 3 129539 sssrinin Solenoid 5 3 129592 Quick disconnect assembly 5 3 003193 Circuit breaker 480 5 4 01087207 Circuit breaker 208 230V 5 4 023519 Power cable 440 5 4 129530 Power cable 208 230 5 4 005112 Pressure Switch 5 5 des Filter regulator subassembly 5 5 011086 Air filter 5 5 OO 2 O ring Air filter element 5 5 014232
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15. Replacement Hand Torch Lead 15 ft 4 5 m with Quick Disconnect 129600 Replacement Hand Torch Lead 25 ft 7 5 m with Quick Disconnect 129601 Replacement Hand Torch Lead 50 ft 15 m with Quick Disconnect powermax600 Service Manual 6 11 10 99 PARTS LIST TORCH AND CONSUMABLES Blank 6 12 powermax600 Service Manual 7 WIRING DIAGRAMS In this section Electrical Schematic 230 400V 013335 Electrical Schematic 208 240 480V 013337 powermax600 Service Manual 7 1 10 99 POWER FACTOR CHOKE L1 2
16. 105095 UMNI pieoq J MOd eoejdeH LL 1 mod eAnoele 8SIMY9019 indino Jedoud si qouy snipe uano jueA L LL 001 19 luawisnipe Ajddns g oe soejdol G uey 558 SI 0UB SISSJ pleoq J MOd uo 9 3 90UB SISO1 0 De 1019 Y29949 9 peaj 12edsu e SUUO G uey 1912916 SI 90UB SISOJ J eoeidx 10M pue 1 1591 se qeuinsuoo SAOWAL JOMOd ZL 199 ae 1019 eAnosjeq p nb se ed 10 pee Z ZL pes 1omod iin 019 1 SI pue Jeedde seop 999IdHIOM SI uonoeuuoo HIOM 1004 puno46 ayenbepeu Jou 72 powermax600 Service Manual 3 20 10 99 MAINTENANCE Voltage Checks WARNING ELECTRIC SHOCK CAN KILL e Use extreme caution when working near live electrical circuits Dangerous volt ages exist inside the power supply that can cause serious injury or death e See warnings on page 3 6 before proceeding Before performing voltage checks complete Visual Inspection Internal Resistance Checks and the troubleshooting guide e Connect the pow
17. lt INSS Id 19 1 LSd ool 151 indu 8 UDIIMS 10lld 6 HO deo O snfpy 1ueun2 SPD sald MO wo O 8031 9031 J8MOd C 7 IN3A3 7235 GL 504 318ISIA 3420 1431NI AL34JVS 31VM O3S 9 291nN0S seg 5 IN3A3 M3ldjV 7235 GL 404 318ISIA MONIS HOMOL SOILSON9OVIO 4135 AVMO WALSAS SNLVLS 53409 WE Figure 3 2 2 Powermax600 208 240 480 Volt Block Diagram 3 7 10 99 powermax600 Service Manual MAINTENANCE Sequence of Operation Fan continues to operate and LOW VOLT System off LED illuminates for approximately 5 sec All LED s are OFF Connect gas supply to filter regulator on power unit Sce e et Connect work lead to workpiece to OFF 0 Apply power at line voltage disconnect box Set circuit breaker 51 to ON I Gas solenoid V1 closes Fan M1 operates and POWER and OK LEDs illuminate Gas flow stops indicating system is ready for operation Other LEDs should be OFF see troubleshooting if ON Arc extinguishes Post flow continues for 10 seconds Turn current adjust knob fully counter clockwise to gas test position Check air pressure setting Move torch to make cut Workpiece falls away after cut e Release plasma start switch
18. pJeoq J MOd uo p 9 e suid pif 189 62 si ainssaid Ajddns Ajuo 15 8679 uolas Ul 5 dnjes s nss d seb ou jeu 16 5 JO si g p 154 OZ 29 ddns 9 poddinbe pue LG pieoq eoejdaiJ sdo s J pleoq J MOd 1J98UU098IQ v eoe doJ J pleoq 18MOd Z v Dumes eu 9SIMYH20 9 qoux uin uleis S 1959 4 1 pue 198109 peuous 11 1 5 U910 JO pesseJd jou 1 18661 si 8831 JI pJeoq UO 804171 423439 A quuesse ooejdoH 3091100 LZ U9IIMS oJnssoaJd ou ejeAnoe O peJinbei s 672 159 66 U91IMS a1nssald Moleq HUN peljddns JO SSO 10 SHUI Jedoud poijddns 1 5 Anes uonisod 1591 seb ul si qouy 1snfpe uano jeubis els peuou
19. DA cusbvaih 5 6 powermax600 Service Manual 5 7 11 99 PARTS LIST 208 240 480V Blank 5 8 powermax600 Service Manual Section 6 PARTS LIST TORCH AND CONSUMABLES In this section PAC123T HAND TORCH ASSEMBLY NO QUICK DISCONNECT 6 2 PAC123T HAND TORCH ASSEMBLY WITH QUICK DISCONNECT 6 4 PAC123M MACHINE TORCH ASSEMBLY NO QUICK DISCONNECT 6 6 PAC123M MACHINE TORCH ASSEMBLY WITH QUICK DISCONNECT 6 8 TORCH CONSUMABLES cccscsssssssssssesessssessssssssssssssusssesescscecesesessessesususususususascscscavavereseseensnsesnsnenes 6 10 RECOMMENDED SPARE PARTS 123 TORCH 6 11 powermax600 Service Manual 6 1 10 99 PARTS LIST TORCH AND CONSUMABLES PAC123T Hand Torch Assembly No Quick Disconnect Part Number Description Quantity 086001 PAC123T Hand Torch Assembly with 15 ft 4 5 m Lead No Quick Disconnect 086002 PAC123T Torch Assembly with 25 ft 7 5 Lead No Quick Disconnect 086003 PAC123T Torch Assembly with 50 ft 15 Lead No Quick Disconnect 6 2 10 99 powermax600 Service Manual 1 001288 Handle 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch switch and wire splices 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring Gutcha 1 6 07533
20. S CURIT el LES BOUTEILLES DE GAZ COMPRIME PEUVENT EXPLOSER EN CAS DE DOMMAGES Wa Cu Les bouteilles de gaz contiennent du gaz haute pression Si une bouteille est endommag e elle peut exploser Manipuler et utiliser les bouteilles de gaz comprim conform ment aux codes locaux ou nationaux Ne jamais utiliser une bouteille qui n est pas plac e la verticale et bien assujettie Le capuchon de protection doit tre plac sur le robinet sauf si la bouteille est en cours d utilisation ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des cl s ou d autres outils pour d bloquer le robinet des bouteilles PACEMAKERS ET PROTHESES AUDITIVES Les champs magnetiques produits par les courants a haute tension peuvent affecter le fonctionnement des protheses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un medecin avant de s approcher d un lieu o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magnetiques Garder loin de soi et du cote du corps le cable de retour et le faisceau de la torche e Faire passer le faisceau de la torche le plus pres possible du cable de retour e Ne pas s enrouler le faisceau
21. Z uolas Ul si JOMOd 1891119919 p LL seul pue uoge eyeudoudde ul JO re Ayyenb 1004 Addns 154 07 5 jou 2 ISd OZ 01 les pue 158 01 qouy 1sn pe juano Z LL Addns uo yes JO 10 Ajddns 5 einssaid Spuooes 5206 Inq 1615 1019 se qeuinsuoo L LL lt se qeuinsuoo 42101 LL powermax600 Service Manual MAINTENANCE jjo 19JsueJ 01U09 z zL 4 HIOM 10U 94e AJUO wajsAS Uonisod 1991109 JOU UOJIMS 121 0810211 1014 09 9 802 EL Ayiqedeo woelsAs 19 011U09 HOIU 00 SI JO Jjopuels LL 10 4210 1 si peaj YOM UO uano 9 Ag 1ndino
22. 041508 442 Power 400V vitse er a an aj R 4 6 Power PCB 230V 4 6 09067 SW Q 4 6 109070 sn GBE MONIS 4 6 109080 DO lt gt 4 6 109008 A UT ET 4 6 Cai Input diode bridge 400V 4 6 LOST Input diode bridge 230V 4 6 puso E EMI s ppression Capacitor 4 6 Thermal grease 5 oz DC 340 4 6 008909 RR UT TUUM 4 6 powermax600 Service Manual 11 99 PARTS LIST 400 230 Blank 4 8 powermax600 Service Manual Section 5 PARTS LIST 208 240 480V In this section POWER SUPPLY EXTERIOR PORN 5 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE 5 3 POWER SUPPLY CIRCUIT BREAKER AND POWER CABLE 5 4 POWER SUPPLY INTERIOR FAN SIDE een 5 5 POWER SUPPLY HEAT SINK ASSEMBLY eee 5 6 RECOMMENDED SPARE PARTS POWERMAX600 208 240 480
23. 3 17 10 99 MAINTENANCE 09SU QOL 10 s 2dAO00 ADO 4 LON Ajquiesse pes 9 210 LON S 2831 eoe deJ pereurunii 28371 2037 pese 10 SOL 10 eun rej ZdOd JOMOd ON powermax600 Service Manual 2 154 OZ 01 eunsseud les pue 1894 01 qouy 1sn pe juano 20 elnsseJd 1edoJduu ou Inq y310 SMOJJ MOJ 5 Se qeuinsuoo eoej deH L OL pedouduui 10 se qeiunsuo9 UDJIMS LIE S 106B11 Jo Yd10 OL pleoq 041uoo 9 9 AJIS p 6 pes 9 U9210 19edsu 1 3 9 4171 6 99e d81 Jo Seul pleoq amod OU Jojoeuuoo 1 101 H2OU9 pue MOI 1521 qouy 1 1ueJuno UN WOJ JOJOBUUOD eA eA 2 6 PIEOQ
24. the controls properly Do not let anyone operate it without instruction e Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION A signal word DANGER or WARNING is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific hazards WARNING safety messages precede related instruc tions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instruc tions in this manual that may result in damage to equipment if not followed correctly CUTTING CAN CAUSE FIRE 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 potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosion Prevention 1 2 11 98 Do not use the plasma system if explosive dust or vapors may be present Do not cut pressurized cylinders pipes or any closed contai
25. 99 3 31 HEAT SINK COMPONENT REPLACEMENT 15 _________ _ _ _ _ _ 3 32 SECTION 4 PARTS LIST 400 230V CE POWER UPRLI EXTERIOR ES 4 2 POWER SUPPLY FRONT INTERIOR RIGHT arcsec 4 3 POWER SUPPLY BACK INTERIOR RIGHT SIDE m e Ka S 4 4 POWER SUPPLY INTERIOR FAN SIDE 3i ssc 4 5 POWER SUPPLY HEAT SINCASZEMBDE za de 00 4 6 RECOMMENDED SPARE PARTS POWERMAX600 230 400 2 2 44 2 4 7 SECTION 5 PARTS LIST 208 240 480V SUPRE ibas A 5 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE AOR PE O 5 3 POWER SUPPLY BACK INTERIOR RIGHT SIDE 5 4 POWER SUPPLY INTERIOR FAN 5 5 POWER SUPPLY HEAT SINKASSEMBLUY riai iiia 5 6 RECOMMENDED SPARE PARTS POWERMAX600 208 240 480 57 SECTION 6 PARTS LIST TORCH AND CONSUMABLES PAC123T HAND TORCH ASSEMBLY NO QUICK DISCONNECT issues 6 2 PAC123T HAND TORCH ASSEMBLY WITH QUICK DISCONNECT 6 4 PAC123M MACHINE TORCH ASSEMBLY NO QUICK DISCONNECT 6 6 PAC123M MACHINE TORCH ASSEMBLY WITH QUICK DISCONNECT 6 8 TORCH enea ER A TEGA 6 10 RECOMMENDED SPARE PARTS PAC123 TORCH
26. affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one 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 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario 183 Canada NFPA Standard 51B Cutting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 11 98 SAFETY WARNING LABEL This warning label is affixed to some power supplies It is 1 Cutting sparks can cause explosion or fire important that the operator and m
27. as shown Use thermal grease on components A and B below Apply a thin coat to the component install with screws and tighten to required torque Use a new thermal pad on components C Re torque after 2 minutes Repeat until torque is maintained Clean excess grease from heat sink 129529exploded eps Reference Notes A Apply thermal grease and Torque to 20 in lb 23 kg cm B Apply thermal grease and Torque to 8 in lb 9 kg cm C Torque to 8 in lb 9 kg cm Figure 3 16 Heat Sink Component Replacement 3 32 powermax600 Service Manual 11 99 Section 4 PARTS LIST 400 230V In this section POWER SUPPLY EXTERIOR 4 2 POWER SUPPLY FRONT INTERIOR RIGHT SIDE 4 3 POWER SUPPLY BACK INTERIOR RIGHT SIDE sse 4 4 POWER SUPPLY INTERIOR FAN SIDE un 4 5 POWER SUPPLY HEAT SINK ASSEMBLY eene nnne tenente 4 6 RECOMMENDED SPARE PARTS POWERMAX600 230 400 4 7 powermax600 Service Manual 4 1 11 99 PARTS LIST 400 230 POWER SUPPLY EXTERIOR 8 BAR MAX No 120 PSI Part Item Number Description Designator Qty 1 001669 Rear end panel 1 2 001668 Front end panel Also order 110242 1 3 110242 Operation lable 1 4 129488 Power supply cover 1 5 008965 Knob 1 6 110261 Warning label 1 7 110258 Instruction label 1 8 110996 Pressure warning label 1 4 2 p
28. be installed for power supply to be in compliance with EMC standard EN50199 YELLOW GREEN Pass 4 wires through Pass all 4 wires through the toroid 2 times the toroid 3 times BLACK WHITE PMX600 12 Figure 3 10 Power Cord Replacement 3 26 powermax600 Service Manual 10 99 MAINTENANCE Torch Lead Replacement For models without quick disconnect Disconnect electrical power and gas supply before removing the old torch lead Installation Refer to Figure 3 11 CAUTION Do not tighten the strain relief collar 4 onto the torch lead until the gas fitting 3 is tight or the gas connection may leak Install the strain relief 1 and secure with nut 2 Connect and tighten the gas fitting 8 Tighten the strain relief collar 4 onto the lead Connect the electrical connections 5 6 and 7 Tighten terminal block screws to 10 in lb 12 kg cm of torque Install the power supply cover Early Configuration W r gt Re Figure 3 11 Torch Lead Replacement powermax600 Service Manual 3 27 10 99 MAINTENANCE Air Filter Element Replacement Removal e Disconnect electrical power e Disconnect gas supply e Remove the power supply cover Refer to Figure 3 12 Compress the hose fitting collar and
29. boots and keep your body 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 the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or 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 enclo sure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system
30. de la torche ou le cable de retour autour du corps Se tenir le plus loin possible de la source de courant 1a 5 08 99 HYPERTHERM Systemes plasma SECURITE Etiquette de s curit 1 Cette tiquette est appos e sur certaines sources de courant Il est important que l utilisateur et le technicien de maintenance comprenne la signification des symboles de s curit Les num ros de la liste 14 correspondent aux num ros des images 1 2 2 1 2 2 2 3 3 1 3 2 3 3 4 1 4 2 4 3 5 1 Les tincelles produites par le coupage peuvent provoquer une explosion ou un incendie Pendant le coupage loigner toute matiere inflammable Conserver un extincteur a proximite et s assurer qu une personne soit pr te a l utiliser Ne jamais couper de r cipients ferm s L arc plasma peut provoquer des blessures et des br lures Couper l alimentation avant de d monter la torche Ne pas tenir la surface couper pres de la trajectoire de coupe Porter des v tements de protection couvrant tout le corps Un choc lectrique caus par la torche ou les c bles peut tre fatal Se prot ger contre les risques de chocs lectriques Porter des gants isolants Ne pas porter de gants mouill s ou abim s S isoler de la surface de travail et du sol D brancher la prise ou la source de courant avant de manipuler l quipement L inhalation des vapeurs produites par le coupage peut tre dange
31. metallic components in the cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection 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 authorized by a person who is competent to assess whether the changes will increase the risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC TC26 sec 9
32. pull the gas hose from the hose fitting 2 Pull the drain hose from the grommet in the floor of the power supply Unscrew the filter bowl Do not discard the O ring 4 Remove the filter element from the filter housing NOTE Do not allow the filter element to turn when loosening the screw 3 28 10 99 5 7 sp 222 7 2 gt E e N m2 Figure 3 12 Air Filter Element Removal powermax600 Service Manual MAINTENANCE Air Filter Element Replacement continued Installation Refer to Figure 3 13 1 Install the new filter element into the filter housing Secure with screw and retainer 2 Install the filter bowl and O ring into the filter housing 8 Push pressure line fully into hose fitting 4 Install the drain hose into the grommet Figure 3 13 Air Filter Element Installation e Install the power supply cover Connect electrical power e Connect gas supply powermax600 Service Manual 3 29 10 99 MAINTENANCE Work Cable Replacement Disconnect electrical power and gas supply before removing the old work cable Installation Refer to Figure 3 14 Install the strain relief 1 to the power supply and secure with nut 2 Install work cable 3 through the strain relief Tie a knot 4 in the end of the work cable Tighten the strain relief collar 5 onto the cable Connect the work cable to the terminal block 6 T
33. 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 e Paint walls and other 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 Input Power sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connect ing the power cord to the power supply be sure to connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating Hypertherm Plasma Systems SAFETY COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and Gas cylinders contain gas under high pressure If fittings designed for the specific application damaged a cylinder can explode Maintain all compressed gas equipment and associ e Handle and use compressed gas cylinders in accor ated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local cod
34. 0221112 1 5 GAS CYLINDERS CAN EXPLODE IF DAMAGED canne eme anra annee 1 5 NOISE CAN DAMAGE HEARING 1 5 PACEMAKER AND HEARING AID 80 000 9 1 5 ADDITIONAL SAFETY INFORMATION 1 5 WARNING LABEL OO 1 6 SECTION 1a S CURIT IDENTIFIER LES CONSIGNES DE S CURIT ccccccccscecescccsccccescccesscesucccsucccsscscesusessuccesuesetucesusersueessueesans SUIVRE LES INSTRUCTIONS DE 02 0 0 0 000 000 00 01010 1 2 LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION eene 1 2 LES CHOCS LECTRIQUES PEUVENT ETRE FATALS ccccccsscessccescccsscecssccscecseccsucccsucesuscsueenseecsuecnsuecaueens 1 3 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES eene 1a 3 PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES 1a 4 LES RAYONS DE PEUVENT BR LER LES YEUX 220 1a 4 MISE LA MASSE ET ALA TERRE u cccccccscececsccesscecsscccsscecsscecesssessscessscssuccssuesuucesuscesseecesusessuecetseesuesensecens 1 4 S CURIT DES BOUTEILLES DE GAZ COMPRIM 0 0 000 000 1 0100120000 1a 5 LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES 1a 5 LE BRUIT PEUT PROVOQUER DES PROBL MES
35. 3 129374 OR Solenoid Valve 4 3 Circ it breaker 400 V 111322 4 4 DOS OB grac FE o CIRCUIT Breaker 230 V 4 4 EMI Filter 400 V eee ee ee eee 4 4 ana pa EMI Filter PCB 200 V NETTE 4 4 29668 ao Power cable 400 aan ea ai 4 4 129410 Power cable 230 NV 4 4 DOS TIE PLOSCU E nets ae 4 5 009999 Capacitor 1800 1900UF 4000 4 5 PN Filter regulator subassembly 4 5 fable 4 5 O ring Air filter element 4 5 O 14201 rt Inductor input choke 5MH 11 400V 4 5 DAS Inductor output choke 80MH 40A 4 5 OAZA Power transformer 400V aanininanaaaaaaaaaaaaaananananasanananananananaannnnna 4 5 OU AZ Power transformer 230V annanananaaaaaaaaaaaananananasanananananananannannnnra 4 5 VR Inductor input choke 5MH 11 230 4 5 Pressure gauge eee nsns nnns nennen nis 4 5 109118 Capacitor 1990 1980 SN ees 4 5 1299808 2 w c Fan subassembly een ares he 4 5 007722 E TOD WIO m 4 6 009849 miss ope4u eum 4 6
36. 4 and IEC TC26 108A CD Arc Welding Equipment Installation and Use Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications WARRANTY A Genuine Hypertherm parts are the factory WARNING recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty GENERAL Hypertherm Inc warrants that products shall be free from defects in materials and workmanship under proper and normal use for which such equipment is recommended for a period of two 2 years except only with respect to the torch for which the warranty period shall be one 1 year from the date of its delivery to you Hypertherm at its sole option shall repair replace or adjust free of charge any Products covered by this war ranty which shall be returned with Hypertherm s prior autho rization which shall not be unreasonably withheld prop erly packed to Hypertherm s place of business in Hanover New Hampshire all costs insurance and freight prepaid and which examination proves not to be free from defects in materials and workmanship Hypertherm shall not be liable for any repairs replacements or adjustments of Products covered by this warranty except th
37. 6 120600 120826 120827 Electrode Swirl Ring Retaining Cap Nozzle Shield Quantity mah powermax600 Service Manual PARTS LIST TORCH AND CONSUMABLES 2 Included with replacement U lead assembly lt PAC123M Machine Torch Assembly and Leads No Quick Disconnect powermax600 Service Manual 6 7 10 99 PARTS LIST TORCH AND CONSUMABLES PAC123M Machine Torch Assembly With Quick Disconnect Part Number Description Quantity 086026 PAC123M Machine Torch Assembly with 15 ft 4 5 m Lead and Quick Disconnect 086027 PAC123M Machine Torch Assembly with 25 ft 7 5 Lead and Quick Disconnect 086029 PAC123M Machine Torch Assembly with 50 ft 15 m Lead and Quick Disconnect 1 120613 Sleeve Machine Torch 2 020620 Sleeve Torch Position 3 128572 Replacement Torch Lead w Quick Disconnect 15 ft 4 5 m 3 128573 Replacement Torch Lead w Quick Disconnect 25 ft 7 5 m 3 128574 Replacement Torch Lead w Quick Disconnect 50 ft 15 m 4 027599 Snap Ring 5 120583 Torch Main Body with Safety Switch 6 044016 O Ring BUNA 90 Duro 0 614 X 0 070 inch 7 028714 On Off Pendant with Lead 25 ft 7 5 m 128061 On Off Pendant with Lead 50 ft 15m 128062 On Off Pendant with Lead 75 ft 23 m Top assembly includes the following consumables 6 8 10 99 120573 120576 120600 120826 120827 Electrode Swirl Ring Retaining Cap Nozzle Shield powermax600 Service Manua
38. 9 Screws P S 4 X 1 2 PH RND S B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O Ring BUNA 90 Duro 614X 070 1 9 129475 Replacement Hand Torch Lead 15 ft 4 5 m 1 9 129476 Replacement Hand Torch Lead 25 ft 7 5 1 9 129477 Replacement Hand Torch Lead 50 ft 15 m 1 Top assembly includes the following consumables 120573 Electrode 1 120576 Swirl Ring 1 120600 Retaining Cap 1 120826 Nozzle 1 120828 Shield 1 PARTS LIST TORCH AND CONSUMABLES 1 l 7 Included with replacement lead assembly PAC123T Hand Torch and Lead Assembly No Quick Disconnect powermax600 Service Manual 6 3 10 99 PARTS LIST TORCH AND CONSUMABLES PAC123T Hand Torch Assembly With Quick Disconnect Part Number Description Quantity 086023 PAC123T Hand Torch Assembly with 15 ft 4 5 Lead and Quick Disconnect 086024 PAC123T Torch Assembly with 25 ft 7 5 Lead and Quick Disconnect 086025 PAC123T Hand Torch Assembly with 50 ft 15 m Lead and Quick Disconnect 6 4 10 99 powermax600 Service Manual 1 001288 Handle 2 Sides 1 2 002244 Safety Trigger 1 3 128377 Replacement Start Switch switch and wire splices 1 4 027254 Trigger Spring 1 5 004764 Retaining Ring Gutcha 1 6 075339 Screws P S 4 X 1 2 PH RND S B 5 7 120570 Torch Main Body with Safety Switch 1 8 044016 O Ring BUNA 90 Duro 614X 070 1 9 129599 Replacem
39. A TORTANG Z 3 2 CONTROLS 3 2 THEORY OF OFERA TION n ee 3 3 CENE m M 3 3 230 400 VOLT FUNCTIONAL DESCRIPTION iaaaaaaaaaaaaaaa aaaaaaaaaan nuuaanananannananunanannannnnannnnnnnnnnnnnnnnnnannnnnnnnnnnaanaaaa 3 4 200 240 460 VOLT FUNCTIONAL a 3 6 SEOUENCE on HIM 3 8 TROUBLE SOJ A 3 9 eee eee ee ee ee ee ee 3 9 TROUBLESHOOTING PROCEDURES AND SEQUEN GQE induunt aoc ER APES R sepes uite testari epus 3 9 VISUAL INSPECTION S ines _________ ____ 3 9 VWISUALINSTFECNON ETNTERNZE zew ss s Wa PE D Vr 3 10 nimejesueszeijiecq 3 11 TROUBLE SHOOTING CUID E 3 14 VOLTAGE CES M 3 21 mai teers eee ieee 3 26 POWER CORD eee eee er eee ee ee ee 3 26 TORCH LEAD REPLACEMENT MODELS WITHOUT QUICK DISCONNECT 3 27 AIR FILTER ELEMENT 2 ee ee ee ee 3 28 WORK CABLE REPLACEMENT eee err eer eee ee ee M 3 30 CAPACITOR REPLACEMENT 22 25
40. AUDITIFS eene 1a 5 PACEMAKERS ET PROTH SES 5 40 0 0 0 00 6061 0 0 0 0 1001100100001010 RELEE EARE REEERE anan 1 5 TIQUETTE DE 21414 10000000 00000001000000 1 6 SECTION 2 SPECIFICATIONS SPECIFICATIONS POWER SUPPLY cccccccsscccsscccescccsscccsssccecscecsucessescsscscssucesusessusessuccessaserscecsaueceueesusesensees 2 9 SPECIFICATIONS PAC123 5 0 02 0 000000000 001000011 0000022 2 3 SETUP SPECIFICATIONS c cccccccesccceccecscecccccssucccsscscssccssuscssucessuccessuccsssscssussesusssstesesecetauecesssessecsusesersueessueeeans 2 4 INSTALL POWER CORD PLUG NON 2 4 CHECK REQUIRED INPUT VOLTAGE 2 4 S MARK 230 400 VOLT 2 2 4 GROUNDING REQUIREMENTS ccccccccccocccccecccccscccsscccsscccsscscssuccsssssssucssssuceesuscssuesssseessuescsueessusesuecetseesssueenses 2 5 POWER CORD EXTENSION 10000 0 101 00100 2 5 GAS annee une 2 6 LINE VOLTAGE DISCONNECT BOX 222 2 6 powermax600 Service Manual TABLE OF CONTENTS SECTION 3 MAINTENANCE CONTROLS AND INDICATORS EA H ae asses EA tux abe d ntn bene eee 3 2 INDIC
41. IGI III Section 1a SECURITE Cette section comprend IDENTIFIER LES CONSIGNES DE 1a 2 SUIVRE LES INSTRUCTIONS DE S CURIT 1a 2 LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION 1a 2 LES LECTRIQUES PEUVENT ETRE 5 21 2 1a 3 LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 1a 3 L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES 0 20 0000000010101000 1a 4 LES RAYONS DE PEUVENT BRULER LES YEUX ET LA PEAU 1a 4 MISE A LA MASSE ET 4 0 02 020000660 01 0 000310520 1a 4 S CURIT DES BOUTEILLES DE GAZ COMPRIM 1a 5 LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES 6 000100100000 50 0 0000004 1 5 LE BRUIT PEUT PROVOQUER DES PROBL MES AUDITIFS 1a 5 PACEMAKERS PROTH SES AUDITIVES 1a 5 ETIQUETTE DE 2 0 10 0 0 0121000100 00 1 6 Systemes plasma 1 1 08 99 SECURITE IDENTIFIER LES CONSIGNES A DE SECURITE Les symboles indiques dans cette section sont utilises pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce s
42. OW VOLTAGE CURRENT 26 POSITION RIBBON CABLE 14 a C LOW PRESSURE START 57 15 5 C CAP OFF 16 NOK is HSTEMPOK RT6 R26 RTI OVER TEMP 18 dar w 19 TFRI FRONT s 041593 22 23 24 dite T 008924 o R41 POWER SUPPLY PART 086000 086007 55 IFB INPUT VOLTAGE 400vac 3 230vac 3 IOCA POWER CORD TURNS 3 2 M PES ON TORROID CIRCUIT BREAKER 51 003193 003195 J15 J16 Expl EMI FILTER BOARD PCB1 041566 041587 SED e dac INPUT BRIDGE D1 109090 109134 0 0 TT POWER BOARD PCB2 041568 041607 GAS HEATSINK e ELEC SCHEM PMX600 230 400V 22 THERMAL 01 3 3 335 REV B PS1 3 POWER FACTOR CHOKE 11 014231 014241 US SOLENOD GE ae POWER XFR T2 014234 014238 BULK CAPS ON POWER BD 009999 2 109118 2 IGBT MODULE Q2 109079 109061 TIMING DIAGRAM 013333 013333 VDC 540 310
43. POWER SUPPLY INTERIOR FAN SIDE Part Item Number Description Designator Qty 1 005112 Pressure Switch PS1 1 2 022027 Pressure gauge 1 3 014232 Inductor output choke 40 L2 1 4 014252 Power transformer 480V 2 1 014251 Power transformer 208 230V 2 1 5 109179 Capacitor 1800 1900UF 450V 480V 2 109187 Capacitor 1800 1900UF 250V 208 230V 2 6 011083 Filter regulator subassembly 1 7 011086 Air filter element 1 8 011087 O ring 1 9 129366 Fan subassembly 480V M1 1 027654 Fan assembly 208 230V M1 1 powermax600 Service Manual 5 5 10 99 PARTS LIST 208 240 480V POWER SUPPLY HEAT SINK ASSEMBLY 5 6 11 99 Part Number 109088 009849 109080 005222 109079 109183 009849 109175 109174 041652 041650 008903 027662 Description Output diode Resistor 20 OHM IGBT pilot arc Temp switch IGBT module 480V IGBT module 208 240V Resistor 20 OHM Input diode bridge 480V Input diode bridge 208 240V Power PCB 480V Power PCB 208 240V Thermal pad Thermal grease 5 oz tube Designator Qty D2 1 2 Q3 1 TS1 1 Q2 1 Q2 1 1 018 1 018 1 2 1 2 1 3 5 places powermax600 Service Manual PARTS LIST 208 240 480V RECOMMENDED SPARE PARTS POWERMAX600 208 240 480V Part Number Description Page Reference 001668 Front end panel HR
44. Refer to the length requirements listed below Input Voltage 208 240 VAC 230 VAC 400 VAC 480 VAC 208 240 VAC 230 VAC 400 VAC 480 VAC Grounding Requirements 10 25 ft 25 50 ft 50 100 ft 100 150 ft 3 7 5 7 5 15 15 30m 30 45 m Recommended Gauge Size 10 10 16 6 6 10 4 8 10 14 12 To ensure personal safety proper operation and to reduce electromagnetic interference the Powermax600 must be properly grounded e The power supply chassis is electrically conductive and can present a shock hazard if it is not properly grounded through the line voltage disconnect box power supply must be properly grounded through the power cord according to national or local electrical codes e hree phase service must use 4 wire cord that includes a protective earth ground e Also see Grounding Safety in Section 1 of this manual powermax600 Service Manual 10 99 SPECIFICATIONS Line Voltage Disconnect Box Use a line disconnect box for each power supply so that the operator can turn the power supply off quickly in an emergency situation Locate the switch near the power supply so that it is easily accessible to the operator The interrupt level of the switch must be equal to or exceed the continu ous rating of the fuses Use slow blow fuses as listed below O PMX600 03 Input Input Current Recommended Voltage Phase 5 6 kw Output Slow Blow Fu
45. a d argon hydrog ne ou de m thane AVERTISSEMENT D tonation de Fhydrogene lors du coupage de l aluminium Lors du coupage de l aluminium sous l eau ou si l eau touche la partie inf rieure de la piece d aluminium de l hydrog ne libre peut s accumuler sous la piece couper et d tonner lors du coupage plasma Installer un collecteur d a ration au fond de la table eau afin d liminer les risques de d tonation de l hydrogene oe r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration HYPERTHERM Systemes plasma 3 SN Toucher une pi ce lectrique sous tension peut provoquer un choc lectrique fatal ou des brulures graves e La mise en fonctionnement du systeme plasma ferme un circuit lectrique entre la torche et la piece couper La pi ce couper et tout autre l ment en contact avec cette pi ce font partie du circuit lectrique e Ne jamais toucher le corps de la torche la pi ce couper ou l eau de la table eau pendant le fonctionnement du syst me plasma Pr vention des chocs lectriques Tous les syst mes plasma Hypertherm utilisent des hautes tensions pour le coupage souvent de 200 400 V On doit prendre les pr cautions suivantes quand on utilise le syst me plasma Porter des bottes et des gants isolants et garder le corps et les v tements au sec e Ne pas se tenir s asseoir ou se coucher sur une surface mouill e ni la toucher
46. action or threatened action DISCLAIMER OF OTHER WARRANTIES HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR OTHERS IN CLUDING WITHOUT IMPLIED LIMITATION WARRAN TIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE EITHER EXPRESS OR PLIED EXCEPT AS PROVIDED HEREIN This warranty is in lieu of any and all warranties express or implied by law or otherwise and Distributors are not authorized to give any other warranty purporting to be binding upon Hypertherm upon resale of Products to their customers INNO EVENT shall Hypertherm be liable for incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any Equipment sold hereunder UPON RECEIPT 1 Verify that all parts and items on your order have been received Alert your distributor if any parts or items are damaged or missing 2 Inspect the power supply for any physical damage that may have occurred during shipping lf there is evidence of damage refer to the Claims section below All communications regarding this equipment must in clude the model number and serial number located on the back of the Powermax600 3 Before setting up and operating the Powermax600 read the Safety section of this manual CLAIMS Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lad
47. aintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on 1 2 Keep a fire extinguisher nearby and have a the label watchperson ready to use it 1 1 Keep flammables away from cutting 1 3 Do not cut on any closed containers 2 The plasma arc can cause injury and burns 2 1 Turn off power before disassembling torch 2 2 Do not hold the material near 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 n s n d 4 1 Keep your head out of the fumes 14 re R 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Use ventilating fan to remove the fumes 5 Arc rays burn eyes and injure skin 5 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 6 Become trained and read the instructions before working on the machine or cutting 110212 7 Do not remove or paint over cover warning labels 1 6 Hypertherm Plasma Systems 8 99 GI LI
48. ches Plasma arc comes on immediately when the torch switch is activated The plasma arc will cut quickly through gloves and skin e Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others ARC RAYS CAN BURN EYES AND SKIN Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin e Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields or a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays Lens Shade AWS USA ISO 4850 No 8 No 11 No 10 No 11 12 No 12 No 13 No 14 No 14 Arc Current Up to 100 A 100 200 A 200 400 A Over 400 A B GROUNDING SAFETY Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to an earth ground in accordance with appropriate national or local electrical codes 1 4 4 99 Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal e Gauntlet gloves safety shoes and hat e Flame retardant clothing to cover all exposed areas e Cuffless trousers to prevent entry of sparks and
49. d crans lat raux ou encore masque de soudure avec des verres teint s appropri s pour prot ger les yeux des rayons ultraviolets et infrarouges de l arc Zone de coupage Pr parer la zone de coupage afin de r duire la reverberation et la transmission de la lumi re ultraviolette e Peindre les murs et autres surfaces de couleur sombre pour r duire la reflexion de la lumi re e Utiliser des crans et autres dispositifs de protection afin de prot ger les autres personnes de la lumi re et de la r verb ration Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux Puissance des verres teint s AWS U ISO 4850 N 8 11 10 N 12 Protection de la peau Porter des v tements de s curit N 11 12 N 13 N 14 pour se prot ger contre les br lures que peuvent causer les rayons ultraviolets les tincelles et le m tal br lant Courant de Jusqu a 100 A 100 200 A 200 400 A Plus de 400 A 14 Alimentation e o assurer que le fil de terre du cordon d alimentation est connect la terre dans le coffret sectionneur Sil est n cessaire de brancher le cordon d alimentation a la source de courant lors de l installation du syst me s assurer que le fil de terre est correctement branch Placer tout d abord le fil de terre du cordon d alimentation sur le plot de mise la terre puis placer les autres fils de terre par dessus Bie
50. d tre endommag si les instructions ne sont pas suivies correctement LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur proximit loigner toute mati re inflammable une distance d au moins 10 m du poste de coupage Tremper le m tal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des mat riaux combustibles Ne jamais couper des r cipients pouvant contenir des matieres inflammables avant de les avoir vid s et nettoy s correctement A rer toute atmosphere potentiellement inflammable avant d utiliser un syst me plasma Lors de l utilisation d oxygene comme gaz plasma un systeme de ventilation par aspiration est n cessaire Pr vention des explosions e Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s e Ne pas couper de r cipients contenant des matieres combustibles 1a 2 08 99 AVERTISSEMENT Risque d explosion Argon hydrogene et m thane Lhydrogene le methane sont des gaz inflammables potentiellement explosifs Conserver a l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de methane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasm
51. duuoo JO 51515000 941 LM Aejos pue H 1081591 pJeoq JOMO si 4816 LOS eu uo 2 Alddns ujejs s ou seijddns pue eu seijddns epoip 941 101991014 sylds pue uoisseiddns esiou 4 121114 941 191111 ou seijddns pue S 4 eui W IS S eui Dy eseud eaJu 1 2 2 4 eos powermax600 Service Manual 3 4 10 99 MAINTENANCE 3 5 4210 seb 0 INSS Id BNOS LA LSd eol LSL deo YOUMS HEIS mE gt el mde U 3 ono um 189 y l P Vd a E En oDpu epoig Sue G indino m ix La J9AQ Q HO C isnipy 1ueun2 BLESS Said MO Q 10 O san zan 19MOd O sag PIOU OS J MOd 108095 JeuuoJsuei losues 1991 1491 YOUMS INSS JId pleog Jo UO 2 101009
52. e et que l op rateur porte un masque respiratoire Les rev tements et m taux contenant ces matieres peuvent produire des vapeurs toxiques lors du coupage Ne jamais couper de r cipients pouvant contenir des matieres inflammables avant de les avoir vid s et nettoy s correctement 1a 3 08 99 SECURITE Torches a allumage instantan L arc plasma s allume imm diatement apres que la torche soit mise en marche PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRULURES L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de metal pres de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes LES RAYONS DE L ARC PEUVENT BRULER LES YEUX LA PEAU Protection des yeux Les rayons de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur e Gants crispin chaussures et casque de s curit e V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles 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 Porter des lunettes de protection lunettes ou masque muni
53. embly with 15 ft 4 5 m Lead with Quick Disconnect 086024 PAC123T Hand Torch Assembly with 25 ft 7 5 m Lead with Quick Disconnect 086025 PAC123T Hand Torch Assembly with 50 ft 15 m Lead with Quick Disconnect 086026 PAC123M Machine Torch Assembly with 15 ft 4 5 m Lead with Quick Disconnect 086027 PAC123M Machine Torch Assembly with 25 ft 7 5 m Lead with Quick Disconnect 086029 PAC123M Machine Torch Assembly with 50 ft 15 m Lead with Quick Disconnect 120570 Hand Torch Main Body with Safety Switch 120583 Machine Torch Main Body with Safety Switch 128374 Replacement Machine Torch Lead 15 ft 4 5 m No Quick Disconnect 128375 Replacement Machine Torch Lead 25 ft 7 5 m No Quick Disconnect 128376 Replacement Machine Torch Lead 50 ft 15 m No Quick Disconnect 120977 Replacement Hand Torch Start Switch switch and wire splices 128572 Replacement Machine Torch Lead 15 ft 4 5 m with Quick Disconnect 128573 sos Replacement Machine Torch Lead 25 ft 7 5 m with Quick Disconnect 128574 Replacement Machine Torch Lead 50 ft 15 m with Quick Disconnect 129475 Replacement Hand Torch Lead 15 ft 4 5 m No Quick Disconnect 129476 Replacement Hand Torch Lead 25 ft 7 5 m No Quick Disconnect 129477 Replacement Hand Torch Lead 50 ft 15 m No Quick Disconnect 129599
54. ent Hand Torch Lead 15 ft 4 5 m 1 9 129600 Replacement Hand Torch Lead 25 ft 7 5 m 1 9 129601 Replacement Hand Torch Lead 50 ft 15 1 Top assembly includes the following consumables 120573 Electrode 1 120576 Swirl Ring 1 120600 Retaining Cap 1 120826 Nozzle 1 120828 Shield 1 PARTS LIST TORCH AND CONSUMABLES uw lt h gt A Included with replacement lead assembly PAC123T Hand Torch and Lead Assembly With Quick Disconnect powermax600 Service Manual 6 5 10 99 PARTS LIST TORCH AND CONSUMABLES PAC123M Machine Torch Assembly No Quick Disconnect ltem NOOO amp D Part Number PAC123M Machine Torch Assembly with 15 ft 4 5 Lead No Quick Disconnect PAC123M Machine Torch Assembly with 25 ft 7 5 Lead No Quick Disconnect PAC123M Machine Torch Assembly with 50 ft 15 m Lead No Quick Disconnect 086004 086005 086006 120613 020620 128374 128375 128376 027599 120583 044016 028714 128061 128062 Description Sleeve Machine Torch Sleeve Torch Position Replacement Torch Lead 15 ft 4 5 m Replacement Torch Lead 25 ft 7 5 m Replacement Torch Lead 50 ft 15 m Snap Ring Torch Main Body with Safety Switch O Ring BUNA 90 Duro 0 614 X 0 070 inch On Off Pendant with Lead 25 ft 7 5 m On Off Pendant with Lead 50 ft 15 m On Off Pendant with Lead 75 ft 23 Top assembly includes the following consumables 6 6 10 99 120573 12057
55. er cord into the line voltage disconnect switch box or plug into a properly grounded outlet e Connect the gas supply to the power supply e Switch the power supply on powermax600 Service Manual 3 21 10 99 MAINTENANCE Voltage Check 1 Figure 3 5 e Check input voltage to the input diode bridge The AC voltage between any 2 input wires should equal the line voltage 230V and 400V OMM PMX600 22 o LJ m cS i Line Voltage Line Voltage um Voltage 480 Only Figure 3 5 Voltage Check 1 Input of Input Diode Bridge 3 22 10 99 powermax600 Service Manual MAINTENANCE Voltage Check 2 Figure 3 6 e Check output voltage of the input diode bridge Line Voltage Output at Bridge 230 VAC 325 VDC 400 VAC 565 VDC 208 240 VAC 300 330 VDC 480 VAC 660 VDC EE and 400 400 U EV _ L
56. es NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing e Use approved ear protection when using plasma system Warn others nearby about the noise hazard ADDITIONAL SAFETY INFORMATION 1 ANSI Standard 249 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 ANSI Standard 749 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 287 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 Hypertherm Plasma Systems dance with applicable national or local codes Never use a cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve PACEMAKER AND HEARING Pacemaker and hearing aid operation can be
57. i uej poljddns si 279 ul LIS 1009 HUN 128 quiesse pee 9 42101 29 5 uedo pieoq uo Salim 9 9 suid uo pue jesu 2 meu Uone eisul Jedoud 104 ejqeuunsuoo o L Z ueuueje eoejdeu p 9 U91IMS eoe daJ uedo S8JIM UO p 9 suid pif uo ISd 62 e oqe si einsse d Ajddns Aluo uie1s S 8 80 469 asn Jaye 1528 ye 4000 SI W IS S U8UM ZS 1081958 olnieloduo 21 JOMOd asn Jaye ses ye 4000 SI W IS S U8UM LS YOHMS ainyesodwe HUISJEOU JO jou ugy peusnes No 91949 10U SJOSU S due 431 1 8 Ajayes pel e sul jou A poyshes no 1 jou 031 su s dey gt N
58. ighten terminal block screw to 10 12 kg cm of torque Install the power supply cover CAUTION This is a high current connection Proper torque is critical Early Configuration Figure 3 14 Work Cable Replacement 3 30 powermax600 Service Manual 10 99 MAINTENANCE Capacitor Replacement Removal Refer to Figure 3 15 Disconnect electrical power and gas supply before removing the power supply cover Remove screws securing capacitor to PC board Remove capacitor from fan side of power supply Capacitor Identification Installation Refer to Figure 3 15 e M Markin Check capacitor identification and install as ng shown below 208 240V 250V 68001 Install new capacitor and secure with 2 screws 250V 4700uf oy 16004 Tighten screws to 20 inch pounds 2 26 N m UT 24 kg cm 400V 1800uf Install the power supply cover 450 1500uf 8 1 Remove and install capacitors from fan side N Correct Installation Positive Positive Figure 3 15 Capacitor Replacement powermax600 Service Manual 3 31 11 99 MAINTENANCE Heat Sink Component Replacement Installation Refer to Figure 3 16 Install components to the heat sink
59. ing upon request If you need additional assistance call Customer Service listed in the front of this manual or your authorized Hypertherm distributor Claims for defective or missing merchandise If any of the merchandise is defective or missing call your authorized Hypertherm distributor If you need additional assistance call Customer Service listed in the front of this manual powermax600 Service Manual TABLE OF CONTENTS m lun A mr SECTION 1 SAFETY RECOGNIZE SAFETY INFORMATION 2 0 00 0 0 0 2 1 arka 01 00110011 001000 1 2 FOLLOW SAFETY INSTRUCTIONS ccccccsccccsscccccececccccssccssscesscccssuccssescesusesstssesseseseccssuecssecsauesstesersesersueeeaness 1 2 CUTTING CAN CAUSE FIRE OR EXPLOSION ccccssccscccccssccceseccssccessuccssuccsesecssucecsueccssescausecsueceseseseesusesenses 12 ELECTRIC SHOCK CAN 1 3 CUTTING CAN PRODUCE TOXIC FUMES 1 2 PLASMA CAN CAUSE INJURY AND BURNS ccccccssccsssccccccccscsccesccessuccssesceseccssucesuccesucecsuesensesessueesaness 1 4 ARC RAYS CAN BURN EYES AND 5 202020202000 5 00 6 600068 1 1 4 GROUNDING 0 10 0 0000000 0 0000 1 4 COMPRESSED GAS EQUIPMENT 5 1 40 0 0 6 6 0
60. istance checks and the power supply still does not operate correctly follow the Troubleshooting Guide Note The Troubleshooting Guide provides most probable cause and solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before purchasing a major replacement component verify the problem with Hypertherm Technical Service or the near est Hypertherm repair facility 3 14 powermax600 Service Manual 10 99 MAINTENANCE 0J1u09 1991109 SI pieoq OU 1981109UI J OQA S 1 1 91 141 O EUld If J MOd uo JO pue JOJOBUUOD f 4 19euuoosi d Jol gol pue 1 12 5 1991109 SI opoip ou 10 129 102 J SHUN HOA 0 c 80c UO 05 SHUN JOA UO 099 pinoys ou SMOJOS OM U99M9Q 814 DOG INSB W Ajuo UWI IS S 80 104 gol pue 1oedsuir 1991109 SI opoip ou 10 1 J abe JOA 1 4 pue pleoq amod uo WOJ SIM AOUWI I
61. itch 208 240 480V 3 2 11 99 Pressure Regulator Current Adjustment Knob a gt ib A if M SED ON I OFF 0 Switch Figure 3 1 Powermax600 Controls powermax600 Service Manual MAINTENANCE THEORY OF OPERATION General Refer to Functional Description Figures 3 2 1 and 3 2 2 Sequence of Operation and the system wiring diagram powermax600 Service Manual 3 3 10 99 MAINTENANCE 230 400 Volt Functional Description 20 LGD 19eueAut 1ndino eu pue 1osues juoJno eu jueJuno eu lulod 198 ou 1 941 lolo 1snfpe eu ou 01195 SI JUNO SUL S INOJIO pue wals s pue SJOHUOW p1eoq 941 pue FH 1891 1olId o J MOd eu uo po EJO sJosues 5 1u9JJno JO SISISUOD eu eui Aq SI pue osjnd e se solelodo J MOd eui JO pue 10128 JAMO 5 esues e 2 JeuuojsueJ JOMOd eu 20 1891 Joi1sisuea Iejodiq pejelosi sjueuo
62. l PARTS LIST TORCH AND CONSUMABLES Included with replacement lead assembly PAC123M Machine Torch Assembly and Leads With Quick Disconnect powermax600 Service Manual 6 9 10 99 PARTS LIST TORCH AND CONSUMABLES Torch Consumables Shield Retaining Cap Nozzle Electrode Swirl Ring Hand Cutting 120608 120600 120831 120827 120600 120576 120826 Machine Cutting 5 Deflector 120303 120600 Unshielded o In CE countries unshielded consumables may only be used machine torch applications 6 10 powermax600 Service Manual 10 99 PARTS LIST TORCH AND CONSUMABLES RECOMMENDED SPARE PARTS PAC123 TORCH Part Number Description 001288 Handle 2 Sides 020620 Sleeve Machine Torch Position 075339 Screws P S 4 X 1 2 PH RND S B 086001 PAC123T Hand Torch Assembly with 15 ft 4 5 m Lead No Quick Disconnect 086002 PAC123T Hand Torch Assembly with 25 ft 7 5 m Lead No Quick Disconnect 086003 PAC123T Hand Torch Assembly with 50 ft 15 m Lead No Quick Disconnect 086004 PAC123M Machine Torch Assembly with 15 ft 4 5 m Lead No Quick Disconnect 086005 PAC123M Machine Torch Assembly with 25 ft 7 5 m Lead No Quick Disconnect 086006 PAC123M Machine Torch Assembly with 50 ft 15 m Lead No Quick Disconnect 086023 PAC123T Hand Torch Ass
63. m M dup T OK ULN2003A 4UF K B 6 CAPON 12 TZ U4 CZ J2 C LOW VOLTAGE C A SPAREN EET CURRENT 26 POSITION RIBBON CABLE 14 sa C LOW PRESSURE ISTART lt TNI ORG 15 45 ORG 5 16 O NOK P VIO START CAP OFF 25 HSTEMPOK RT4 R8 A C OVER TEMP 18 E P CONT PA 19 7X 5 eom 041654 R55 22 23 24 va 008924 R58 25 R56 26 O loca Z REG NZ A 24 POWER SUPPLY PART 086021 086022 rade se i s 552 H 2 INPUT VOLTAGE 208 240vac 1E 480 E CORD 129530 023519 GAS HEATSINK C 2 Q TS2 CIRCUIT BREAKER S1 003202 003193 FAULT CODES Pst FAN SENSORN LENOID M1 POWER TRANSFORMER INPUT BRIDGE D18 109174 109175 LED7 LED6 STATUS POWER BOARD PCB2 041650 041652 OFF OFF SYSTEM OKAY POWER 2 014251 014252 OFF ON SELF DIAGNOSTICS FAILURE BULK CAPS 109187 2 109179 2 cone Sloe ON OFF INVERTER SAFETY INTERLOCK GET MODULE DAR VISIBLE FOR 15 SEC AFTER EVENT TIMING DIAGRAM 013333 013333 TORCH STUCK OPEN ELEC SCHEM 600 208 240 480V VDC 330 660 VISIBLE FOR 15 SEC AFTER EVENT 013 3 337 REV
64. m moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap BEFORE handling PC boards Visual Inspection Internal 1 Set the power switch to off unplug the power cord and disconnect the gas supply 2 Remove the cover of the power supply by removing the securing screws 3 Inspect the inside of the power supply especially on the side with the power board Look for broken or loose wiring connections burn and char marks damaged components etc Repair or replace as necessary 3 10 powermax600 Service Manual 10 99 MAINTENANCE Resistance Checks All resistance values were taken with the power cord disconnected and all internal power supply wires attached Perform Visual Inspection Internal before continuing in this section e If your resistance values 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 e After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power unit for proper operation 230V and 400V Resistance Check 1 Figure 3 3 1 Turn switch ON power disconnected 300 500 2 Check resistance across input leads 3 Check resistance from input leads to ground 208V 240V 600 5 01 Figure 3 3 Resistance Check 1 Across Input Leads and Input to Ground p
65. n serrer l crou de retenue S assurer que toutes les connexions sont bien serr es pour viter la surchauffe MISE LA MASSE ET LA TERRE C ble de retour Bien fixer le c ble de retour ou de masse la pi ce couper ou la table de travail de facon assurer un bon contact m tal m tal Ne pas fixer le c ble de retour la partie de la piece qui doit se d tacher Table de travail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s 1a 4 08 99 HYPERTHERM Systemes plasma SECURITE DES BOUTEILLES DE GAZ COMPRIME Ne jamais lubrifier les robinets des bouteilles ou les r gulateurs avec de l huile ou de la graisse Utiliser uniquement les bouteilles regulateurs tuyaux et accessoires appropri s et con us pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz contenu dans chaque tuyau Se r f rer aux codes locaux ou nationaux en vigueur LE BRUIT PEUT PROVOQUER DES PROBLEMES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs Utiliser un casque de protection homologu lors de l utilisation du systeme plasma e Pr venir les personnes aux alentours des risques encourus en cas d exposition au bruit
66. ncorn Cheshire England WA7 1TQ Tel 44 1928 579 074 Fax 44 1928 579 604 France 10 All e de l Isara F 95000 Cergy Pontoise France Tel 33 1 34 24 03 05 33 1 34 25 09 64 Italy Via Torino 2 20123 Milan Italy Tel 39 02 725 46 312 Fax 39 02 725 46 400 The Netherlands Burg Haverkampstraat 13 7091 CN Dinxperlo Holland Tel 31 315 655866 Fax 31 315 655886 EMC INTRODUCTION The CE power supplies have been built in compliance with standard EN50199 To ensure that the equipment works in a compatible manner with other radio and electronic systems the equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity In such cases it may be necessary to use other measures to further reduce interference This plasma equipment should be used only in an industrial environment It may be difficult to ensure electromagnetic compatibility in a domestic environment INSTALLATION AND USE The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer In some cases
67. ner Do not cut containers that have held combustible materials WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma WARNING A Hydrogen Detonation with Aluminum Cutting e When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen deto nation Refer to the Appendix section of this manual for aeration manifold details Hypertherm Plasma Systems SAFETY A gt ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause a fatal shock or severe burn Operating the plasma system completes an electrical circuit between the torch and the workpiece The workpiece and anything touching the workpiece are part of the electrical circuit Never touch the torch body workpiece or the water in a water table when the plasma system is operating Electric Shock Prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and
68. ns Figure 2 3 PAC123M Machine Torch Dimensions powermax600 Service Manual 2 3 10 99 SPECIFICATIONS S MARK 230 400 VOLT ONLY The 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 mark compliance SETUP SPECIFICATIONS Check Required Input Voltage se la nun Look at U1 data plate to check input voltage requirements The data plate is on the back of the power supply See Figure 2 4 powermax600 Plasma Cutting System HANOVER NH 03755 MADE IN U S A No 086000 S N 3 50199 PI EN50192 20A 88V 40A 96V 500V 20A 108V 40A 116V PRET 60 1007 HYP 12 40A 56 28 U HYP Ua 140V 140V 140V 0 12 40A 36A 29A Y 500 IEC 116V 114V 111V cos V 95 IP23CS COOLING E INSULATION Hi 190941 REV Figure 2 4 Data Plate Input Voltage Install Power Cord Plug Use a power cord plug that is certified by national or local electrical codes The plug should be connected to the power cord by a licensed electrician 2 4 powermax600 Service Manual 10 99 Power Cord Extension Cord SPECIFICATIONS Use cord that is certified by national or local codes The cord should be installed by a licensed electrician
69. oit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE S CURIT Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non autoris es sur la machine peuvent engendrer des probl mes de s curit et raccourcir la dur e d utilisation de l quipement DANGER AVERTISSEMENT PR CAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSE MENT sont situ es sur la machine pour signaler certains dangers sp cifiques Les messages d AVERTISSEMENT pr cedent les instructions d utilisation expliqu es dans ce manuel et signalent les risques de blessures ou de mort au cas ou ces instructions ne seraient pas suivies correctement Les messages de PRECAUTION pr c dent les instructions d utilisation contenues dans ce manuel et signalent que le mat riel risque
70. on hand torch or remote start switch for machine torch Gas solenoid valve V1 opens to purge system and to allow setting of pressure Cutting arc transfers to workpiece Pilot arc stops Cut arc starts Set gas pressure to 70 psi 4 5 bar Select cutting amps with current adjust knob Gas solenoid valve V1 opens Gas flow starts Gas solenoid valve V1 Pilot arc starts closes Gas flow stops Position torch on workpiece Power circuits ready e Depress plasma start switch on hand torch or remote start switch for machine torch 3 8 powermax600 Service Manual 10 99 MAINTENANCE TROUBLESHOOTING The complexity of the circuits require that service technicians have a working knowledge of inverter power supply theory 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 the phone numbers listed in the front of this manual Test Equipment e Multimeter Troubleshooting Procedures and Sequence Power OFF amp Disconnected e Refer to the system wiring diagram when performing the troubleshooting procedures Visual Inspection External e To locate power supply components refer to Section 4 Refer to Section 5 for torch components Visual Inspection e After the problem has been located and repaired refer to the Seq
71. ose made pursuant to this paragraph or with 5 written consent This warranty shall not apply to any Product which has been mishandled incorrectly installed modified or assembled by you or any other person Hypertherm shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable warranty period specified herein above THE FOREGOING SHALL CONSTITUTE THE SOLE REMEDY TO DISTRIBUTORS OR THEIR CUSTOMERS FOR ANY BREACH HYPERTHERM OF ITS WARRANTY PATENT INDEMNITY Except only in cases of Products not manufactured by Hypertherm or manufactured by a person other than Hyper therm not in strict conformity with Hypertherm s specifica tions and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm agrees to indemnify protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers be cause of the use in or about the construction or operation of equipment or any design system formula combination article or material which infringes or alleges to infringe on any patent or other right Distributors shall notify Hyper therm promptly upon learning of any action or threatened action in connection with any such alleged infringement and each party may appoint its own counsel for any such
72. owermax600 Service Manual 10 99 PARTS LIST 400 230V POWER SUPPLY FRONT INTERIOR RIGHT SIDE Part ltem Number Description Designator Qty 1 041593 Control PCB assembly PCB3 1 2 108090 Terminal block 1 3 129374 Solenoid valve V1 1 4 123375 Work Cable with clamp 4 6 m 15 ft 1 powermax600 Service Manual 4 3 10 99 PARTS LIST 400 230 POWER SUPPLY BACK INTERIOR RIGHT SIDE Part 5 r Designato Description Number Item v rrr r rrr T y m OO Ona gt gt gt gt gt gt WT AN OO OO OO X f f xr LT Deu DOL 0029 85 56555 EESPSOOB EO O O LL LLI LO ON O O O O N LO LO O SO FO O OO O O FT TAN NOOO O O O O r O t LO powermax600 Service Manual 4 4 10 99 PARTS LIST 400 230V POWER SUPPLY INTERIOR FAN SIDE Part Number 005112 022027 014232 014234 014238 009999 109118 014231 014241 011083 011086 011087 129366 Description Pressure Switch Pressure gauge Inductor output choke 80MH 40 Power transformer 400V Power transformer 230V Capacitor 1800 1900UF 400V Capacitor 1800 1900UF 230V Inductor input choke 5MH 11 400V Inductor input choke 5MH 11 230V Filter regulator subas
73. owermax600 Service Manual 3 11 10 99 MAINTENANCE Resistance Check 2 Figure 3 4 e Check resistance from power board connection to chassis 230 and 400V F gt 10MQ ww w e gt 10MQ 9 ___ PMX600 20 Figure 3 4 Resistance Check 2 Power Board to Chassis 3 12 powermax600 Service Manual 10 99 MAINTENANCE Resistance Check 3 Figure 3 5 e Check resistance across output diode bridge 230V and 400V J CE 6 to 9 KQ ZZ ZZ 4 to 7 v __ s PMX600 21 F Figure 3 5 Resistance Check 3 Output Diode Bridge powermax600 Service Manual 3 13 10 99 MAINTENANCE Troubleshooting Guide WARNING ELECTRIC SHOCK CAN KILL e Use extreme caution when working near live electrical circuits Dangerous volt ages exist inside the power supply that can cause serious injury or death e See warnings page 3 6 before proceeding If no problems were found during the initial res
74. powermax600 Plasma Arc Cutting System Service Manual 803400 Revision 2 u u na na la n um Ing pci LIGI The world leader in plasma cutting technology powermax600 Plasma Arc Cutting System Service Manual IM 340 P N 803400 Revision 2 NOVEMBER 1999 Hypertherm Inc Hanover NH USA http www hypertherm com email info hypertherm com Copyright 1999 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 Offices Worldwide Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA Tel 603 643 3441 Main Office Fax 603 643 5352 All Departments Tel 800 643 9878 Technical Service Tel 800 737 2978 Customer Service email info hypertherm com General Information email service hypertherm com Technical Customer Services Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 0 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 European Technical Support Organization ETSO Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Germany Tel 49 6181 58 2100 Fax 49 6181 58 2134 Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore Tel 65 841 2489 Fax 65 841 2490 Hypertherm U K 9 Berkeley Court Manor Park Ru
75. quand on utilise le syst me plasma S isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol s av re n cessaire de travailler dans ou pres d un endroit humide proc der avec une extr me prudence Installer sectionneur avec fusibles appropri s proximit de la source de courant Ce dispositif permet l op rateur d arr ter rapidement la source de courant en cas d urgence En cas d utilisation d une table eau s assurer que cette derni re est correctement mise la terre S CURIT LES CHOCS LECTRIQUES PEUVENT ETRE FATALS e Installer et mettre la terre l quipement selon les instructions du pr sent manuel et conform ment aux codes lectriques locaux et nationaux Inspecter fr quemment le cordon d alimentation primaire pour s assurer qu il n est ni endommag ni fendu Remplacer imm diatement un cordon endommag Un c ble d nud peut tuer Inspecter et remplacer les c bles de la torche qui sont us s ou endommag s Ne pas saisir la piece couper ni les chutes lors du coupage Laisser la pi ce couper en place ou sur la table de travail le c ble de retour connect lors du coupage Avant de v rifier de nettoyer ou de remplacer les pieces de la torche couper l alimentation ou d brancher la prise de courant Ne jamais contourner ou court circuiter le
76. reuse pour la sant Garder le visage l cart des vapeurs Utiliser un syst me de ventilation par aspiration ou d chappement localis pour dissiper les vapeurs Utiliser un ventilateur pour dissiper les vapeurs Les rayons de l arc peuvent br ler les yeux et provoquer des l sions de la peau Porter un casque et des lunettes de s curit Se prot ger les oreilles et porter une chemise dont le col peut tre d boutonn Porter un casque de soudure dont la protection filtrante est suffisante Porter des v tements protecteurs couvrant la totalit du corps oe former la technique du coupage et lire les instructions avant de manipuler l quipement ou de proc der au coupage Ne pas retirer ou peindre recouvrir les tiquettes de s curit 1a 6 HYPERTHERM Systemes plasma 08 99 Section 2 SPECIFICATIONS In this section SPECIFICATIONS POWER SUPPLY sise 2 2 SPECIFICATIONS 123 TORCHES 2 3 SETUP SPECIFICATIONS eene nnne retener ttt nnn 2 4 INSTALL POWER CORD 2 4 CHECK REQUIRED INPUT VOLTAGE 50 2 4 MARK 230 400 VOLT ONLY 2 4 GROUNDING REQUIREMENTS eene nnne nnn 2 5 POWER CORD EXTENSION 000 0000000000 0 2 5 GAS 2 6 LINE VOLTAGE DISCONNECT
77. s JO 196611 4210 pesseideq 1ueJno oJnsseJd sojeuiuinj 037 5 9 Ay zgod JoMod uedo yonis LA pesseid jou UDJIMS ue1S 1966111 43107 42101 SMO 1 7 371 Inq uo 1 JEUBIS ues 037 2 1591 SED ul si wajsAS Sjueuoduioo EuJ9 ui 5 paijdde si 414 11n2J125 Z uonipuoo 19AQ powermax600 Service Manual O TL 10 99 MAINTENANCE JeuuoJsueJ JBMOd uey 191e9JD UO 291 suid 7 f uo eoueisisoJ Aq JOSUAS 499u2 t 8 PLP 01 YOUMS YOOUD YOUMS 99e de1 uedo JO YOUMS H99U9 pue UOJIMS oinje19dW8 SAOWAL OU J J MOd uo 9 suid Aununuoo Aq youms 429u2 pleoq eoejdai jou xoeuo 1uesoud pleoq uo 9 suid OL 2 ou ue eoe dai juoseld s
78. s verrouillages de s curit Avant d enlever le capot du syst me ou de la source de courant couper l alimentation lectrique Attendre ensuite 5 minutes pour que les condensateurs se d chargent Ne jamais faire fonctionner le systeme plasma sans que les capots de la source de courant ne soient en place Les raccords expos s de la source de courant sont extr mement dangereux Lors de l installation des connexions attacher tout d abord la prise de terre appropri e Chaque syst me plasma Hypertherm est concu pour tre utilis uniquement avec des torches Hypertherm sp cifiques Ne pas utiliser des torches inappropri es qui pourraient surchauffer et pr senter des risques pour la s curit LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES 2 NI Le coupage peut produire des vapeurs et des gaz toxiques qui r duisent le niveau d oxygene dans l air et peuvent provoquer des blessures voire la mort Conserver le poste de coupage bien a r ou utiliser un masque respiratoire homologu Ne pas proc der au coupage pr s d endroits s effectuent le d graissage le nettoyage ou la vaporisation Certains solvants chlor s se d composent sous l effet des rayons ultraviolets et forment du phosgene HYPERTHERM Systemes plasma e Ne pas couper des m taux peints ou contenant des matieres toxiques comme le zinc galvanis le plomb le cadmium ou le b ryllum moins que la zone de travail Soit tr s bien ventil
79. se Size 208 240 VAC 230 VAC 400 VAC 480 VAC PMX600 04 Gas Requirements Air must be filtered to remove all dirt water and oil Contaminants can damage the power supply torch and consummables The power supply will not power up if the gas inlet pressure is below minimum CAUTION Do not exceed 120 psi 8 3 bar pressure at the power supply gas inlet Damage to system may result from higher pressures Minimum Gas Inlet Pressure 90 psi 6 2 bar Gas Flow 6 scfm 90 psi 170 l min 6 2 bar 2 6 powermax600 Service Manual 10 99 Section 3 MAINTENANCE In this section CONTROLS AND INDICATORS 3 2 INDICATOR LAMPS nnne tnt 3 2 eeu Tm 3 2 THEORY OF OPERATION 3 3 GENERAL AE 3 3 230 400 VOLT FUNCTIONAL DESCRIPTION siennes 3 4 208 240 480 VOLT FUNCTIONAL DESCRIPTION 3 6 SEQUENCE OF OPERATION eene ener nnn entren tnn 3 8 TROUBLESHOOTING 3 9 TEST EQUIPMENT 3 9 TROUBLESHOOTING PROCEDURES AND SEQUENCE 3 9 VISUAL INSPECTION EXTERNAL suisses 3 9 VISUAL INSPECTION INTERNAL 92 3 10 RESISTANCE CHECKS seen tette tette 3 11 TROUBLESHOOTING GUIDE eee ennemi 3 14 VOLTAGE
80. sembly Air filter element O ring Fan subassembly powermax600 Service Manual Designator PS1 L2 T2 T2 L1 L1 M1 10 99 PARTS LIST 400 230 POWER SUPPLY HEAT SINK ASSEMBLY 8 PMX600 28 Part Number Description Designator Qty 1 109088 Output diode D2 1 2 129406 EMI suppression capacitor 1 3 009849 Resistor 20 OHM 2 4 109080 IGBT pilot arc Q3 1 5 005222 Temp switch TS1 1 6 109079 IGBT module Q2 1 7 009849 Resistor 20 OHM 1 8 109067 MOV 1 9 109090 Input diode bridge 400V D1 1 109134 Input diode bridge 230V D1 1 10 041568 Power PCB 400V PCB2 1 041607 Power PCB 230V PCB2 1 11 008903 Thermal pad 3 12 027662 Thermal grease 5 02 tube 5 places 4 6 powermax600 Service Manual 11 99 PARTS LIST 400 230V RECOMMENDED SPARE PARTS POWERMAX600 230 400V Part Number Description Page Reference 001608 a Front end panel 4 2 001669 Rear end panel ERO 4 2 008965 5 se 4 2 110242 Operation 4 2 110258 instruction 4 2 11325 er Warning 2165 4 2 129400 POWO CON 4 2 041593 Control PCB assembly 4 3 1080908 Terminal DI00K 4 3 123070 m Work Cable with clamp 4 6 m 15 ft 4
81. the boundaries of the premises METHODS OF REDUCING EMISSIONS Mains Supply Cutting equipment should be connected to the mains supply according to the manufacturer s recommendations interference occurs it may be necessary to take additional precautions such as filtering of mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations powermax600 Service Manual Cutting Cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all
82. this remedial action may be as simple as earthing the cutting circuit see Earthing of Workpiece other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome ASSESSMENT OF AREA Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment ELECTROMAGNETIC COMPATIBILITY e Health of the people around for example the use of pacemakers and hearing aids f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond
83. uence of Operation flow diagram in this section to test the power supply for proper operation Resistance Checks Power ON Troubleshooting Voltage Checks Visual Inspection External 1 Inspect the outside of the power supply for damage to the cover and external components 2 Inspect the torch and the torch lead for damage powermax600 Service Manual 3 9 10 99 MAINTENANCE WARNING ELECTRIC SHOCK CAN KILL e Turn off the power and remove the input power plug from its receptacle before removing the cover from the power supply If the power supply is directly connected to a line disconnect box switch the line disconnect to OFF In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death Do not attempt to repair the power board or control board Do not cut away or remove any protective conformal coating from either board To do so will risk a short circuit between the AC input circuit and the output circuit and may result serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING FAN CAN CAUSE INJURY Keep hands away fro
84. unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard CUTTING CAN PRODUCE TOXIC FUMES 32 Cutting can produce toxic fumes and gases deplete oxygen and cause injury or death e Keep the cutting area well ventilated or use an approved air supplied respirator Do not cut in locations near degreasing cleaning or spraying operations The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation Do not cut metal coated or containing toxic materi als such as zinc galvanized lead cadmium or Hypertherm Plasma Systems beryllium unless the area is well ventilated and the operator wears an air supplied respirator The coatings and any metals containing these elements can produce toxic fumes when cut Never cut containers with potentially toxic materials inside they must be emptied and properly cleaned first This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer 1 3 8 99 SAFETY PLASMA ARC CAN CAUSE INJURY AND BURNS Instant On Tor

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