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S ERI ES

G3

_

+

4.05.0

5060

AC

7080

V

BAR

6.0

PSI

AMPS

30

40

100

80

60

Plasma Arc

Cutting System

Service Manual

804470 Revision 2

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Service Manual

(P/N 804470)

Revision 2 June, 2003

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Hypertherm, Inc.

Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)[email protected] (Main Office Email)

800-643-9878 Tel (Technical Service)[email protected] (Technical Service Email)800-737-2978 Tel (Customer Service)[email protected] (Customer Service Email)

Hypertherm Automation, LLC

5 Technology Drive, Suite 300West Lebanon, NH 03755 USA603-298-7970 Tel603-298-7977 Fax

Hypertherm Plasmatechnik, GmbH

Technologiepark HanauRodenbacher Chaussee 663457 Hanau-Wolfgang, Deutschland49 6181 58 2100 Tel49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

No. 19 Kaki Bukit Road 2K.B. Warehouse Complex

Singapore 417847, Republic of Singapore65 6 841 2489 Tel65 6 841 2490 Fax

65 6 841 2489 (Technical Service)

Hypertherm UK, Ltd.

9 Berkeley Court, Manor ParkRuncorn, Cheshire, England WA7 1TQ44 1928 579 074 Tel44 1928 579 604 Fax

France

15 Impasse des Rosiers95610 Eragny, France00 800 3324 9737 Tel00 800 4973 7329 Fax

Hypertherm S.r.l.

Via Torino 220123 Milano, Italia39 02 725 46 312 Tel39 02 725 46 400 Fax

39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.

Vaartveld 94704 SE Roosendaal, Nederland31 165 596907 Tel31 165 596901 Fax31 165 596908 Tel (Marketing)

31 165 596900 Tel (ETSO Technical Service)

00 800 49 73 7843 Tel (ETSO Technical Service

toll-free in Europe)

Japan

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ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION

Hypertherm's CE-marked equipment is builtin compliance with standard EN50199. The

equipment should be installed and used inaccordance with the information below toachieve electromagnetic compatibility.

The limits required by EN50199 may not beadequate to completely eliminate interfer-ence when the affected equipment is inclose proximity or has a high degree ofsensitivity. In such cases it may be neces-sary to use other measures to furtherreduce interference.

This plasma equipment is designed for useonly in an industrial environment.

INSTALLATION AND USE

The user is responsible for installing andusing the plasma equipment according tothe manufacturer's instructions. If electro-magnetic disturbances are detected then itshall be the responsibility of the user to re-solve the situation with the technical assis-tance of the manufacturer. In some casesthis remedial action may be as simple asearthing the cutting circuit, see Earthing ofWorkpiece. In other cases it could involveconstructing an electromagnetic screenenclosing the power source and the workcomplete with associated input filters. In allcases electromagnetic disturbances mustbe reduced to the point where they are nolonger troublesome.

ASSESSMENT OF AREA

Before installing the equipment the usershall make an assessment of potential elec-tromagnetic problems in the surroundingarea. The following shall be taken intoaccount:a. Other supply cables, control cables,signalling and telephone cables; above,below and adjacent to the cutting equip-

ment.b. Radio and television transmitters andreceivers.c. Computer and other control equipment.d. Safety critical equipment, for exampleguarding of industrial equipment.e. Health of the people around, forexample the use of pacemakers and hear-i id

Earthing of Workpiece

Where the workpiece is not bonded to earthfor electrical safety, nor connected to earth

because of its size and position, for example,ship's hull or building steelwork, a connectionbonding the workpiece to earth may reduceemissions in some, but not all instances.Care should be taken to prevent the earthingof the workpiece increasing the risk of injuryto users, or damage to other electrical equip-ment. Where necessary, the connection ofthe workpiece to earth should be made by adirect connection to the workpiece, but insome countries where direct connection isnot permitted, the bonding should beachieved by suitable capacitances selectedaccording to national regulations.

Note. The cutting circuit may or may not beearthed for safety reasons. Changing theearthing arrangements should only be au-thorized by a person who is competent toassess whether the changes will increasethe risk of injury, for example, by allowingparallel cutting current return paths which

may damage the earth circuits of otherequipment. Further guidance is given in IECTC26 (sec)94 and IEC TC26/108A/CD ArcWelding Equipment Installation and Use.

Screening and Shielding

Selective screening and shielding of othercables and equipment in the surroundingarea may alleviate problems of interference.Screening of the entire plasma cutting

installation may be considered for specialapplications

The size of the surrounding area to beconsidered will depend on the structure ofthe building and other activities that are tak-ing place. The surrounding area may extendbeyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Cutting equipment must be connected to themains supply according to the manufactur-er's recommendations. If interferenceoccurs, it may be necessary to takeadditional precautions such as filtering ofthe mains supply. Consideration should begiven to shielding the supply cable of per-manently installed cutting equipment, inmetallic conduit or equivalent. Shieldingshould be electrically continuous throughoutits length. The shielding should be connect-ed to the cutting mains supply so that goodelectrical contact is maintained between theconduit and the cutting power sourceenclosure

Maintenance of Cutting Equipment

The cutting equipment must be routinelymaintained according to the manufacturer'srecommendations. All access and servicedoors and covers should be closed andproperly fastened when the cuttingequipment is in operation. The cuttingequipment should not be modified in anyway except for those changes and adjust-ments covered in the manufacturer'sinstructions. In particular, the spark gaps ofarc striking and stabilizing devices shouldbe adjusted and maintained according tothe manufacturer's recommendations.

Cutting Cables

The cutting cables should be kept as shortas possible and should be positioned closetogether, running at or close to the floorlevel.

Equipotential Bonding

Bonding of all metallic components in thecutting installation and adjacent to it shouldbe considered. However, metallic compo-nents bonded to the workpiece will increasethe risk that the operator could receive a

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WARRANTY

WARNINGGenuine Hypertherm parts are the factory-recommendedreplacement parts for your Hypertherm system. Any damage

caused by the use of other than genuine Hypertherm parts maynot be covered by the Hypertherm warranty.

WARNINGYou are responsible for the safe use of the Product.Hypertherm does not and cannot make any guarantee orwarranty regarding the safe use of the Product in yourenvironment.

GENERALHypertherm, Inc. warrants that its Products shall be free fromdefects in materials and workmanship, if Hypertherm is notifiedof a defect (i) with respect to the power supply within a periodof two (2) years from the date of its delivery to you, with theexception of G3 Series power supplies, which shall be within aperiod of three (3) years from the date of delivery to you, and(ii) with respect to the torch and leads within a period of one (1)year from its date of delivery to you. This warranty shall notapply to any Product which has been incorrectly installed,

modified, or otherwise damaged. Hypertherm, at its soleoption, shall repair, replace, or adjust, free of charge, anydefective Products covered by this warranty which shall bereturned with Hypertherms prior authorization (which shall notbe unreasonably withheld), properly packed, to Hyperthermsplace of business in Hanover, New Hampshire, or to anauthorized Hypertherm repair facility, all costs, insurance andfreight prepaid. Hypertherm shall not be liable for any repairs,replacement, or adjustments of Products covered by thiswarranty, except those made pursuant to this paragraph or with

Hypertherms prior written consent. The warranty above isexclusive and is in lieu of all other warranties, express,implied, statutory, or otherwise with respect to theProducts or as to the results which may be obtainedtherefrom, and all implied warranties or conditions ofquality or of merchantability or fitness for a particularpurpose or against infringement. The foregoing shallconstitute the sole and exclusive remedy for any breachby Hypertherm of its warranty. Distributors/OEMs may offerdifferent or additional warranties, but Distributors/OEMs are

not authorized to give any additional warranty protection to youor make any representation to you purporting to be bindingupon Hypertherm.

PATENT INDEMNITYExcept only in cases of products not manufactured byHypertherm or manufactured by a person other than

Hypertherm, infringes any patent of any third party. You shallnotify Hypertherm promptly upon learning of any action orthreatened action in connection with any such alleged

infringement, and Hypertherms obligation to indemnify shall beconditioned upon Hypertherms sole control of, and theindemnified partys cooperation and assistance in, the defenseof the claim.

LIMITATION OF LIABILITYIn no event shall Hypertherm be liable to any person orentity for any incidental, consequential, indirect, orpunitive damages (including but not limited to lost profits)regardless of whether such liability is based on breach of

contract, tort, strict liability, breach of warranties, failure ofessential purpose or otherwise and even if advised of thepossibility of such damages.

LIABILITY CAPIn no event shall Hypertherms liability, whether suchliability is based on breach of contract, tort, strict liability,breach of warranties, failure of essential purpose orotherwise, for any claim action suit or proceeding arisingout of or relating to the use of the Products exceed in theaggregate the amount paid for the Products that gave riseto such claim.

INSURANCEAt all times you will have and maintain insurance in suchquantities and types, and with coverage sufficient andappropriate to defend and to hold Hypertherm harmless inthe event of any cause of action arising from the use of theProducts.

NATIONAL AND LOCAL CODESNational and Local codes governing plumbing and electricalinstallation shall take precedent over any instructionscontained in this manual. In no event shall Hypertherm beliable for injury to persons or property damage by reason of anycode violation or poor work practices.

TRANSFER OF RIGHTSYou may transfer any remaining rights you may have

hereunder only in connection with the sale of all or substantiallyall of your assets or capital stock to a successor in interest whoagrees to be bound by all of the terms and conditions of thisWarranty.

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TABLE OF CONTENTS

Electromagnetic Compatibility.......................................................................................................................................iWarranty.......................................................................................................................................................................ii

Section 1 SafetyRecognize Safety Information...................................................................................................................................1-2Follow Safety Instructions.........................................................................................................................................1-2Cutting Can Cause Fire or Explosion .......................................................................................................................1-2Electric Shock Can Kill..............................................................................................................................................1-3Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4

Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4Grounding Safety......................................................................................................................................................1-4Compressed Gas Equipment Safety ........................................................................................................................1-5Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5Noise Can Damage Hearing.....................................................................................................................................1-5Pacemaker and Hearing Aid Operation ....................................................................................................................1-5A Plasma Arc Can Damage Frozen Pipes ................................................................................................................1-5Additional Safety Information....................................................................................................................................1-5

Warning Label...........................................................................................................................................................1-6

Section 1a ScuritIdentifier les consignes de scurit.........................................................................................................................1a-2Suivre les instructions de scurit ..........................................................................................................................1a-2Danger Avertissement Prcaution ........................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2

Prvention des incendies, Prvention des explosions ...................................................................................1a-2

Risque dexplosion argon-hydrogne et mthane..........................................................................................1a-2Dtonation de lhydrogne lors du coupage de laluminium...........................................................................1a-2

Les chocs lectriques peuvent tre fatals...............................................................................................................1a-3Prvention des chocs lectriques ..................................................................................................................1a-3

Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3Larc plasma peut provoquer des blessures ou des brlures .................................................................................1a-4

Torches allumage instantan ......................................................................................................................1a-4Les rayons de larc peuvent brler les yeux et la peau...........................................................................................1a-4

Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4Mise la masse et la terre...................................................................................................................................1a-4

Cble de retour, Table de travail, Alimentation...............................................................................................1a-4Scurit des bouteilles de gaz comprim ...............................................................................................................1a-5Les bouteilles de gaz comprim peuvent exploser en cas de dommages .............................................................1a-5

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TABLE OF CONTENTS

Section 2 SpecificationsSpecifications Power Supply .................................................................................................................................2-2

Power Connection............................................................................................................................................2-3

Engine Drives...................................................................................................................................................2-3Duty Cycle........................................................................................................................................................2-4Power Supply Dimensions and Weight .........................................................................................................2-4

Specifications T100 Torches ..................................................................................................................................2-5Torch Dimensions .....................................................................................................................................................2-6Symbols and Markings .............................................................................................................................................2-7

Section 3 Maintenance

Controls and Indicators.............................................................................................................................................3-2Theory of Operation..................................................................................................................................................3-3General ............................................................................................................................................................3-3Functional Description......................................................................................................................................3-3

Sequence of Operation.............................................................................................................................................3-4Troubleshooting ........................................................................................................................................................3-5

Test Equipment ................................................................................................................................................3-5Troubleshooting Procedures and Sequence....................................................................................................3-5

Visual Inspection External.............................................................................................................................3-5Visual Inspection Internal ..............................................................................................................................3-6

Resistance Checks ...................................................................................................................................................3-7Troubleshooting Guide..............................................................................................................................................3-9Voltage Checks.......................................................................................................................................................3-14Component Replacement .......................................................................................................................................3-20

Power Cord Replacement ..............................................................................................................................3-20Torch Installataion ..........................................................................................................................................3-21

Filter Element Replacement...........................................................................................................................3-23Work Cable Replacement ..............................................................................................................................3-24Capacitor Replacement..................................................................................................................................3-25Heat Sink Component Replacement..............................................................................................................3-26

Section 4 Parts Power SupplyExterior .....................................................................................................................................................................4-2Interior Right Side .....................................................................................................................................................4-3

Back Interior Right side.............................................................................................................................................4-4Interior Fan Side .......................................................................................................................................................4-5Heat Sink Assembly..................................................................................................................................................4-6Recommended Spare Parts .....................................................................................................................................4-7

Section 5 Parts List Torch and Consumables

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Section 1

SAFETY

In this section:

Recognize Safety Information...................................................................................................................................1-2Follow Safety Instructions.........................................................................................................................................1-2Cutting Can Cause Fire or Explosion .......................................................................................................................1-2Electric Shock Can Kill..............................................................................................................................................1-3

Cutting Can Produce Toxic Fumes ...........................................................................................................................1-3A Plasma Arc Can Cause Injury and Burns ..............................................................................................................1-4Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4Grounding Safety......................................................................................................................................................1-4Compressed Gas Equipment Safety ........................................................................................................................1-5Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5Noise Can Damage Hearing.....................................................................................................................................1-5Pacemaker and Hearing Aid Operation ....................................................................................................................1-5

A Plasma Arc Can Damage Frozen Pipes ................................................................................................................1-5Additional Safety Information....................................................................................................................................1-5Warning Label...........................................................................................................................................................1-6

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SAFETYSAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used toidentify potential hazards. When you see a safetysymbol in this manual or on your machine, understandthe potential for personal injury, and follow the relatedinstructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual andsafety labels on your machine.

Keep the safety labels on your machine in goodcondition. Replace missing or damaged labelsimmediately.

Learn how to operate the machine and how to usethe controls properly. Do not let anyone operate it

without instruction.

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 asafety 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

instructions in this manual that may result in injuryor death if not followed correctly.

CAUTION safety messages precede relatedinstructions in this manual that may result in

damage to equipment if not followed correctly.

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 thecutting area.

Quench hot metal or allow it to cool before handlingor before letting it touch combustible materials.

Never cut containers with potentially flammable

materials inside they must be emptied andproperly cleaned first. Ventilate potentially flammable atmospheres before

cutting. When cutting with oxygen as the plasma gas, an

exhaust ventilation system is required.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNING

Explosion HazardArgon-Hydrogen and Methane

Hydrogen and methane are flammable gases thatpresent an explosion hazard. Keep flames away fromcylinders and hoses that contain methane or hydrogenmixtures. Keep flames and sparks away from the torchwhen using methane or argon-hydrogen plasma.

WARNING

Hydrogen Detonation with Aluminum Cutting

When cutting aluminum underwater, or with the

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Touching live electrical parts can cause a fatal shockor severe burn.

Operating the plasma system completes anelectrical circuit between the torch and theworkpiece. The workpiece and anything touchingthe workpiece are part of the electrical circuit.

Never touch the torch body, workpiece or the water

in a water table when the plasma system isoperating.

Electric Shock Prevention

All Hypertherm plasma systems use high voltagein the cutting process (200 to 400 VDC are

common). Take the following precautions whenoperating this system:

Wear insulated gloves and 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 anyphysical contact with the work or ground. If you mustwork in or near a damp area, use extreme caution.

Provide a disconnect switch close to the powersupply with properly sized fuses. This switch allows

the operator to turn off the power supply quickly inan emergency situation.

When using a water table, be sure that it is correctlyconnected to earth ground.

ELECTRIC SHOCK CAN KILL

Install and ground this equipment according to theinstruction manual and in accordance with nationaland local codes.

Inspect the input power cord frequently for damageor cracking of the cover. Replace a damaged powercord immediately. Bare wiring can kill.

Inspect and replace any worn or damaged torchleads.

Do not pick up the workpiece, including the wastecutoff, while you cut. Leave the workpiece in placeor on the workbench with the work cable attachedduring the cutting process.

Before checking, cleaning or changing torch parts,disconnect the main power or unplug the powersupply.

Never bypass or shortcut the safety interlocks. Before removing any power supply or system

enclosure cover, disconnect electrical input power.Wait 5 minutes after disconnecting the main powerto allow capacitors to discharge.

Never operate the plasma system unless the powersupply covers are in place. Exposed power supplyconnections present a severe electrical hazard.

When making input connections, attach propergrounding conductor first.

Each Hypertherm plasma system is designed to be

used only with specific Hypertherm torches. Do notsubstitute other torches which could overheat andpresent a safety hazard.

Cutting can produce toxic fumes and gases thatdeplete oxygen and cause injury or death.

Keep the cutting area well ventilated or use an

CUTTING CAN PRODUCE TOXIC FUMES

beryllium, unless the area is well ventilated and theoperator wears an air-supplied respirator. Thecoatings and any metals containing these elementscan produce toxic fumes when cut

SAFETY

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SAFETYSAFETY

Instant-On TorchesPlasma arc comes on immediately when the torchswitch is activated.

A PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc will cut quickly through gloves andskin. Keep away from the torch tip. Do not hold metal near the cutting path. Never point the torch toward yourself or others.

Eye Protection Plasma arc rays produce intensevisible and invisible (ultraviolet and infrared) rays thatcan burn eyes and skin. Use eye protection in accordance with applicable

national or local codes. Wear eye protection (safety glasses or goggles with

side shields, and a welding helmet) with appropriatelens shading to protect your eyes from the arcsultraviolet and infrared rays.

Lens Shade

Arc Current AWS (USA) ISO 4850Up to 100 A No. 8 No. 11

100-200 A No. 10 No. 11-12200-400 A No. 12 No. 13Over 400 A No. 14 No. 14

ARC RAYS CAN BURN EYES AND SKIN

Skin Protection Wear protective clothing to protectagainst burns caused by ultraviolet light, sparks andhot metal. Gauntlet gloves, safety shoes and hat.

Flame-retardant clothing to cover all exposed areas. Cuffless trousers to prevent entry of sparks and

slag. Remove any combustibles, such as a butane lighter

or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reducereflection and transmission of ultraviolet light: 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.

Work Cable Attach the work cable securely to theworkpiece or the work table with good metal-to-metalcontact. Do not connect it to the piece that will fall

GROUNDING SAFETY Input Power Be sure to connect the power cord ground wire to

the ground in the disconnect box. If installation of the plasma system involves

connecting the power cord to the power supply, besure to connect the power cord ground wire

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SAFETYSAFETY

Never lubricate cylinder valves or regulators with oilor grease.

Use only correct gas cylinders, regulators, hosesand fittings designed for the specific application.

Maintain all compressed gas equipment andassociated parts in good condition.

Label and color-code all gas hoses to identify thetype of gas in each hose. Consult applicablenational or local codes.

GAS CYLINDERS CANEXPLODE IF DAMAGED

COMPRESSED GAS EQUIPMENT SAFETY

Gas cylinders contain gas under high pressure. Ifdamaged, a cylinder can explode. Handle and use compressed gas cylinders in

accordance 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.

Prolonged exposure to noise from cutting or gougingcan damage hearing. Use approved ear protection when using plasma

system. Warn others nearby about the noise hazard.

NOISE CAN DAMAGE HEARING

Pacemaker and hearing aid operation can be affectedby magnetic fields from high currents.Pacemaker and hearing aid wearers should consult adoctor before going near any plasma arc cutting andgouging operations.

To reduce magnetic field hazards: Keep both the work cable and the torch lead to oneside, away from your body.

Route the torch leads as close as possible to thework cable.

Do not wrap or drape the torch lead or work cablearound your body.

Keep as far away from the power supply aspossible.

PACEMAKER AND HEARINGAID OPERATION

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, AmericanWelding Society, 550 LeJeune RoadP.O. Box 351020, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma ArcCutting, American Welding Society550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases inCylinders, Compressed Gas Association1235 Jefferson Davis Highway Arlington VA 22202

A PLASMA ARC CANDAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you

attempt to thaw them with a plasma torch.

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SAFETYSAFETY

WARNING LABELThis warning label is affixed to some power supplies. It isimportant that the operator and maintenance technician

understand the intent of these warning symbols as described.The numbered text corresponds to the numbered boxes onthe label.

1. Cutting sparks can cause explosion or fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, and havea watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury andburns.

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 ordamaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power beforeworking on machine.

4. Breathing cutting fumes can be hazardousto your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust toremove the fumes.

4.3 Use ventilating fan to remove the fumes.

5. Arc rays can burn eyes and injure skin.

5.1 Wear hat and safety glasses. Use earprotection and button shirt collar. Use

welding helmet with correct shade of filter.Wear complete body protection.

6. Become trained and read the instructionsbefore working on the machine or cutting.

7. Do not remove or paint over (cover)warning labels

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Section 1a

SCURIT

Dans cette section :

Identifier les consignes de scurit.........................................................................................................................1a-2Suivre les instructions de scurit ..........................................................................................................................1a-2Danger Avertissement Prcaution ........................................................................................................................1a-2Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2

Prvention des incendies, Prvention des explosions ...................................................................................1a-2Risque dexplosion argon-hydrogne et mthane..........................................................................................1a-2Dtonation de lhydrogne lors du coupage de laluminium...........................................................................1a-2

Les chocs lectriques peuvent tre fatals...............................................................................................................1a-3Prvention des chocs lectriques ..................................................................................................................1a-3

Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3Larc plasma peut provoquer des blessures ou des brlures .................................................................................1a-4

Torches allumage instantan ......................................................................................................................1a-4Les rayons de larc peuvent brler les yeux et la peau...........................................................................................1a-4

Protection des yeux, Protection de la peau, Zone de coupage ....................................................................1a-4Mise la masse et la terre...................................................................................................................................1a-4

Cble de retour, Table de travail, Alimentation...............................................................................................1a-4Scurit des bouteilles de gaz comprim ...............................................................................................................1a-5Les bouteilles de gaz comprim peuvent exploser en cas de dommages .............................................................1a-5Le bruit peut provoquer des problmes auditifs......................................................................................................1a-5Pacemakers et prothses auditives........................................................................................................................1a-5Un arc plasma peut endommager les tuyaux gels................................................................................................1a-5

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SCURIT

IDENTIFIER LES CONSIGNESDE SCURIT

Les symboles indiqus dans cette section sont utiliss pouridentifier les risques ventuels. Si vous trouvez un symbolede scurit, que ce soit dans ce manuel ou surlquipement, soyez conscient des risques de blessures etsuivez les instructions correspondantes afin dviter cesrisques.

SUIVRE LES INSTRUCTIONSDE SCURIT

Lire attentivement toutes les consignes de scurit dans leprsent manuel et sur les tiquettes de scurit se trouvantsur la machine.

Les tiquettes de scurit doivent rester lisibles.Remplacer immdiatement les tiquettes manquantes ouabmes.

Apprendre faire fonctionner la machine et utiliser

correctement les commandes. Ne laisser personne utiliserla machine sans connatre son fonctionnement.

Garder la machine en bon tat. Des modifications nonautorises sur la machine peuvent engendrer desproblmes de scurit et raccourcir la dure dutilisation

de lquipement.

DANGER AVERTISSEMENT PRCAUTION

Les signaux DANGER ou AVERTISSEMENT sont utilissavec un symbole de scurit, DANGER correspondant auxrisques les plus srieux.

Les tiquettes de scurit DANGER et AVERTISSEMENTsont situes sur la machine pour signaler certainsdangers spcifiques.

Les messages dAVERTISSEMENT prcdent lesinstructions dutilisation expliques dans ce manuel etsignalent les risques de blessures ou de mort au cas oces instructions ne seraient pas suivies correctement.

Les messages de PRCAUTION prcdent lesinstructions dutilisation contenues dans ce manuel et

signalent que le matriel risque dtre endommag si lesinstructions ne sont pas suivies correctement.

Prvention des incendies Avant de commencer, sassurer que la zone de coupage

ne prsente aucun danger. Conserver un extincteur proximit.

loigner toute matire inflammable une distance daumoins 10 m du poste de coupage.

Tremper le mtal chaud ou le laisser refroidir avant dele manipuler ou avant de le mettre en contact avec des

matriaux combustibles. Ne jamais couper des rcipients pouvant contenir desmatires inflammables avant de les avoir vids etnettoys correctement.

Arer toute atmosphre potentiellement inflammableavant dutiliser un systme plasma.

Lors de lutilisation doxygne comme gaz plasma un

LE COUPAGE PEUT PROVOQUER UN INCENDIEOU UNE EXPLOSION

AVERTISSEMENTRisque dexplosion

argon-hydrogne et mthane

Lhydrogne et le mthane sont des gaz inflammables etpotentiellement explosifs. Conserver lcart de touteflamme les bouteilles et tuyaux contenant des mlanges base dhydrogne ou de mthane. Maintenir toute flamme

et tincelle lcart de la torche lors de lutilisation dunplasma dargon-hydrogne ou de mthane.

AVERTISSEMENTDtonation de lhydrogne lors du

coupage de laluminium

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SCURIT

Toucher une pice lectrique sous tension peut provoquerun choc lectrique fatal ou des brlures graves.

La mise en fonctionnement du systme plasma ferme uncircuit lectrique entre la torche et la pice couper. Lapice couper et tout autre lment en contact avec cettepice font partie du circuit lectrique.

Ne jamais toucher le corps de la torche, la pice couperou leau de la table eau pendant le fonctionnement dusystme plasma.

Prvention des chocs lectriques

Tous les systmes plasma Hypertherm utilisent des hautestensions pour le coupage (souvent de 200 400 V). Ondoit prendre les prcautions suivantes quand on utilise le

systme plasma : Porter des bottes et des gants isolants et garder le corpset les vtements au sec.

Ne pas se tenir, sasseoir ou se coucher sur une surfacemouille, ni la toucher quand on utilise le systme plasma.

Sisoler de la surface de travail et du sol en utilisant destapis isolants secs ou des couvertures assez grandespour viter tout contact physique avec le travail ou le sol.Sil savre ncessaire de travailler dans ou prs dun

endroit humide, procder avec une extrme prudence. Installer un sectionneur avec fusibles appropris, proximit de la source de courant. Ce dispositif permet loprateur darrter rapidement la source de courant encas durgence.

En cas dutilisation dune table eau, sassurer que cettedernire est correctement mise la terre.

LES CHOCS LECTRIQUES PEUVENT TRE FATALS

Installer et mettre la terre lquipement selon lesinstructions du prsent manuel et conformment auxcodes lectriques locaux et nationaux.

Inspecter frquemment le cordon dalimentation primairepour sassurer quil nest ni endommag, ni fendu.Remplacer immdiatement un cordon endommag.Un cble dnud peut tuer.

Inspecter et remplacer les cbles de la torche qui sontuss ou endommags. Ne pas saisir la pice couper ni les chutes lors du

coupage. Laisser la pice couper en place ou sur latable de travail, le cble de retour connect lors ducoupage.

Avant de vrifier, de nettoyer ou de remplacer les picesde la torche, couper lalimentation ou dbrancher la prisede courant.

Ne jamais contourner ou court-circuiter les verrouillagesde scurit. Avant denlever le capot du systme ou de la source de

courant, couper lalimentation lectrique. Attendre ensuite5 minutes pour que les condensateurs se dchargent.

Ne jamais faire fonctionner le systme plasma sans queles capots de la source de courant ne soient en place.Les raccords exposs de la source de courant sontextrmement dangereux.

Lors de linstallation des connexions, attacher tout dabordla prise de terre approprie. Chaque systme plasma Hypertherm est conu pour tre

utilis uniquement avec des torches Hyperthermspcifiques. Ne pas utiliser des torches inappropries quipourraient surchauffer et prsenter des risques pour lascurit.

Le coupage peut produire des vapeurs et des gaz toxiquesqui rduisent le niveau doxygne dans lair et peuventprovoquer des blessures, voire la mort.

Conser er le poste de co page bien ar o tiliser n

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

soit trs bien ventile et que loprateur porte un masquerespiratoire. Les revtements et mtaux contenant cesmatires peuvent produire des vapeurs toxiques lors duco page

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SCURIT

Torches allumage instantan

Larc plasma sallume immdiatement aprs que la torchesoit mise en marche.

LARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRLURES

Larc plasma coupe facilement les gants et la peau. Rester loign de lextrmit de la torche. Ne pas tenir de mtal prs de la trajectoire de coupe. Ne jamais pointer la torche vers soi ou dautres

personnes.

Protection des yeux Les rayons de larc plasmaproduisent de puissants rayons visibles ou invisibles(ultraviolets et infrarouges) qui peuvent brler les yeux et lapeau.

Utiliser des lunettes de scurit conformment aux codeslocaux ou nationaux en vigueur. Porter des lunettes de protection (lunettes ou masque

muni dcrans latraux et encore masque de soudure)avec des verres teints appropris pour protger les yeuxdes rayons ultraviolets et infrarouges de larc.

Puissance des verres teintsCourant de larc AWS (.-U.) ISO 4850

Jusqu 100 A No

8 No

11100-200 A No 10 No 11-12200-400 A No 12 No 13Plus de 400 A No 14 No 14

Protection de la peau Porter des vtements de scuritpour se protger contre les brlures que peuvent causer lesrayons ultraviolets, les tincelles et le mtal brlant :

LES RAYONS DE LARC PEUVENT BRLER LES YEUX ET LA PEAU

Gants crispin, chaussures et casque de scurit. Vtements ignifuges couvrant toutes les parties exposes

du corps. Pantalon sans revers pour viter que des tincelles ou

des scories puissent sy loger. Avant le coupage, retirer de ses poches tout objetcombustible comme les briquets au butane ou lesallumettes.

Zone de coupage Prparer la zone de coupage afin derduire la rverbration et la transmission de la lumireultraviolette : Peindre les murs et autres surfaces de couleur sombre

pour rduire la rflexion de la lumire. Utiliser des crans et autres dispositifs de protection afinde protger les autres personnes de la lumire et de larverbration.

Prvenir les autres personnes de ne pas regarder larc.Utiliser des affiches ou des panneaux.

Cble de retour Bien fixer le cble de retour (ou demasse) la pice co per o la table de tra ail de faon

MISE LA MASSE ET LA TERRE Alimentation Sassurer que le fil de terre du cordon dalimentation est

connect la terre dans le coffret du sectionneur. Sil est ncessaire de brancher le cordon dalimentation

la source de courant lors de linstallation du systme

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SCURIT

Ne jamais lubrifier les robinets des bouteilles ou lesrgulateurs avec de lhuile ou de la graisse.

Utiliser uniquement les bouteilles, rgulateurs, tuyaux etaccessoires appropris et conus pour chaque applicationspcifique.

Entretenir lquipement et les pices dquipement gazcomprim afin de les garder en bon tat.

tiqueter et coder avec des couleurs tous les tuyaux degaz afin didentifier le type de gaz contenu dans chaquetuyau. Se rfrer aux codes locaux ou nationaux envigueur.

LES BOUTEILLES DE GAZCOMPRIM PEUVENT EXPLOSEREN CAS DE DOMMAGES

SCURIT DES BOUTEILLES DEGAZ COMPRIM

Les bouteilles de gaz contiennent du gaz haute pression.Si une bouteille est endommage, elle peut exploser. Manipuler et utiliser les bouteilles de gaz comprim

conformment aux codes locaux ou nationaux. Ne jamais utiliser une bouteille qui nest pas place la

verticale et bien assujettie. Le capuchon de protection doit tre plac sur le robinet

sauf si la bouteille est en cours dutilisation ou connecte

pour utilisation. viter tout prix le contact lectrique entre larc plasma et

une bouteille. Ne jamais exposer des bouteilles une chaleur

excessive, aux tincelles, aux scories ou aux flammesnues.

Ne jamais utiliser des marteaux, des cls ou dautresoutils pour dbloquer le robinet des bouteilles.

Une exposition prolonge au bruit du coupage ou dugougeage peut provoquer des problmes auditifs. Utiliser un casque de protection homologu lors de

lutilisation du systme plasma. Prvenir les personnes aux alentours des risquesencourus en cas dexposition au bruit.

LE BRUIT PEUT PROVOQUER DESPROBLMES AUDITIFS

Les champs magntiques produits par les courants hautetension peuvent affecter le fonctionnement des prothsesauditives et des pacemakers. Les personnes portant cetype dappareil doivent consulter un mdecin avant de

sapprocher dun lieu o seffectue le coupage ou legougeage plasma.

Pour rduire les risques associs aux champs magntiques : Garder loin de soi et du mme ct du corps le cble de

retour et le faisceau de la torche. Faire passer le faisceau de la torche le plus prs possible

du cble de retour. Ne pas senrouler le faisceau de la torche ou le cble de

retour autour du corps. Se tenir le plus loin possible de la source de courant.

PACEMAKERS ETPROTHSES AUDITIVES

Les tuyaux gels peuvent tre endommags ou clatersi l'on essaie de les dgeler avec une torche plasma.

UN ARC PLASMAPEUT ENDOMMAGER

LES TUYAUX GELS

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SCURIT

tiquette de scuritCette tiquette est affiche sur la source de courant. Il est importantque lutilisateur et le technicien de maintenance comprennent la

signification des symboles de scurit. Les numros de la listecorrespondent aux numros des images.

1. Les tincelles produites par le coupagepeuvent provoquer une explosion ou unincendie.

1.1 Pendant le coupage, loigner toute matireinflammable.

1.2 Conserver un extincteur proximit etsassurer quune personne soit prte lutiliser.

1.3 Ne jamais couper de rcipients ferms.

2. Larc plasma peut provoquer des blessureset des brlures.

2.1 Couper lalimentation avant de dmonter latorche.

2.2 Ne pas tenir la surface couper prs de latrajectoire de coupe.

2.3 Porter des vtements de protectioncouvrant tout le corps.

3. Un choc lectrique caus par la torche oules cbles peut tre fatal. Se protgercontre les risques de chocs lectriques.

3.1 Porter des gants isolants. Ne pas porter degants mouills ou abms.

3.2 Sisoler de la surface de travail et du sol.

3.3 Dbrancher la prise ou la source decourant avant de manipuler lquipement.

4. Linhalation des vapeurs produites par le

coupage peut tre dangereuse pour lasant.

4.1 Garder le visage lcart des vapeurs.

4.2 Utiliser un systme de ventilation paraspiration ou dchappement localis pourdissiper les vapeurs.

4.3 Utiliser un ventilateur pour dissiper lesvapeurs.

5. Les rayons de larc peuvent brler les yeuxet provoquer des lsions de la peau.

5.1 Porter un casque et des lunettes descurit. Se protger les oreilles et porterune chemise dont le col peut tredboutonn. Porter un casque de soudure

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Section 2

SPECIFICATIONS

In this section:

Specifications Power Supply .................................................................................................................................2-2

Power Connection............................................................................................................................................2-3Engine Drives...................................................................................................................................................2-3Duty Cycle........................................................................................................................................................2-4Power Supply Dimensions and Weight .........................................................................................................2-4

Specifications T100 Torches ..................................................................................................................................2-5Torch Dimensions .....................................................................................................................................................2-6Symbols and Markings .............................................................................................................................................2-7

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Rated Open Circuit Voltage (U0) 300 VDC

Output Characteristic* Drooping*Defined as a plot of output voltageversus output currentRated Output Current (I2) 30A 100AHypertherm Standard Rated Output 160 VDCVoltage (U2)Duty Cycle (X*) at 104F (40C) at U1 Volts AC rms Xrated conditions (U1, I1, U2, I2) 200-208 VAC 3PH 60%

230-240 VAC 3PH 70%*X = Ton/Tbase, 380-415 VAC 3PH 80%

Ton = time, minutes 480 VAC 3PH 80%Tbase = 10 minutes 600 VAC 3PH 80%

Operating temperature 14o to 104o F (-10o to 40o C)Rated AC phases (PH) and line frequency (Hz) PH Hz

Standard and CE Model 3 50-60Rated Input Voltage (U1), rated Input U1 Volts AC rms I1-Amps rms I1eff

Current (I1) and I1eff* at rated Output 200-208 VAC 3PH 53 41U2 and I2 cutting only. 230-240 VAC 3PH 46 38380-415 VAC 3PH 27 24

*I1eff = (I1) X used to determine 480 VAC 3PH 22 20rating of power cord. 600 VAC 3PH 21 19

U1 Volts AC rms Harmonic DisplacementPower Factor Power Factor

Power Factor 200-208 VAC 3PH 0.94 0.98230-240 VAC 3PH 0.94 0.98

380-415 VAC 3PH 0.94 0.99480 VAC 3PH 0.94 0.99600 VAC 3PH 0.78 0.99

Rsce Short Circuit RatioCE Model only U1 Volts AC rms, 3PH Rsce400 VAC 191230 VAC 142

This equipment conforms to IEC 61000-3-12,provided that Rsce min= 191 at 400VAC 3PH

and 142 at 230 VAC 3PH.

IP codeDegree of protection IP23CS*provided by enclosure IP International Protection

2 No ingress foreign objects >=12.5mm (0.5 in)3 No harmful ingress spraying waterC AC line circuits protected against ingress of

tool >=2.5 mm dia. x 100 mm long

SPECIFICATIONS

Specifications Power Supply

SPECIFICATIONS

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SPECIFICATIONS

Standard Model

Input Voltage 200-208 230-240 400 480 600

Input Current at 16kw Output 53 46 27 22 21

Input Current during ArcStretch 75 72 42 34 33

Recommended Fuse 80 80 50 40 40

CE Model

Input Voltage 230 400

Input Current at 16kw Output 46 27

Input Current during ArcStretch 72 42

Recommended Fuse 80 50

Three Phase

Three Phase

Power Connection

The Powermax1650 is a universal power supply that configures itself to operate with AC voltages from 200 to 600

3PH (230-400 3PH for CE model). Use a line disconnect switch for each power supply so that the operator can turnoff the power supply quickly in an emergency. Locate the switch so it is easily accessible to the operator. Theinterrupt level of the switch must be equal to or exceed the continuous rating of the fuses. Use slow-blow fusesrated per local and national electrical codes.

Engine Drives

When using an engine drive to power the Powermax1650:

The engine drive must be dedicated to powering the plasma cutting system. Engine drive operation:

1. Set the engine drive output to 3 phase AC.2. Plug the Powermax1650 power cord into the power outlet.3. Set the engine drive to the maximum output (see table below).

Use unshielded consumables if you experience difficulty cutting thicker material (non-CE systems only).

Standard Unit3 Phase, 50/60 hz, 200 600 VAC (480 VAC recommended for best performance)

CE Unit3 Phase 50/60 hz 230 400 VAC (400 VAC recommended for best performance)

SPECIFICATIONS

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SPECIFICATIONS

_

+

4.05.0

5060

AC

7080

V

BAR

6.0

PSI

AMPS

30

40

100

80

60

Power Supply Dimensions and Weight

Weight of power supplywithout torch

124 lb(56.2 kg)

26.4 in

(671 mm)

16.8 in(427 mm)

25.8 in

(655 mm)

Duty Cycle

Duty cycle is the percentage of time, during a 10 minute period, that the power supply can cut continuously. The

diagram below depicts an 80% duty cycle.Note: Refer to Specifications Power Supply to determine the duty cycle that corresponds with the input power.

8 minutescutting

2 minutesresting

SPECIFICATIONS

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SPECIFICATIONS

Cutting Capacity At 100 Amps

Recommended capacity 1-1/4 inch (32 mm)

Maximum capacity 1-1/2 inch (38 mm)

Severance capacity 1-3/4 inch (45 mm)

Gouging Capability 22.8 pounds (10.4 kg) hour(metal removal rate on mild steel)

Weight

T1007.2 pounds (3.3 kg) with 25 ft (7.5 m) lead

13.9 pounds (6.3 kg) with 50 ft (15 m) lead

8.3 pounds (3.8 kg) with 25 ft (7.5 m) leadT100M 11.0 pounds (5.0 kg) with 35 ft (10.7 m) lead

15.0 pounds (6.8 kg) with 50 ft (15 m) lead

Specifications T100 Torches

SPECIFICATIONS

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SPECIFICATIONS

Torch Dimensions

T100 Hand Torch Dimensions

8.9" (226 mm)

4.2"

(107 mm)

1.5"(38 mm)

1.00"(25 mm)

T100M Machine Torch Dimensions

15.47"(393 mm)

1.00"(25 mm)

1.38"

(35 mm)

2.35"(60mm)

8"(203 mm)

32 pitch .125" (3.2 mm) width

2.55"(65 mm)

SPECIFICATIONS

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SPECIFICATIONS

Symbols and Markings

S MARK

The S mark indicates that the power supply and torch are suitable for use in environments with increased hazardof electrical shock. The hand torches must have shielded consumable parts to maintain S mark compliance.

IEC Symbols Used

The following symbols may appear on the power supply data plate, control labels and switches.

O

l

Direct Current (DC)

The terminal for the externalprotective (earth) conductor

AC input power connection

Plasma torch cutting and gouging

Alternating current (AC)

An inverter-based powersource

Volt/amp curve, "drooping"characteristic

Power is off

Power is on

Plasma torch in the TESTposition (cooling and cuttinggas exiting nozzle)

SPECIFICATIONS

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SPECIFICATIONS

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Section 3

MAINTENANCE

In this section:

Controls and Indicators.............................................................................................................................................3-2

Theory of Operation..................................................................................................................................................3-3General ............................................................................................................................................................3-3Functional Description......................................................................................................................................3-3

Sequence of Operation.............................................................................................................................................3-4Troubleshooting ........................................................................................................................................................3-5

Test Equipment ................................................................................................................................................3-5Troubleshooting Procedures and Sequence....................................................................................................3-5Visual Inspection External.............................................................................................................................3-5Visual Inspection Internal ..............................................................................................................................3-6

Resistance Checks ...................................................................................................................................................3-7Troubleshooting Guide..............................................................................................................................................3-9Voltage Checks.......................................................................................................................................................3-14Component Replacement .......................................................................................................................................3-20

Power Cord Replacement ..............................................................................................................................3-20Torch Installataion ..........................................................................................................................................3-21Filter Element Replacement...........................................................................................................................3-23Work Cable Replacement ..............................................................................................................................3-24Capacitor Replacement..................................................................................................................................3-25

Heat Sink Component Replacement..............................................................................................................3-26

MAINTENANCE

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Controls and Indicators

_ +

4.0 5.0

50 60

AC

70 80

V

BAR

6.0

PSI

AMPS

30

40

100

80

60

Current(Amps)Adjustment /Gas TestKnob

Mode Switch

IndicatorLEDs

PressureGauge

PressureRegulator

ON (I) / OFF (0)Switch

Green Power ON LEDWhen illuminated, indicates that power is applied to system and power switch is ON ( I ).

Gas Pressure LEDYellow: When flashing, indicates that the gas pressure is below 65 psig (4.5 bar) for cutting, or 40 psig(2.8 bar) for gouging.Green: When illuminated, indicates acceptable gas pressure for torch operation.

Yellow Torch Cap LEDWhen illuminated, indicates that the Retaining Cap is loose or not installed.NOTE: Condition must be corrected and power turned OFF then ON to clear LED.

Yellow Temp LEDWhen illuminated, indicates that the power supply temperature has exceeded its operating limit.

AC

Indicator LEDs

MAINTENANCE

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Theory of Operation

General

Refer to Functional Description, Sequence of Operation and the system wiring diagram in Section 6.

Functional DescriptionAC power enters the system through the power switch S1 to the input diode bridge D24. The voltage from the diodebridge supplies the Power Factor Correction (PFC) Boost Converter which provides a 750 VDC bus voltage. Thebus voltage then supplies the inverter and the flyback system power supply (DC to DC converter) on the powerboard PCB2. The power board provides noise suppression and spike protection. A "soft start" is implemented via

the power board resistor and relay K1.

The PFC Boost Converter consists of an isolated gate bipolar transistor (IGBT) Q14, choke and control circuit. It providesa 750 VDC bus voltage when input AC voltage is between 170 and 540 VAC. When the input voltage is above 540 VACthe bus voltage will rise to Vin* 2.

The inverter consists of an IGBT Q13, the power transformer T2, a current sense transformer, and sections of thepower board. The inverter operates as a pulse-width, modulator-controlled bridge circuit, and is rectified by theoutput diode.

The output circuitry consists of 2 current transfer sensors located on the power board, the pilot arc IGBT Q15 andthe output choke.

The control boards microprocessor monitors and regulates system operation and safety circuits. The current is setto the desired value by adjusting the current adjustment knob. The system compares the set point to the outputcurrent by monitoring the current sensor and adjusting the pulse width output of the inverter IGBT Q13.

The control board PCB3 includes a pilot arc control switch, allowing the operator to turn the pilot arc ON (useful

when cutting expanded metal), OFF (for maximum life of consumables), or increase the pilot arc to 30A (useful forgouging or non-transferred-arc cutting).

MAINTENANCE

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Sequence of Operation

System OFF

Connect gas supply to filter on power unit. Connect work lead to work piece.

Apply power at line voltage disconnect box. Set ON/OFF switch S1 to ON (I)

Set power switch S1 to OFF (0).

Gas solenoid valve V1 closes. Gas flow stops.

Consumables reseat.

Arc extinguishes. Post flow continues for 30 seconds.

Arc transfers to plate. Move torch to make cut. Work piece falls away after cut. Release plasma start switch on hand torch or

remote start switch for machine torch.

Inverter starts. Current flows through torch with nozzle and

electrode shorted. Gas solenoid valve V1 opens. Gas flow starts. Torch "blows back" - nozzle and electrode

separate. Pilot arc starts.

Position torch on work piece. Depress plasma start switch on hand torch or

remote start switch for machine torch.

Set gas pressure (see Setupsection inOperator Manual).

Select desired cutting amps with currentadjustment knob.

Gas solenoid valve V1 opens to purge systemand to allow setting of pressure.

Turn current adjustment knobcounterclockwise to gas test position.

Check air pressure setting.

Power ON lamp illuminates and GasPressure LED illuminates green, indicatingsystem is ready for operation.

Fault LEDs should not be illuminated (seeTroubleshootingfor more information)

MAINTENANCE

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TROUBLESHOOTING

The complexity of the circuits requires 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 nearest Hypertherm Technical Services Department listed inthe front of this manual.

Test Equipment

Multimeter

Troubleshooting Procedures and Sequence

When performing the troubleshooting procedures,

Refer to Section 6 for the system wiring diagram;

Refer to Section 4to locate power supply components;

Refer to Section 5 for torch components.

After the problem has been located and repaired, refer to theSequence of Operationflow diagram in this section to test the powersupply for proper operation.

Visual Inspection External1. 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.

Power OFF &Disconnected

Visual InspectionExternal

Power ON

Visual Inspection

Internal

Resistance Checks

TroubleshootingGuide

Voltage Checks

MAINTENANCE

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WARNING


Turn off the power and remove the input power plug from its receptacle before removingthe cover from the power supply. If the power supply is directly connected to a linedisconnect box, switch the line disconnect to OFF (O). 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 powersupply that can cause serious injury or death.

Do not attempt to repair the power board or control board. Do not cut away or removeany protective conformal coating from either board. To do so will risk a short circuitbetween the AC input circuit and the output circuit and may result serious injury ordeath.

HOT PARTS CAN CAUSE SEVERE BURNS

Allow the power supply to cool before servicing.

MOVING BLADES CAN CAUSE INJURY

Keep hands away from moving parts.

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards.

Visual Inspection Internal

1. Set the ON/OFF switch S1 to O (OFF), unplug the power cord and disconnect the gas supply.

2. Remove the cover of the power supply by removing the 18 securing screws.

3. Inspect the inside of the power supply, especially on the side with the power board. Look for broken or loosewiring connections, burn and char marks, damaged components, etc. Repair or replace as necessary.

MAINTENANCE

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Resistance Checks

All resistance values must be taken with the power cord disconnected and all internal power supply wires attached.

Perform Visual Inspection Internal before continuing in this section.

If resistance values are not close to the values given in this section, isolate the problem by removing wiresattached to the resistance check points or component until the problem is found.

After the problem has been located and repaired, refer to the Sequence of Operationflow diagram in thissection to test the power unit for proper operation.

Resistance Check #1

1. With the power disconnected, set the ON/OFF switch S1 to ON.

2. Check resistance across input leads.

3. Check resistance from input leads to ground.

Note: All values are 15%.

2.4 M

2.4 M2.4 M

>20 M

MAINTENANCE

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Resistance Check #2 Remove the linkage bar as shown below. Check each diode (connection 1 and 3) with an ohm meter in diode test mode.

Value should be open with meter leads in one direction and 0.1V to 1.0V with meter leads reversed.Diode is shorted if value is less than 0.1V. Replace diode.Diode is open if value is greater than 1.0V in both directions. Replace diode.

Linkage bar

Note: Black marker on wireto lower diodes.

MAINTENANCE

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WARNING


Use extreme caution when working near live electrical circuits. Dangerous voltages existinside the power supply that can cause serious injury or death.

See warnings on page 3-7 before proceeding.

If no problems were found during the initial resistance checks and the power supply still does not operate correctly,see the Troubleshooting Guideon the following pages.

Note: The Troubleshooting Guideprovides most probable causes and solutions. Study the system wiring diagramand understand the theory of operation before troubleshooting. Before purchasing a major replacementcomponent, verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility.

Troubleshooting Guide

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MA

3-12

0

Worn consumables Worn-out consumables Replace consumablesWhen pressing torcht i / t t it h il t

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AINTENANCE

2

powermax1650ServiceManu

al

Improper air pressuresetting or low flow

Insufficient supply or air leakon supply line

Turn current adjust knob to test flow and set pressureregulator to 75 psi (5.2 bar) for cutting or 50 psi (3.4bar) for gouging. If unable to adjust to proper setting,verify that inlet pressure is between 90 psi (6.1 bar)and 120 psi 8.3 bar .

Poor quality air Moisture or contaminates in airsuppl Add appropriate filtration and purge lines with nitrogento flush out oil and moisture.Insufficient input power Undersized electrical supply

installation:- Breaker/fuse- Supply wire

Verify external electrical power is installed perspecifications in section 2. Check input voltage whiletrying to fire torch. Voltage drop indicates undersizedelectrical supply installation.

Inverter fault or interlock Power board (PCB2) failure If the control board (PCB2) IF LED illuminates and oneor more of the fault LEDs illuminate, then the fault iscaused by the parameter monitored by the fault LED. Ifno fault LED is illuminated replace power board.

Poor work lead connection Verify work lead is attached to workpiece andworkpiece is free of rust, paint, etc.

Damaged work lead Check continuity of work lead. Replace or repair asre uired.

Defective pilot arc IGBT (Q15) Turn power OFF, remove consumables, checkresistance between plunger and work piece. Ifresistance is greater than 8k ohms. Inspect work lead.Check pilot arc IGBT resistance between two screws atQ15 on power board. If resistance is less than 5kohms replace pilot arc IGBT.

Current adjustment set too low Verify current adjust knob is at proper setting (turn tomax, full clockwise .

Defective power board currentsensor

Replace power board. Can confirm power output bymeasurin with a DC current clamp meter on work

Mode switch set wrong Set mode switch to correct position.

Faulty control board (PCB3) Replace control board.

Inadequate ground

Low output from powersupply

Losing pilot arc when going

off plate while in continuous

ilot mode

Continous pilot arc doesnot work.

trigger/start switch, pilot arc

starts but pops out beforethe normal 5 second time-out

period

Machine will not cut material(does not appear to be

operating at full cutting

power)

MAINTENANCE

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This May Mean Cause Solution

Start LED on control board(PCB3) and Fault lamp areilluminated

Continuous start signal Shorted start wires ordepressed start triggerswitch

Check start wires (blueand orange wires in torch)for short.

Receiving start signal fromCNC

Check CNC cable for startsignal (Machine interfacepins 3 and 4).

Start and XFR LEDs on

control board (PCB3)

Arc transfer Normal operation N/A

SDF LED on control board(PCB3) and Fault lamp are

illuminated

Self diagnostic failure Microprocessor failure Replace control board(PCB3). If SDF LEDpersists replace powerboard (PCB2).

Start and IF LEDs on

control board (PCB3) and

Fault lamp are illuminated

Invertor interlock No current from invertor,power board (PCB2),control board (PCB3), orIGBTs

Start and TSO LEDs on

control board (PCB3)

Torch stuck in openposition

Torch plunger stuck,consumables are worn, ordefective Pilot Arc IGBT

See Resistance Check#3, in this section.

Problem

(VISIBLE FOR 10 SEC. AFTER EVENT)

TORCH STUCK OPEN

(VISIBLE FOR 10 SEC. AFTER EVENT)

7050STATUS

GAS

45 6055 65 75 80 85

TSO

SP SPARE

DIAGNOSTIC LED'S

START SIGNAL VALID

INVERTER INTERLOCK

(BLINKING @ 1 SEC. RATE)

SELF DIAGNOSTICS FAILURECPA

NORMAL

GOUGECURRENT DOWN

MID

UP

P1

XFR

SDF

IF

TRANSFER

START

START

XFR

START

SDF

IF

START

START

MAINTENANCE

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Voltage Checks

Voltage Check #1

Check input voltage to the input diode bridge. The AC voltage between any 2 input wires should equal the line voltage.


= Line Voltage*

= Line Voltage

= Line Voltage*

MAINTENANCE

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Voltage Check #2 Check output voltage of the input diode bridge. Output VDC = Line Voltage * 1.414


Line Voltage * 1.414

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Voltage Check #3 Check voltage across IGBT module (Q14).


750 VDC

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Voltage Check #4 Check voltage across IGBT module (Q13).


750 VDC

375 VDC

375 VDC

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Voltage Check #5 Check voltage across power supply capacitors.


375 VDC

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Resistance Check #3 Troubleshoot illuminated Torch Stuck Open LED on control board PCB3.

1. Check resistance between Q15 and J17. The value should be < 1

.If not, check torch leads, torch head, and consumables.

2. Check resistance between Q15 and J17 with system in Gas Test mode. The value should be > 1 M.If not, verify electrode and torch plunger move freely.

3. Pilot arc shorted check resistance between Q15 and J17 with torch removed. If value is < 1 K replace PilotArc IGBT.

4. Pilot arc open use a jumper wire to jump J14 to Q15. Then attempt to fire the torch. If the torch fires replacethe Pilot Arc IGBT.


J17

Pilot Arc IGBTQ15

J14

MAINTENANCE

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WARNING


Use extreme caution when working near live electrical circuits. Dangerous voltages existinside the power supply that can cause serious injury or death.

See warnings on page 3-7 before proceeding.

Component Replacement

_

+

4.05.0

50 60

AC

70 80

V

BAR

6.0

PSI

AMPS

30

40

100

80

60

L1

#10

Ground

L2

6 (152 mm)

9.5 (241 mm)

Route power cord

through strain

relief and tighten.

Power Switch

L1

L3

Strain relief

Strip and prepare the power cord wires as shown below:

Power Cord Installation

Connect power cord to power switch.

Note: Select the smallest strain relief insertthat fits on to the power cord.

Standard Unit CE Unit

L1 Black Black (U)

L2 White Blue (V)

L3 Red Brown (W)

PE Green Green/Yellow

L3L2

MAINTENANCE

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Torch Installation

Turn OFF power.

Remove power cord from power receptacle.

Open Easy Torch Removal (ETR) door and route lead through the end cap.

OFF

ON

AC V

AMPS

30

40

100

80

60

MAINTENANCE

f

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Align marks on strain relief.

Pull back quick-release collar and insert the leads gas fitting.

Slide quick-release collar foward to lock the gas fitting in place. Make sure that thegas fitting is secure.

Make sure that the red dot on the connector is on top, then plug in the electricalconnector. Close ETR door.

Quick ReleaseCollar

MAINTENANCE

Filt El t R l t

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Filter Element Replacement

A

B

C

Disconnect electrical power and gas supply.Remove filter bowl on new and old filter.A. Pull down black release tab and hold.B. Rotate filter bowl until it is released.C. Pull filter bowl down to remove. Do not discard the

O-ring.

B

Install filter bowl.

A. Slide filter bowl over filter element.B. Align marks on filter bowl and filter body.C. Rotate filter bowl until it locks in place.

Remove the filter element (Part No. 011092) from thefilter housing.

NOTE: Do not allow the filter element to turn whenloosening the screw.

MAINTENANCE

Work Cable Replacement

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Work Cable Replacement

Disconnect electrical power, gas supply, torch lead, and remove ETR barrier before removing the old work cable.

Installation Refer to figure below.

1. Install the strain relief to the power supply and secure with nut.

2. Tighten the strain relief collar onto the cable.

3. Connect the work cable to the power board at J14.Tighten nut to 10 in-lb (12 kg cm) of torque.

4. Install ETR barrier

5. Install the power supply cover.

CAUTION: This is a high-current connection.

Proper torque is critical.

StrainRelief

Connect to J14

MAINTENANCE

Capacitor Replacement

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Capacitor Replacement

Removal Refer to figure below.

Disconnect electrical power and gas supply before removing the power supply cover.

Remove screws securing capacitor to power board.

Remove capacitor from fan side of power supply.

Remove lower capacitor first. Then the upper capacitor may be tipped down and removed.

Installation Refer to figure below.

Align bleeder hole on capacitor with view holeon power board.

Install new capacitor and secure with 2 screws.Tighten screws to 30 inch pounds (36 kg cm).

Install the power supply cover.

Correct orientation of bleeder hole

Bleeder hole

View hole

MAINTENANCE

Heat Sink Component Replacement

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Heat Sink Component Replacement

Installation

Install components to the heat sink as shown below.

Use new thermal pads on temperature sensor.

Use white thermal grease (Part no. 330002) on all components except for IGBT, PFC (Part no. 128745). Usegrey thermal grease (Part no. 128836) on IGBT, PFC, see Note 3. Apply a thin coat to the component, install withscrews, and tighten to required torque. Note: Remix grease if material seperates.

Re-torque after 2 minutes. Repeat until torque is maintained. Clean excess grease from heat sink.

Thermal Pad

Thermal Grease

DC-340PMX600.28

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Section 4

PARTS - POWER SUPPLY

In this section:

Exterior .....................................................................................................................................................................4-2Interior Right Side .....................................................................................................................................................4-3

Back Interior Right side.............................................................................................................................................4-4Interior Fan Side .......................................................................................................................................................4-5Heat Sink Assembly..................................................................................................................................................4-6Recommended Spare Parts .....................................................................................................................................4-7


Power Supply Exterior

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Power Supply Exterior

PartItem Number Description Designator Qty.

128750 Label Kit, Domestic 1128758 Label Kit, CE 1

1 128766 Front end panel, Domestic 1128765 Front end panel, CE 1

2 008965 Current adjustment knob 1C l P l L b l

_

+

4.05.0

5060

AC

7080

V

BAR

6.0

PSI

AMPS

30

40

100

80

60


Power Supply Interior Right Side

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pp y g


1 128736 Control PCB assembly, Domestic PCB3 12 128659 Pressure Transducer 13 128801 Pressure Regulator 14 128699 Pilot Arc IGBT Gate Drive Cable 15 128810 ETR Box 1

G M if ld V

POWER SUPPLY PARTS

Power Supply Back interior right side

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Part

Item number Description Designator Quantity

1 128757 Front caster 22 128763 Rear axel 1

3 128764 Rear wheel replacement 24 128706 EMI filter PCB, CE only PCB1 1

5 128672 Power switch CSA S1 1P i h CE

_

+

4.05.0

5060

AC

7080

V

BAR

6.0

PSI

AMPS

30

40

100

80

60

1

2

3

4

5


Power Supply Interior Fan Side

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1 128627 Filter bowl 1011093 Air filter element 1011094 O-ring 1

2 128749 Inductor, input choke L2 13 128741 Capacitor 2

P f T


Power Supply Heat Sink Assembly

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027662 Thermal grease, 5 oz. DC-340 11 128733 Output diode bridge 12 128747 Snubber resister assembly 1

3 128743 IGBT, inverter Q13 14 128744 Temperature Switch PCB4 1

5 128745 IGBT, PFC Q14 16 128746 Input diode bridge D24 1

Recommended Spare Parts


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Part Number ..................................Description...................................................................................................PageReference

128689............................................Front end panel, Domestic................................................................................4-2128750...................

Documents

Hyper Therm 1650