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Hypertherm powermax1000 Service Manual
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Hypertherm powermax1000 Service Manual

Hypertherm powermax1000 Service Manual

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Service Manual
804300 – Revision 1
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25
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60
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Summary of Contents for Hypertherm powermax1000

  • Page 1 ® Plasma Arc Cutting System Service Manual 804300 – Revision 1 AMPS...
  • Page 2 (P/N 804300) Revision 1 – May, 2006 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2006 Hypertherm, Inc. All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries...
  • Page 3 Rua Jati, 33 65 6 841 2489 (Technical Service) CEP 07180-350 Cumbica Guarulhos, SP - Brasil Hypertherm (Shanghai) Trading Co., Ltd. 55 11 6482 1087 Tel Unit 1308-09, Careri Building 55 11 6482 0591 Fax 432 West Huai Hai Road...
  • Page 4 The size of the surrounding area to be Earthing of Workpiece considered will depend on the structure of Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth the building and other activities that are tak- in compliance with standard EN50199. The for electrical safety, nor connected to earth ing place.

  • Page 5: Warranty

    Hypertherm system. Any damage infringement, and Hypertherm’s obligation to indemnify shall be caused by the use of other than genuine Hypertherm parts may conditioned upon Hypertherm’s sole control of, and the not be covered by the Hypertherm warranty.

  • Page 6: Table Of Contents

    Sécurité des bouteilles de gaz comprimé .......................1a-5 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............1a-5 Le bruit peut provoquer des problèmes auditifs......................1a-5 Pacemakers et prothèses auditives ........................1a-5 Un arc plasma peut endommager les tuyaux gelés....................1a-5 Étiquette de sécurité ...............................1a-6 powermax1000 Service Manual...
  • Page 7 Maintenance Controls and indicators .............................3-3 Indicator LEDs..............................3-3 Theory of operation..............................3-4 General ................................3-4 Functional description ............................3-4 Sequence of operation .............................3-5 Troubleshooting preparation .............................3-6 Test equipment..............................3-6 Troubleshooting procedures and sequence .....................3-6 External inspection............................3-6 Internal inspection ............................3-7 Initial resistance check..............................3-7 powermax1000 Service Manual...
  • Page 8 Hypertherm IGBT tester ...........................3-9 Indicator LEDS and device tests ........................3-9 IGBT test preparation .............................3-10 IGBT device test using the Hypertherm tester ....................3-10 Troubleshoot the Hypertherm IGBT tester .....................3-11 Schematic for building an IGBT tester......................3-11 IGBT device test using non-Hypertherm tester ....................3-12 Troubleshooting guide ............................3-14...
  • Page 9 TABLE OF CONTENTS T60 consumable configurations ..........................5-6 T60M consumable configurations ..........................5-7 Recommended spare parts ............................5-8 Section 6 Wiring diagrams Timing diagrams ...............................6-2 Electrical schematic ..............................6-5 powermax1000 Service Manual...

  • Page 10: Safety

    Compressed Gas Equipment Safety ........................1-5 Gas Cylinders Can Explode If Damaged ........................1-5 Noise Can Damage Hearing .............................1-5 Pacemaker and Hearing Aid Operation ........................1-5 A Plasma Arc Can Damage Frozen Pipes ........................1-5 Additional Safety Information ............................1-5 Warning Label................................1-6 Hypertherm Plasma Systems...

  • Page 11: Recognize Safety Information

    • Install an aeration manifold on the floor of the water closed container. table to eliminate the possibility of hydrogen • Do not cut containers that have held combustible detonation. Refer to the Appendix section of this materials. manual for aeration manifold details. Hypertherm Plasma Systems 11-98...

  • Page 12: Electric Shock Can Kill

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

  • Page 13: A Plasma Arc Can Cause Injury And Burns

    Work Table Connect the work table to an earth power cord ground. Fasten the retaining nut tightly. ground, in accordance with appropriate national or • Tighten all electrical connections to avoid excessive local electrical codes. heating. Hypertherm Plasma Systems 5/6/02...

  • Page 14: Compressed Gas Equipment Safety

    Protection Association, 470 Atlantic Avenue, Boston, MA 02210 Hazardous Substances, American Welding Society 10. OSHA, Safety and Health Standards, 29FR 1910 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135 U.S. Government Printing Office, Washington, D.C. 20402 Hypertherm Plasma Systems 11-98...

  • Page 15: Warning Label

    Wear complete body protection. Become trained and read the instructions before working on the machine or cutting. Do not remove or paint over (cover) warning labels. 110391 Rev A Hypertherm Plasma Systems 8-99...

  • Page 16: Section 1A Sécurité

    Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............1a-5 Le bruit peut provoquer des problèmes auditifs......................1a-5 Pacemakers et prothèses auditives ........................1a-5 Un arc plasma peut endommager les tuyaux gelés....................1a-5 Étiquette de sécurité ...............................1a-6 Hypertherm Systèmes plasma 1a-1 2/12/01...

  • Page 17: Identifier Les Consignes De Sécurité

    • Ne pas couper de récipients contenant des matières Se référer à l’annexe du manuel pour plus de combustibles. renseignements sur les collecteurs d’aération. 1a-2 Hypertherm Systèmes plasma 2/12/01...

  • Page 18: Les Chocs Électriques Peuvent Être Fatals

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

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

    Bien serrer l’écrou de retenue. Table de travail Raccorder la table de travail à la terre, • S’assurer que toutes les connexions sont bien serrées conformément aux codes de sécurité locaux ou nationaux pour éviter la surchauffe. appropriés. 1a-4 Hypertherm Systèmes plasma 5/6/02...

  • Page 20: Sécurité Des Bouteilles De Gaz Comprimé

    LES TUYAUX GELÉS • Se tenir le plus loin possible de la source de courant. Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma. Hypertherm Systèmes plasma 1a-5 2/12/01...

  • Page 21: Étiquette De Sécurité

    6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. 7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 Hypertherm Systèmes plasma 2/12/01...
  • Page 22 Los cilindros de gas pueden explotar si están dañados ..................1b-5 El ruido puede deteriorar la audición ........................1b-5 Operación de marcapasos y de audífonos ......................1b-5 Un arco plasma puede dañar tubos congelados ....................1b-5 Etiqueta de advertencia ............................1b-6 HYPERTHERM Sistemas plasma 1b-1 2/12/01...

  • Page 23: Reconocimiento De Información De Seguridad

    Consulte la sección del apéndice de este • No corte depósitos que hayan contenido materiales manual para conocer detalles acerca del múltiple de combustibles. aireación. 1b-2 HYPERTHERM Sistemas plasma 2/12/01...

  • Page 24: El Choque Eléctrico Puede Provocar La Muerte

    Prevención ante el electrochoque cortando. Deje la pieza en su lugar o sobre la mesa de Todos los sistemas por plasma de Hypertherm usan alto trabajo con el cable de trabajo conectado en todo voltaje en el proceso de corte (son comunes los voltajes CD momento.

  • Page 25: El Arco De Plasma Puede Causar Lesiones Y Quemaduras

    Ajuste firmemente la tuerca eléctricos nacionales o locales apropiados. de retención. • Asegúrese de que todas las conexiones eléctricas están firmemente realizadas para evitar sobrecalentamientos. 1b-4 HYPERTHERM Sistemas plasma 4/11/03...

  • Page 26: Seguridad De Los Equipos De Gas Comprimido

    • Manténgase tan lejos de la fuente de energía como sea posible. Se puede hacer daño a los tubos congelados, o se los puede reventar, si uno trata de descongelarlos con una antorcha por plasma. HYPERTHERM Sistemas plasma 1b-5 2/12/01...

  • Page 27: Etiqueta De Advertencia

    Proteja su cuerpo 110391 Rev A completamente. 6. Antes de trabajar en la máquina o de proceder a cortar, capacítese y lea las instrucciones completamente. 7. No retire las etiquetas de advertencia ni las cubra con pintura. 1b-6 HYPERTHERM Sistemas plasma 2/12/01...

  • Page 28: Specifications

    Section 2 SPECIFICATIONS In this section: Power supply ................................2-2 Dimensions and weight ............................2-3 T60 torches ................................2-4 Dimensions ..............................2-5 Symbols and markings .............................2-6 S Mark................................2-6 IEC symbols ..............................2-6 powermax1000 Service Manual...

  • Page 29: Power Supply

    Drooping *Defined as a plot of output voltage versus output current Rated output current (I 20A – 60A Hypertherm standard rated output 140 VDC voltage (U Duty cycle (X*) at 104°F (40°C) at – Volts AC rms rated conditions (U...

  • Page 30: Dimensions And Weight

    SPECIFICATIONS Dimensions and weight 76 lb (34.5 kg) 10.5 in (267 mm) 23 in (584 mm) Weight of power supply without torch 19.5 in AMP S (495 mm) powermax1000 Service Manual...

  • Page 31: T60 Torches

    8.3 pounds (3.8 kg) with 25 ft (7.5 m) lead 9.9 pounds (4.5 kg) with 35 ft (10.7 m) lead 15.0 pounds (6.8 kg) with 50 ft (15 m) lead 21.7 pounds (9.9 kg) with 75 ft (22.5 m) lead powermax1000 Service Manual...

  • Page 32: Dimensions

    3.9" (99 mm) 2.25" (57 mm) 1.00" (25 mm) T60M machine torch dimensions 1.00" 15.25" (25 mm) (387 mm) 2.03" 8" 1.38" (52mm) (203 mm) (35 mm) 32 pitch 0.125" (3.2 mm) width 0.125" (3.2 mm) height powermax1000 Service Manual...

  • Page 33: Symbols And Markings

    Plasma torch in the TEST position (cooling and cutting gas exiting nozzle) Plasma torch cutting and gouging Power is on AC input power connection Power is off The terminal for the external Volt/amp curve, “drooping” protective (earth) conductor characteristic powermax1000 Service Manual...

  • Page 34: Maintenance

    Hypertherm IGBT tester ...........................3-9 Indicator LEDS and device tests ........................3-9 IGBT test preparation .............................3-10 IGBT device test using the Hypertherm tester ....................3-10 Troubleshoot the Hypertherm IGBT tester .....................3-11 Schematic for building an IGBT tester......................3-11 IGBT device test using non-Hypertherm tester ....................3-12 Troubleshooting guide ............................3-14...
  • Page 35 T60 hand torch connector pinouts and assembly ....................3-29 T60M machine torch connector pinouts and assembly ..................3-30 Component replacement ............................3-31 Power cord replacement ..........................3-31 Torch replacement............................3-32 Filter element replacement..........................3-34 Work cable replacement ..........................3-35 Capacitor replacement ...........................3-36 Heat sink component replacement.........................3-37 powermax1000 Service Manual...

  • Page 36: Controls And Indicators

    When illuminated, indicates that a fault condition exists, which prevents system operation. Yellow low line voltage LED When illuminated, indicates that line voltage is below 170 VAC or above 680 VAC. On CE units, it can also indicate a missing phase. powermax1000 Service Manual...

  • Page 37: Theory Of Operation

    The control board (PCB3) includes a pilot arc control switch, which allows the operator to turn ON the pilot arc (useful when cutting expanded metal), turn OFF the pilot arc (for maximum life of consumables), or to increase the pilot arc to 20A (useful for gouging or non-transferred-arc cutting). powermax1000 Service Manual...

  • Page 38: Sequence Of Operation

    • Pull the plasma start trigger on the hand torch or amps with the current press the remote start switch for the machine torch. adjustment knob. • Gas solenoid valve (V1) closes. The power circuits are ready. • The gas flow stops. powermax1000 Service Manual...

  • Page 39: Troubleshooting Preparation

    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 in the front of this manual.

  • Page 40: Internal Inspection

    • After the problem has been located and repaired, refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation. powermax1000 Service Manual...

  • Page 41: Check Power Switch

    The Troubleshooting guide provides most probable causes 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 nearest Hypertherm repair facility.

  • Page 42: Hypertherm Igbt Tester

    MAINTENANCE Hypertherm IGBT tester Use the Hypertherm IGBT tester (part number 128883) as described in the following sections or assemble your own IGBT tester from the schematic diagram shown in IGBT tester schematic and use it to test the IGBTs.

  • Page 43: Igbt Device Test Using The Hypertherm Tester

    Collector 1, (C1) Black lead Emitter 1 (E1) IGBT device test using the Hypertherm tester Using the Hypertherm IGBT tester, press and hold the switch in the desired position to perform the tests described in the following table. Switch position...

  • Page 44: Troubleshoot The Hypertherm Igbt Tester

    MAINTENANCE Troubleshoot the Hypertherm IGBT tester 1. Inspect the leads and the IGBT tester for damage. 2. Verify that the battery voltage is greater than 8V. 3. Test the IGBT Tester, itself, as shown below. If the results do not match the table, replace the lead connections.

  • Page 45: Igbt Device Test Using Non-Hypertherm Tester

    MAINTENANCE IGBT device test using non-Hypertherm tester The device tester shown in Schematic for building an IGBT tester has one LED and one pushbutton switch that are used in combination to perform two tests. 1. Visually inspect the IGBT for cracks or black marks. If damaged, replace the IGBT.
  • Page 46 MAINTENANCE powermax1000 3-13 Service Manual...
  • Page 47 MAINTENANCE powermax1000 3-14 Service Manual...
  • Page 48 MAINTENANCE powermax1000 3-15 Service Manual...
  • Page 49 MAINTENANCE powermax1000 3-16 Service Manual...
  • Page 50 MAINTENANCE powermax1000 3-17 Service Manual...

  • Page 51: Control Board Leds

    SELF DIAGNOSTICS FAILURE NORMAL (Blinking at 1 sec. rate) DOWN GOUGE CURRENT INVERTER INTERLOCK (Visible for 10 sec. after event) TORCH STUCK OPEN (Visible for 10 sec. after event) SPARE STATUS START START START START START powermax1000 3-18 Service Manual...

  • Page 52: Test 1 - Voltage Input

    CE unit Black Black (U) White Blue (V) Brown (W) Green Green/Yellow Ground (PE) Input diode bridge Power switch (S1) = Line voltage* = Line voltage = Line voltage* * Single phase Line voltage x 1.414 powermax1000 3-19 Service Manual...

  • Page 53: Test 2 - Voltage Balance

    Note: Bulk capacitors must be out of circuit. R126 = 20.8k R120 = 21.2k R125 = 21.0k R127 = 21.2k R124 = 24.1k R119 = 24.1k Inverter IGBT (Q6) 750 VDC 375 VDC 375 VDC 375 VDC 375 VDC powermax1000 3-20 Service Manual...

  • Page 54: Test 3 - Output Diodes

    The diode is open if the value is greater than 1.0V in both directions. Replace the diode. Note: In each case, common (black) should be on 3. C100 3 to 2 = .179V 3 to 1 = 1.8V Bottom 3 to 2 = .180V 3 to 1 = 1.8V powermax1000 3-21 Service Manual...

  • Page 55: Test 4 - Pilot Arc Igbt (Q8)

    • If the values are correct, check the pilot arc IGBT (Q8) with an IGBT Tester. If it fails, replace the power board (PCB2) and the pilot arc IGBT (Q8). Gate drive resistors R108 = 1kΩ R110 = 10kΩ Pilot arc IGBT (Q8) powermax1000 3-22 Service Manual...

  • Page 56: Test 5 - Inverter Igbt (Q6) And Pfc Igbt (Q7)

    Inverter C100 C100 R82 = 994Ω R87 = 994Ω R83 = 6.1Ω R56 = 4.1Ω R65 = 995Ω R98 = 1Ω R75 = 6.1Ω R84 = 10.4Ω R96 = .4Ω PFC IGBT (Q7) Inverter IGBT (Q6) powermax1000 3-23 Service Manual...

  • Page 57: Test 6 - Flyback Circuit

    R2 = 18 VDC D7 = 10 VDC R9 = -6 VDC D9 = 18 VDC R18 = 5 VDC Visually inspect for damage. D17 = 5 VDC R26 = 18 VDC R55 = 18 VDC powermax1000 3-24 Service Manual...

  • Page 58: Test 7 - Torch Stuck Open (Tso)

    • Check to see if the pilot arc IGBT (Q8) is open by putting a jumper wire from J14 to the Pilot Arc IGBT (Q8). Then attempt to fire the torch. If the torch fires, replace the Pilot Arc IGBT (Q8). Note: All values are ±25%. Pilot arc IGBT powermax1000 3-25 Service Manual...

  • Page 59: Test 8 - Plasma Start

    • Put a jumper wire between pins 3 and 4 of U23 with the power OFF. • Turn ON the power. If the torch cap sensor LED goes out, replace the power board (PCB2). If the LED remains illuminated, replace the control board (PCB3). ETR connector (J18) powermax1000 3-26 Service Manual...

  • Page 60: Test 10 - Gas Solenoid

    If not, replace the fan. • Check the voltage between the left side of R7 and ground (TP1). If the VDC is zero (0), replace the control board (PCB3). If the value is 5 VDC, replace the power board (PCB2). powermax1000 3-27 Service Manual...

  • Page 61: Test 14 - Aux Switch

    5 VDC (±0.5V), disconnect the control board and measure for 5 VDC again. If it is still not a constant 5 VDC, replace the power board (PCB2). • If no problems are found while completing the previous steps, replace the control board (PCB3). powermax1000 3-28 Service Manual...

  • Page 62: T60 Hand Torch Connector Pinouts And Assembly

    Pin 1 Pin 10 violet wire (trigger) White wires (plunger) Red wire (nozzle) Pin 3 Orange wire (cap sensor/trigger) Pin 12 blue wire (cap sensor) Not used Right handle Left handle Torch body Spring Screws (5) Trigger powermax1000 3-29 Service Manual...

  • Page 63: T60M Machine Torch Connector Pinouts And Assembly

    Pin 10 not used White wires (plunger) Pin 3 Orange wire (cap sensor) Red wires (nozzle) Pin 12 blue wire (cap sensor) Strain relief Strain relief lock Torch Positioning body sleeve Mounting sleeve Screws (3) O-ring powermax1000 3-30 Service Manual...

  • Page 64: Component Replacement

    5. Reconnect the electrical power and the gas supply. L1 (U) L2 (V) L3 (W) Ground (PE) Ground (PE) Three phase Single phase Standard unit CE unit Standard unit Black Black (U) Black White Blue or Grey (V) White Brown (W) Green Green Green/Yellow powermax1000 3-31 Service Manual...

  • Page 65: Torch Replacement

    MAINTENANCE Torch replacement Turn OFF (O) the power switch. Unplug the power cord from the power receptacle. Open the ETR door and route the lead through the end cap. ETR door End cap powermax1000 3-32 Service Manual...
  • Page 66 Slide the quick-release collar forward to lock in the gas fitting. Verify that the gas fitting is secure. Verify that the red dot on the connector is on top, then plug in the electrical connector. Close the ETR door. powermax1000 3-33...

  • Page 67: Filter Element Replacement

    Re-install the filter bowl over the new filter element. A. Slide the filter bowl over the filter element. B. Align the marks on the filter bowl and the filter body. C. Rotate the filter bowl until it locks in place. powermax1000 3-34 Service Manual...

  • Page 68: Work Cable Replacement

    J14. Tighten the nut to 10 in-lb (12 kg cm) Proper torque is critical. of torque. 4. Install the ETR barrier. 5. Install the power supply cover. Connect to J14 Strain relief barrier Work cable powermax1000 3-35 Service Manual...

  • Page 69: Capacitor Replacement

    Tighten the screws to 20 in-lb (24 kg cm) of torque. 3. Install the power supply cover. Screws for C94 Screws for Remove and install screws from power board side. Remove and install Correct installation capacitors from fan side. powermax1000 3-36 Service Manual...

  • Page 70: Heat Sink Component Replacement

    Thermal pad Notes: Apply thermal grease and torque to 8 in-lb (9 kg cm). Apply thermal grease and torque to 20 in-lb (23 kg cm). Apply thermal grease and torque to 35 in-lb (40 kg cm). powermax1000 3-37 Service Manual...
  • Page 71 MAINTENANCE powermax1000 3-38 Service Manual...

  • Page 72: Parts - Power Supply

    Section 4 PARTS – POWER SUPPLY In this section: Exterior ..................................4-2 Interior right side ...............................4-3 Back interior right side ..............................4-4 Interior fan side .................................4-5 Heat sink assembly..............................4-6 Recommended spare parts ............................4-7 powermax1000 Service Manual...

  • Page 73: Exterior

    Current adjustment knob 128630 Kit: End panel screws 123645 Ground clamp 011096 Regulator knob 128629 Kit: Cover screws 128690 Kit: Power supply cover with labels, domestic 128688 Kit: Power supply cover with labels, CE 128973 Kit: Rear panel powermax1000 Service Manual...

  • Page 74: Interior Right Side

    Tubing, 8mm OD, 6mm ID, nylon 3 ft. 128963 Kit: RCD resistor replacement (S/N < 1000-013717) 108211 On/Off Knob 128662 Kit: Machine interface 128665 Kit: Strain relief, arc voltage 128695 Kit: Power board PCB2 123602 Gate drive cables powermax1000 Service Manual...

  • Page 75: Back Interior Right Side

    Item number Description Designator Qty. 128672 Kit: Power switch 128706 Kit: EMI filter PCB, CE only PCB1 128666 Kit: 8 ft (2.5 m) power cable, domestic 3PH 128705 Kit: 8 ft (2.5 m) power cable, CE 3PH powermax1000 Service Manual...

  • Page 76: Interior Fan Side

    128627 Kit: Filter 011093 Air filter element 011094 O-ring, NAF3000 filter 011105 O-ring, AF30 filter 128707 Kit: Fan 128693 Kit: Inductor, input choke 128691 Kit: Capacitor C94, C98 128692 Kit: Power transformer 128694 Kit: Inductor, output choke powermax1000 Service Manual...

  • Page 77: Heat Sink Assembly

    128708 Kit: PFC IGBT 128696 Kit: Input diode bridge Kit: Snubber resister (7.5 Ω) 128670 128699 Kit: Pilot arc IGBT Kit: Snubber resister (20 Ω) 128669 Reference Section 3, Heat sink component replacement , for torque specifications. powermax1000 Service Manual...

  • Page 78: Recommended Spare Parts

    011105 ..........O-ring, AF30 filter....................4-5 128707..........Kit: Fan ......................4-5 128691..........Kit: Capacitor ....................4-5 127128..........Thermal grease, 10 cc ..................4-6 128677..........Kit: Output diode bridge ..................4-6 128697..........Kit: Inverter IGBT ....................4-6 128708..........Kit: PFC IGBT ....................4-6 128696..........Kit: Input diode bridge..................4-6 128699..........Kit: Pilot arc IGBT .....................4-6 powermax1000 Service Manual...
  • Page 79 PARTS – POWER SUPPLY powermax1000 Service Manual...

  • Page 80: Parts - Torch And Consumables

    Section 5 PARTS – TORCH AND CONSUMABLES In this section: T60 hand torch assembly ............................5-2 T60M machine torch assembly ..........................5-4 T60 consumable configurations ..........................5-6 T60M consumable configurations ..........................5-7 Recommended spare parts ............................5-8 powermax1000 Service Manual...

  • Page 81: T60 Hand Torch Assembly

    Kit: ETR connector replacement 128642 Kit: T60 Start switch replacement * Top assembly includes the following consumables (See T60 consumable configurations for descriptions of consumable parts): 120926 Electrode 120925 Swirl ring 120928 Retaining cap 120929 Shield 120931 Nozzle powermax1000 Service Manual...
  • Page 82 PARTS – TORCH AND CONSUMABLES powermax1000 Service Manual...

  • Page 83: T60M Machine Torch Assembly

    128645 Kit: T60M Torch mounting (for reassembly after installation) * Top assembly includes the following consumables (See T60M consumable configurations for descriptions of consumable parts): 120926 Electrode 120925 Swirl ring 120928 Retaining cap 120930 Shield 120931 Nozzle powermax1000 Service Manual...
  • Page 84 PARTS – TORCH AND CONSUMABLES powermax1000 Service Manual...

  • Page 85: T60 Consumable Configurations

    Swirl ring Shield Retaining cap Nozzle O-ring 058519 120929 120928 120932 120926 120925 120929 120928 120931 O-ring 058519 220325* 120928 220329 120926 220327 120979 * For use with CE systems. O-ring 058519 120977 120928 220059 120926 120925 powermax1000 Service Manual...

  • Page 86: T60M Consumable Configurations

    Maintain torch-to-work distance of approximately 3/16 inch (4.8 mm). *** Use an ohmic sensing cap when a 220061*** compatible torch height controller is installed. O-ring 058519 120979 120928 220006 120926 120925 120979 120928 220007 powermax1000 Service Manual...

  • Page 87: Recommended Spare Parts

    Kit: T60/T60M torch cap sensor replacement 128888 Kit: FineCut consumables 128889 Kit: FineCut consumables – CE 083172 T60 hand torch assembly with 25 ft (7.6 m) lead 083175 T60M machine torch assembly with 25 ft (7.6 m) lead powermax1000 Service Manual...

  • Page 88: Wiring Diagrams

    Section 6 WIRING DIAGRAMS In this section: Timing diagrams ...............................6-2 Electrical schematics ..............................6-5 powermax1000 Service Manual...
  • Page 89 Service Manual...
  • Page 90 Service Manual...
  • Page 91 WIRING DIAGRAMS powermax1000 Service Manual...
  • Page 92 PROPRIETARY AND MAY NOT BE USED FRACTIONS ±1/64 FOR MANUFACTURING OR FABRICATION ANGULAR ±.5∞ PART MUST BE FREE OF BURRS AND SHARP PURPOSES WITHOUT PERMISSION EDGES. BREAK SHARP EDGES IF NECESSARY FROM HYPERTHERM, INC. WITH CHAMFER OR RADIUS .015 MAX.