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Hypertherm powermax1250 Service Manual
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Hypertherm powermax1250 Service Manual

Plasma arc cutting system
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powermax1250
Plasma Arc
Cutting System
Service Manual
803940 – Revision 3
®
AMPS
40
60
25
80
AC
50
PSI
60
70
80
4.0
5.0
6.0
BAR
_
+

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Summary of Contents for Hypertherm powermax1250

  • Page 1 ® Plasma Arc Cutting System Service Manual 803940 – Revision 3 AMPS...
  • Page 2 SM 803940 Rev 0 to Rev 1 October 2004 Page of Change Description of Change Corrected dimensions on T80M. SM 803940 Rev 1 to Rev 2 October 2004 Page of Change Description of Change Added weight of 75' torches. 5.2-5.5 Added 75' torch and leads.
  • Page 3 Page of Change Description of Change SM 803940 Rev 2 to Rev 3 October 2004 Page of Change Description of Change Added pressure sensor to the parts list, corrected P/N for the pressure regulator. Added length to the description of the power cables. Added designator for the capacitors.

  • Page 4: Service Manual

    (P/N 803940) Revision 3 – October, 2004 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2004 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 5 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 (Technical Service) Hypertherm (Shanghai) Consulting Co., Ltd. Suite 305, CIMIC Towers 1090 Century Boulevard, Pudong Shanghai 200120 P.R. China...
  • Page 6 Earthing of Workpiece The size of the surrounding area to be 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 7: 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 8: 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 powermax1250 Service Manual...
  • Page 9 Recommended spare parts ............................4-7 Section 5 Parts – torch and consumables T80 Hand torch assembly ............................5-2 T80M Machine torch assembly ..........................5-4 Torch consumable configurations ..........................5-6 Recommended spare parts ............................5-8 Section 6 Wiring diagrams Timing diagram .................................6-2 Electrical schematic ..............................6-5 powermax1250 Service Manual...

  • Page 10: Safety

    Grounding Safety ............................1-4 Compressed Gas Equipment Safety.......................1-5 Gas Cylinders Can Explode If Damaged ......................1-5 Noise Can Damage Hearing ...........................1-5 Pacemaker and Hearing Aid Operation......................1-5 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 4-99...

  • Page 14: Compressed Gas Equipment Safety

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

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

  • 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 Section 2 SPECIFICATIONS In this section: Specifications – power supply ..........................2-2 Power supply – dimensions and weight ......................2-3 Specifications – T80 torches.............................2-4 Torch dimensions ..............................2-5 Symbols and markings .............................2-6 powermax1250 Service Manual...

  • Page 23: Specifications

    Drooping *Defined as a plot of output voltage versus output current Rated output current (I 25A – 80A Hypertherm standard rated output 150 VDC voltage (U Duty cycle (X*) at 104°F (40°C) at – Volts AC rms rated conditions (U...

  • Page 24: Power Supply - Dimensions And Weight

    SPECIFICATIONS Power supply – dimensions and weight 90 lb (41 kg) 10.5 in (267 mm) 23 in (584 mm) Weight of power supply without torch 19.5 in (495 mm) AMP S powermax1250 Service Manual...

  • Page 25: Specifications - T80 Torches

    8.3 pounds (3.8 kg) with 25 ft (7.5 m) lead T80M 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 powermax1250 Service Manual...

  • Page 26: Torch Dimensions

    3.9" (99 mm) 2.25" (57 mm) 1.00" (25 mm) T80M machine torch dimensions 15.06" (383 mm) 1.38" 1.00" (35 mm) (25 mm) 1.13" 8" (29mm) (203 mm) 32 pitch 0.125" (3.2 mm) width 0.125" (3.2 mm) height powermax1250 Service Manual...

  • Page 27: 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 powermax1250 Service Manual...
  • Page 28 Visual inspection – external ..........................3-5 IGBT tester...............................3-6 Visual inspection – internal ..........................3-7 Troubleshooting guide ............................3-10 Tests ..................................3-15 Component replacement ............................3-26 Power cord replacement..........................3-26 Torch installataion ............................3-27 Filter element replacement ..........................3-29 Work cable replacement ..........................3-30 Capacitor replacement...........................3-31 Heat sink component replacement ........................3-32 powermax1250 Service Manual...

  • Page 29: 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. powermax1250 Service Manual...

  • Page 30: Theory Of Operation

    IGBT Q6. The control board PCB3 includes a pilot arc control switch, allowing the operator to turn the pilot arc ON (useful when cutting expanded metal) or OFF (for maximum life of consumables). powermax1250 Service Manual...

  • Page 31: Sequence Of Operation

    • Select desired cutting amps • Depress plasma start switch on hand torch or with current adjustment knob. remote start switch for machine torch. • Gas solenoid valve V1 closes. Power circuits are ready. • Gas flow stops. powermax1250 Service Manual...

  • Page 32: 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 in the front of this manual.

  • Page 33: Igbt Tester

    If LED does not illuminate then the IGBT is open, replace IGBT. IGBT, Inverter and PFC IGBT, Pilot arc Yellow lead Yellow lead Gate (G) Gate 2 (G2) Red lead Black lead Collector (C) Emitter 2 (E2) Red lead Black lead Collector 2, Emitter (E) Emitter 1 (C2,E1) powermax1250 Service Manual...

  • Page 34: Visual Inspection - Internal

    2. Remove the cover of the power supply by removing the 12 securing screws. 3. Inspect the inside of the power supply, especially on the side with the power board. Look for broken or loose wiring connections, burn and char marks, damaged components, etc. Repair or replace as necessary. powermax1250 Service Manual...

  • Page 35: Initial Resistance Check

    Note: 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. powermax1250...
  • Page 36 MAINTENANCE powermax1250 Service Manual...
  • Page 37 MAINTENANCE 3-10 powermax1250 Service Manual...
  • Page 38 MAINTENANCE powermax1250 Service Manual 3-11...
  • Page 39 MAINTENANCE 3-12 powermax1250 Service Manual...
  • Page 40 MAINTENANCE powermax1250 Service Manual 3-13...

  • Page 41: Control Board Leds

    ������������ ����������������������� ������������� ��������������������� ������������������ ��������������� ��������� ���������� ����� ������������������������� ����������������������� ��������������������������� �������������������������� �� ���������������������� �������������������� ��������������������� ��������������� ����� �������� ������ ������� �������������������������� ��������� ������������������������� ��� ����������������������������� ���������������������� �������������������� ��������������������� ����� ���������������������������� ������� ������� ���������������� �� 3-14 powermax1250 Service Manual...
  • Page 42 Input diode bridge Power switch (S1) = Line voltage* = Line voltage = Line voltage * Single phase Line voltage * 1.414 Standard unit CE unit Black Black (U) White Blue (V) Brown (W) Green Green/Yellow Ground (PE) powermax1250 Service Manual 3-15...

  • Page 43: Tests

    R119 = 75kΩ R120 = 75kΩ R124 = 75kΩ R125 = 75kΩ R126 = 75kΩ R127 = 75kΩ Note: Remove screws from C94 and C98 before measuring resistors. 750 VDC 375 VDC 375 VDC 375 VDC 375 VDC 3-16 powermax1250 Service Manual...
  • Page 44 • 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. powermax1250 Service Manual 3-17...
  • Page 45 • If values are good, check pilot arc IGBT (Q8) with an IGBT Tester. If it fails replace power board (PCB2) and pilot arc IGBT (Q8). Gate drive resistors R108 = 1kΩ R110 = 10Ω R111 = 10Ω Pilot arc IGBT (Q8) (Q8) 3-18 powermax1250 Service Manual...
  • Page 46 R65 = 1kΩ R75 = 5.6Ω R84 = 10Ω R98 = 1Ω RT1 = Resettable fuse RT2 = Resettable fuse RT8 = Resettable fuse Inverter IGBT (Q6) Inverter IGBT (Q6) PFC IGBT (Q8) PFC IGBT (Q8) powermax1250 Service Manual 3-19...
  • Page 47 D5 = 24VDC R2 = 18VDC D7 = 10VDC R9 = -6VDC D9 = 18VDC R18 = 5VDC Visually inspect for damage D17 = 5VDC R26 = 18VDC R55 = 18VDC Note: Check voltage to TP1 3-20 powermax1250 Service Manual...
  • Page 48 • Pilot Arc IGBT (Q8) open – use a jumper wire to jump J14 to Pilot Arc IGBT (Q8). Then attempt to fire the torch. If the torch fires replace the Pilot Arc IGBT (Q8). Pilot arc IGBT Note: All values are ±15%. powermax1250 Service Manual 3-21...
  • Page 49 • If open, check wiring in torch leads and cap sense switch. • Jump between pins 3 and 4 of U23 with power OFF. • Turn power ON, if cap sense LED goes out, replace power board (PCB2). If LED remains illuminated, replace control board (PCB3). 3-22 powermax1250 Service Manual...
  • Page 50 Pin 1 Pin 10 not used White wires (plunger) Orange wire (cap sense) Pin 3 Red wires (nozzle) Pin 12 blue wire (cap sense) ������ ������ ������ ������ ���� ����� ����������� ���� ������ �������� ������ ���������� ������ powermax1250 Service Manual 3-23...
  • Page 51 Pin 1 White wires (plunger) Pin 10 purple wire (trigger) Pin 3 Red Wire (Nozzle) Orange wire (cap sense/trigger) Pin 12 blue wire (cap sense) Not used Right Handle Left Handle Torch Body Spring Screws (5) Trigger 3-24 powermax1250 Service Manual...
  • Page 52 • Check voltage between the left side of R7 and ground (TP1). If 0VDC replace control board (PCB3). If 5VDC replace power board (PCB2). �� �� �� �� ��� ��� ��� �� ��� powermax1250 Service Manual 3-25...

  • Page 53: Component Replacement

    2. Install the power cord connections where shown. 3. Tighten the strain relief onto the power cord. 4. Install the power supply cover. 5. Reconnect electrical power and gas supply. Black White Black White Green Green Single phase Three phase 3-26 powermax1250 Service Manual...

  • Page 54: Torch Installation

    MAINTENANCE Torch installation Turn power OFF.  Remove power cord from power receptacle.  Open ETR door and route the lead through the end cap.  Door End Cap powermax1250 Service Manual 3-27...
  • Page 55 Slide quick-release collar foward to lock in the gas fitting. Make sure that the gas fitting is secure.  Make sure that the red dot on the connector is on top, then plug in the electrical connector. Close ETR  door. 3-28 powermax1250 Service Manual...

  • Page 56: Filter Element Replacement

    Note: Do not allow the filter element to turn when loosening the screw. 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. powermax1250 Service Manual 3-29...

  • Page 57: Work Cable Replacement

    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. Connect to J14 Strain relief barrier Work cable 3-30 powermax1250 Service Manual...

  • Page 58: Capacitor Replacement

    Install new capacitor and secure with 2 screws. Tighten screws to 20 in-lb (24 kg cm) of torque. Install the power supply cover. Remove and install screws from power board side. Remove and install Correct Installation capacitors from fan side. powermax1250 Service Manual 3-31...

  • Page 59: Heat Sink Component Replacement

    1. Apply thermal grease and torque to 8 in-lb (9 kg cm.) 2. Apply thermal grease and torque to 20 in-lb (23 kg cm). 3. Apply thermal grease and torque to 35 in-lb (40 kg cm). 3-32 powermax1250 Service Manual...

  • Page 60: 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 powermax1250 Service Manual...

  • Page 61: Exterior

    Front end panel, Domestic 128625 Front end panel, CE 128626 Rear end panel 128620 Power supply cover with labels, Domestic 128621 Power supply cover with labels, CE 123645 Ground clamp 128629 Cover screws 128630 End cap screws 011096 Regulator knob powermax1250 Service Manual...

  • Page 62: Interior Right Side

    Pressure Sensor 128801 Pressure Regulator 123604 Pilot Arc IGBT Gate Drive Cable 128622 Gas Manifold 128628 ETR Box 046116 Tubing, 8mm OD, 6mm ID, nylon 3 ft. 123602 Gate Drive Cables 128663 Power PCB PCB2 108211 On/Off Knob powermax1250 Service Manual...

  • Page 63: Back Interior Right Side

    Qty. 128662 Machine interface 128665 Strain relief, arc voltage 128672 Power switch 128671 EMI Filter PCB, CE only PCB1 128666 8 ft (2.5 m) Power cable, Domestic 3PH 128667 8 ft (2.5 m) Power cable, CE 3PH powermax1250 Service Manual...

  • Page 64: Interior Fan Side

    Power supply – interior fan side Part Item number Description Designator Qty. 128627 Filter bowl 011093 Air filter element 011094 O-ring 128683 Fan subassembly 128680 Inductor, input choke 128673 Capacitor C94, C98 128664 Power transformer 128679 Inductor, output choke powermax1250 Service Manual...

  • Page 65: Heat Sink Assembly

    Thermal grease, 5 oz. DC-340 128677 Output diode bridge 128676 IGBT, inverter 128684 Temperature Switch PCB4 128675 IGBT, PFC 128678 Input diode bridge 128670 Snubber resister 128674 IGBT, pilot arc 128669 Snubber resister Reference page 3-24 for torque specifications. powermax1250 Service Manual...

  • Page 66: Recommended Spare Parts

    PARTS – POWER SUPPLY Recommended spare parts – Powermax1250 Part number ........Description....................Page reference 008965..........Current adjustment knob ..................4-2 128660..........Control PCB assembly, Domestic..............4-3 128661..........Control PCB assembly, CE................4-3 123605..........Pressure sensor....................4-3 128801..........Pressure regulator ....................4-3 128622..........Gas manifold.....................4-3 128668..........Work cable with clamp, 15 ft (4.6 m) ..............4-3 128663..........Power PCB .......................4-3...
  • Page 67 PARTS – POWER SUPPLY powermax1250 Service Manual...

  • Page 68: Parts - Torch And Consumables

    Section 5 PARTS – TORCH AND CONSUMABLES In this section: T80 Hand torch assembly ............................5-2 T80M Machine torch assembly ..........................5-4 Torch consumable configurations ..........................5-6 Recommended spare parts ............................5-8 powermax1250 Service Manual...

  • Page 69: T80 Hand Torch Assembly

    75 ft (22.5 m) Torch Lead Replacement 128638 ETR Repair Kit 128642 Start Switch * Top assembly includes the following consumables (See page 5-6 for details of consumable parts): 120926 Electrode 120925 Swirl Ring 120928 Retaining Cap 120929 Shield 120927 Nozzle powermax1250 Service Manual...
  • Page 70 PARTS – TORCH AND CONSUMABLES powermax1250 Service Manual...

  • Page 71: T80M Machine Torch Assembly

    ETR Repair Kit 128645 Torch Mounting Kit (for reassembly after installation) * Top assembly includes the following consumables (See page 5-6 for details of consumable parts): 120926 Electrode 120925 Swirl Ring 120928 Retaining Cap 120929 Shield 120927 Nozzle powermax1250 Service Manual...
  • Page 72 PARTS – TORCH AND CONSUMABLES powermax1250 Service Manual...

  • Page 73: Torch Consumable Configurations

    Swirl ring Shield Retaining cap Nozzle O-ring 058519 120929 120928 120932 120926 120925 120929 120928 120931 120929 120928 120927 O-ring 058519 220325* 120928 220329 120926 220327 120979 O-ring 058519 120977 120928 220059 120926 120925 120977 120928 120978 powermax1250 Service Manual...
  • Page 74 Maintain torch-to-work distance of approximately 3/16 inch (4.8 mm). *** Use an ohmic sensing cap when a 220061*** compatible torch height contoller is installed. O-ring 058519 120979 120928 220006 120979 120928 220007 120926 120925 120979 120928 120980 powermax1250 Service Manual...

  • Page 75: Recommended Spare Parts

    128639 T80/T80M Torch Cap Sensor Replacement Kit 128888 FineCut Consumable Kit 128889 FineCut Consumable Kit – CE 087001 T80 Hand Torch Assembly with 25 ft (7.6 m) Lead 087004 T80M Machine Torch Assembly 25 ft (7.6 m) powermax1250 Service Manual...

  • Page 76: Wiring Diagrams

    Section 6 WIRING DIAGRAMS In this section: Timing diagrams ...............................6-2 Electrical schematics ..............................6-5 powermax1250 Service Manual...
  • Page 77 Service Manual...
  • Page 78 Service Manual...
  • Page 79 WIRING DIAGRAMS powermax1250 Service Manual...

  • Page 80: Timing Diagram

    FOR MANUFACTURING OR FABRICATION ANGULAR ±.5∞ DRAWN BY DATE APPROVED BY DATE PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND SHARP EDGES. BREAK SHARP EDGES IF NECESSARY FROM HYPERTHERM, INC. 5-11-01 WITH CHAMFER OR RADIUS .015 MAX. powermax1250 Service Manual...