Hypertherm powermax600 Service Manual page 7

T C
ABLE OF ONTENTS
SECTION 3 MAINTENANCE
CONTROLS AND INDICATORS ........................................................................................................................... 3-2
INDICATOR LAMPS ............................................................................................................................................. 3-2
CONTROLS. ......................................................................................................................................................... 3-2
THEORY OF OPERATION ................................................................................................................................... 3-3
GENERAL ............................................................................................................................................................. 3-3
230/400 VOLT FUNCTIONAL DESCRIPTION ...................................................................................................... 3-4
208-240/480 VOLT FUNCTIONAL DESCRIPTION .............................................................................................. 3-6
SEQUENCE OF OPERATION .............................................................................................................................. 3-8
TROUBLESHOOTING .......................................................................................................................................... 3-9
TEST EQUIPMENT ............................................................................................................................................... 3-9
TROUBLESHOOTING PROCEDURES AND SEQUENCE .................................................................................. 3-9
VISUAL INSPECTION - EXTERNAL .................................................................................................................... 3-9
VISUAL INSPECTION - INTERNAL ................................................................................................................... 3-10
RESISTANCE CHECKS ...................................................................................................................................... 3-11
TROUBLESHOOTING GUIDE ............................................................................................................................ 3-14
VOLTAGE CHECKS ............................................................................................................................................ 3-21
COMPONENT REPLACEMENT ......................................................................................................................... 3-26
POWER CORD REPLACEMENT ....................................................................................................................... 3-26
TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT) ............................................... 3-27
AIR FILTER ELEMENT REPLACEMENT ........................................................................................................... 3-28
WORK CABLE REPLACEMENT ........................................................................................................................ 3-30
CAPACITOR REPLACEMENT ........................................................................................................................... 3-31
HEAT SINK COMPONENT REPLACEMENT ..................................................................................................... 3-32
SECTION 4 PARTS LIST - 400/230V CE
POWER SUPPLY - EXTERIOR ........................................................................................................................... 4-2
POWER SUPPLY - FRONT INTERIOR RIGHT SIDE .......................................................................................... 4-3
POWER SUPPLY - BACK INTERIOR RIGHT SIDE ............................................................................................ 4-4
POWER SUPPLY - INTERIOR FAN SIDE ........................................................................................................... 4-5
POWER SUPPLY - HEAT SINK ASSEMBLY ....................................................................................................... 4-6
RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V ....................................................................... 4-7
SECTION 5 PARTS LIST - 208-240/480V
POWER SUPPLY - EXTERIOR ........................................................................................................................... 5-2
POWER SUPPLY - FRONT INTERIOR RIGHT SIDE .......................................................................................... 5-3
POWER SUPPLY - BACK INTERIOR RIGHT SIDE ............................................................................................ 5-4
POWER SUPPLY - INTERIOR FAN SIDE ........................................................................................................... 5-5
POWER SUPPLY - HEAT SINK ASSEMBLY ....................................................................................................... 5-6
RECOMMENDED SPARE PARTS - POWERMAX600- 208-240/480V ................................................................ 5-7
SECTION 6 PARTS LIST - TORCH AND CONSUMABLES
PAC123T HAND TORCH ASSEMBLY (NO QUICK DISCONNECT) .................................................................... 6-2
PAC123T HAND TORCH ASSEMBLY (WITH QUICK DISCONNECT) ................................................................ 6-4
PAC123M MACHINE TORCH ASSEMBLY (NO QUICK DISCONNECT) ............................................................. 6-6
PAC123M MACHINE TORCH ASSEMBLY (WITH QUICK DISCONNECT) ......................................................... 6-8
TORCH CONSUMABLES ................................................................................................................................... 6-10
RECOMMENDED SPARE PARTS - PAC123 TORCH ........................................................................................ 6-11
SECTION 7 WIRING DIAGRAMS
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Service Manual
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