Hypertherm POWERMAX350 Service Manual
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Hypertherm POWERMAX350 Service Manual

Hypertherm POWERMAX350 Service Manual

Plasma arc cutting system
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Plasma Arc
Cutting System
Service Manual
802920 Revision 1
EN50199
EN50192
®

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Summary of Contents for Hypertherm POWERMAX350

  • Page 1 ® Plasma Arc Cutting System Service Manual 802920 Revision 1 EN50199 EN50192...
  • Page 2 Hanover, New Hampshire 03755-5010 Tel.: 603 643-3441 Fax: 603 643-5352 http://www.hypertherm.com © Copyright 1998 Hypertherm, Inc. All Rights Reserved Hypertherm, HyDefinition, Powermax and LongLife are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries...
  • Page 3 D-63457 Hanau-Wolfgang, Germany 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm Singapore Pte Ltd No. 19 Kaki Bukit Road 2 K.B. Warehouse Complex Singapore 417847, Republic of Singapore 65 841 2489 Tel...

  • Page 4: Hypertherm Plasma Systems

    The size of the surrounding area to be con- Earthing of Workpiece sidered will depend on the structure of the Hypertherm's CE-marked equipment is built Where the workpiece is not bonded to earth building and other activities that are taking in compliance with standard EN50199.

  • Page 5: Warranty

    Hypertherm warranty. LIMITATION OF LIABILITY WARNING In no event shall Hypertherm be liable to any person or You are responsible for the safe use of the Product. entity for any incidental, consequential, indirect, or...

  • Page 6: Table Of Contents

    ABLE OF ONTENTS ELECTROMAGNETIC COMPATIBILITY .......................i WARRANTY ................................ii SECTION 1 SAFETY ..........................1-1 Recognize Safety Information ..........................1-2 Follow Safety Instructions ..........................1-2 Cutting Can Cause Fire or Explosion ......................... 1-2 Electric Shock Can Kill ............................1-3 Cutting Can Produce Toxic Fumes ........................1-3 A Plasma Arc Can Cause Injury and Burns .......................
  • Page 7 Wiring Harness Diagram, 200 Volt Unit .................. 3-18 Figure 3-6 PAC110 Torch Repair ......................3-21 Figure 4-1.1 115/230 Volt Powermax350 Power Supply ................4-3 Figure 4-1.2 200 Volt Powermax350 Power Supply ..................4-5 Figure 4-2 PAC110 Assembly and Torch Leads ..................4-6 Figure 4-3 Consumable Parts ........................
  • Page 8 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 9: 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 10: 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 11: 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 12: 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 13: Warning Label

    Use welding helmet with correct shade of filter. 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. HYPERTHERM Plasma Systems 8-99...

  • Page 14: Section 1A

    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 ÉTIQUETTE DE SÉCURITÉ ................1a-6 HYPERTHERM Systèmes plasma 1a-1 08/99...

  • Page 15: Identifier Les Consignes De Sécurité

    Se référer à l’annexe du manuel pour plus de • Ne pas couper de récipients contenant des matières renseignements sur les collecteurs d’aération. combustibles. 1a-2 HYPERTHERM Systèmes plasma 08/99...

  • Page 16: 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 17: 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 08/99...

  • Page 18: Sécurité Des Bouteilles De Gaz Comprimé

    • Faire passer le faisceau de la torche le plus près possible du câble de retour. • Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps. • Se tenir le plus loin possible de la source de courant. HYPERTHERM Systèmes plasma 1a-5 08/99...

  • Page 19: Étiquette De Sécurité

    Porter des vêtements protecteurs couvrant la totalité du corps. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité. 1a-6 HYPERTHERM Systèmes plasma 08/99...

  • Page 20: Specifications

    PECIFICATIONS Section 2 SPECIFICATIONS In this section: Introduction ...................... 2-2 Specifications ....................2-2 Power Supply ....................2-2 PAC110 Torch ....................2-3 S Mark ......................2-4 IEC Symbols Used ................... 2-4 Service Manual...

  • Page 21: Introduction

    PECIFICATIONS INTRODUCTION The Powermax350 plasma cutting system uses a chopper power supply to cut mild steel, stainless steel, aluminum and other metals. Cylinder air or shop air is used as the plasma gas. Air used for plasma cutting must be clean, dry and oil-free.

  • Page 22: Pac110 Torch

    Work Lead PAC110 Torch Figure 2-1 Powermax350 Plasma Cutting System PAC110 Torch Recommended Cutting Capacity ........1/4 inch (6 mm) @ 25A (35% duty cycle) Maximum Cutting Capacity ........... 3/8 inch (10 mm) @ 25A (35% duty cycle) Severance Cutting Capacity .......... 1/2 inch (12 mm) @ 25A (35% duty cycle) Gas Flow ...............

  • Page 23: Mark

    PECIFICATIONS MARK The Powermax350 conforms to standard EN50192. The S mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. IEC SYMBOLS USED Direct Current (DC). Alternating current (AC). Plasma cutting torch.

  • Page 24: Maintenance

    AINTENANCE Section 3 MAINTENANCE In this section: Routine Maintenance ..................3-2 Theory of Operation ..................3-3 General ....................... 3-3 Functional Description ................3-3 Trouble LED Indicators..................3-8 Pressure ..................... 3-8 Torch Cap ....................3-8 Over-Temp ....................3-8 Troubleshooting....................3-9 PAC110 Torch Repair ..................3-20 Technical Questions ..................

  • Page 25: Routine Maintenance

    AINTENANCE ROUTINE MAINTENANCE WARNING SHOCK HAZARD: Always turn off the power and unplug the cord before changing consumable parts. Do not rely on the cap-on sensor switch to remove power. It is provided strictly for safety backup. In the U.S., use a "lock-out / tag-out" procedure until the service or maintenance work is complete.

  • Page 26: Theory Of Operation

    AINTENANCE THEORY OF OPERATION General 115/230 Volt Unit The 115/230 volt power supplies are shipped to operate at 115 volts. To operate at 230 volts, the input voltage selector switch must be set to the 230V position (Figure 3-1) and a 230V plug must be installed on the power cord.
  • Page 27 AINTENANCE Input Filter FL1 (CE units only) Provides input power noise filtering. Power Switch S1 Provides on/off control of power to main transformer T1. Input Voltage Selector Switch S2 Connects primary of main transformer T1 for 115 or 230 VAC operation. Line Input Input Power...
  • Page 28 AINTENANCE Motor 115 or 230 VAC Main Integrated Transformer Rectifier Primary Secondary 18 and 24 36 VAC Center- Tapped DC Power Power Control Board Pilot (+) Electrode (-) 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Contactor Control Signal 1 2 3 4...
  • Page 29 AINTENANCE Power Switch S1 Provides on/off control of power to main transformer T1. Main Transformer T1 Supplies power to output circuit, power control board PC1, safety control board PC2, and fan motor FM. Input Power 200 VAC Resistor Switch S1 1 Ø...
  • Page 30 AINTENANCE Motor Main Integrated Transformer Rectifier Primary Secondary 18 and 24 36 VAC Center- Tapped DC Power Power Control Board Pilot (+) Electrode (-) 1 2 3 4 1 2 3 4 1 2 3 4 Contactor Control Signal 1 2 3 4 1 2 3 4 5 6 7 8 9 0 1 2 3 4 Work (+) 1 2 3 4 5 6 7 8 9 0 1 2 3 4...

  • Page 31: Trouble Led Indicators

    AINTENANCE TROUBLE LED INDICATORS If certain problems occur, the READY LED extinguishes, a trouble LED illuminates and the torch stops firing. • PRESSURE LED - Illuminates if air pressure is below 40 psi (2.8 bar). Turn power Off (O) and check for proper air pressure. •...

  • Page 32: Troubleshooting

    AINTENANCE TROUBLESHOOTING Refer to Figure 3-4 and 3-5 to assist in the troubleshooting process. WARNING SHOCK HAZARD: Always turn off the power and unplug the cord or set the line disconnect switch to Off before servicing the unit or changing consumable parts.
  • Page 33 AINTENANCE Problem Cause/Solution 2.5 Check resistance and connections of input resistor R2 which is rated at 10 ohms ±10 %. Replace if necessary. 2.6 Check coil voltage and connections of control relay CR6. Check continuity of coil and condition of contacts. Replace if necessary. 2.7 Check transformer T1 for signs of winding failure.
  • Page 34 AINTENANCE Problem Cause/Solution 6.1 Check air system for leaks. 6. No air flow; POWER ON and READY LEDs illuminated; PRESSURE, TORCH CAP and OVER- 6.2 Check for proper torch lead connections. TEMP LEDs extinguished; fan operating. 6.3 Check coil voltage and connections of gas valve GS1.
  • Page 35 AINTENANCE WARNING SHOCK HAZARD: Always turn off the power and unplug the cord or set the line disconnect switch to Off before servicing the unit or changing consumable parts. 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.
  • Page 36 AINTENANCE Resistance Values Voltage Readings Tolerance ± 10 % unless specified a) Tolerance ± 10 % unless specified Turn Off (O) and remove input power b) Reference - to circuit common, lead 43 unless noted plug from receptacle before checking resistance. V1, V2, V3 115 VAC All values for T1 are less than 1 ohm...
  • Page 37 AINTENANCE WARNING SHOCK HAZARD: Always turn off the power and unplug the cord or set the line disconnect switch to Off before servicing the unit or changing consumable parts. 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.
  • Page 38 AINTENANCE Resistance Values Voltage Readings Tolerance ± 10 % unless specified a) Tolerance ± 10 % unless specified Turn Off (O) and remove input power b) Reference - to circuit common, lead 43 unless noted plug from receptacle before checking resistance. 115 VAC All values for T1 are less than 1 ohm 200 VAC...
  • Page 39 AINTENANCE 36A 37A To Torch Cap Switch To PC2-RC10 PLG10 To Torch Trigger 35A 38A To Base To Base Ground Ground Power Cord To T1-PLG23 To Fan Motor 3-16 Service Manual 7-98...
  • Page 40 AINTENANCE Figure 3-5.1 Wiring Harness Diagram, 115/230 Volt Service Manual 3-17 7-98...
  • Page 41 AINTENANCE To Torch Cap Switch 36A 37A PLG10 To Torch Trigger To PC2-RC10 35A 38A LOAD LINE PLG22 To Base Ground Power Cord 3-18 Service Manual 7-98...
  • Page 42 AINTENANCE To SR1 Pos To SR1 Neg To Torch Electrode To R1 To Torch Pilot To R1 PLG4 To PC1-RC4 To Center Baffle Ground To 1T To SR1 AC To CR1 PLG6 To PC1-RC6 PLG1 To PC1-RC1 To GS1 15A 14A To S3 8A 9A PLG11...

  • Page 43: Pac110 Torch Repair

    AINTENANCE PAC110 TORCH REPAIR Parts and Required Tools The PAC110 torch can be repaired in the field by removing the torch main body from the torch assembly and installing a new torch main body and a plastic cinch strap (Tyrap). To perform the repair, the following customer- supplied tools are required: •...

  • Page 44: Figure 3-6 Pac110 Torch Repair

    AINTENANCE 5. Install the new cinch strap (Tyrap) as shown. 6. Install the torch main body assembly and torch switch into one of the handle halves. While positioning the handle halves together, be careful not to pinch any wires, especially around the torch switch retainers. 7.

  • Page 45: Technical Questions

    AINTENANCE TECHNICAL QUESTIONS If you are unable to fix the problem with your Powermax350 by following this basic troubleshooting guide or if you need further assistance: 1. Call your distributor, who will be able to help you, or refer you to an authorized Hypertherm repair facility.

  • Page 46: Parts List

    ARTS Section 4 PARTS LIST In this section: 115/230 Volt Power Supply ................4-2 200 Volt Power Supply ..................4-4 PAC110 Torch Assembly and Leads ..............4-6 Consumable Parts .................... 4-7 Service Manual 7-98...

  • Page 47: 115/230 Volt Power Supply

    ARTS 115/230 VOLT POWER SUPPLY Index No. Part No. Description Ref. Desig. Quantity 060074 Varistor 060044 Rectifier, integ 40A 800V 060052 Heat Sink 060042 Insulator, end 060043 Bracket, resistor 060049 Resistor, wire wound, fixed 338W 1.5 ohm 060015 Stand-Off Support PC card 060065 Switch, Pressure 40 psi fixed 060055...

  • Page 48: Figure 4-1.1 115/230 Volt Powermax350 Power Supply

    ARTS (fan mounted to blow inward) PAC110 Torch See Figure 4-2 Figure 4-1.1 115/230 Volt Powermax350 Power Supply Service Manual 7-98...

  • Page 49: 200 Volt Power Supply

    ARTS 200 VOLT POWER SUPPLY Index No. Part No. Description Ref. Desig. Quantity 060074 Varistor 060044 Rectifier, integ 40A 800V 060129 Thermostat, NC open 70C 060052 Heat Sink 060042 Insulator, end 060043 Bracket, resistor 060049 Resistor, wire wound, fixed 338W 1.5 ohm 060015 Stand-Off Support PC card 060065...

  • Page 50: Figure 4-1.2 200 Volt Powermax350 Power Supply

    ARTS (fan mounted to blow inward) Figure 4-1.2 200 Volt Powermax350 Power Supply Service Manual 7-98...

  • Page 51: Pac110 Torch Assembly And Torch Leads

    ARTS PAC110 Torch Assembly Index No. Part No. Description Quantity 070057 Torch Assembly with 15 ft (4.5 m) Lead 070058 Torch Assembly with 25 ft (7.6 m) Lead 001192 Handle, PAC110 075339 Screws, P/S, # 4 X 1/2, PH, RND, S/B 075341 Screws, P/S, # 4 X 3/4, PH, RND, S/B 005094...

  • Page 52: Consumable Parts

    ARTS CONSUMABLE PARTS Index No. Part No. Description Quantity 020239 Ring, Swirl 020382 Electrode, Extended 120504 Nozzle, Extended, 25A 020218 Cap, Retaining The consumable parts are found in a box, located in the left side of the power supply cover. Figure 4-3 Consumable Parts Service Manual 7-98...

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Powermax 350

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