Hypertherm MAX42 Manuals

Manuals and User Guides for Hypertherm MAX42. We have 1 Hypertherm MAX42 manual available for free PDF download: Service Manual

Hypertherm MAX42 Service Manual (100 pages)

Brand: Hypertherm | Category: Welding System | Size: 2.04 MB

Service Manual
2
Table of Contents
6
SECTION a SAFETY
11
Recognize Safety Information
11
Follow Safety Instructions
11
Cutting Can Cause Fire or Explosion
11
Electric Shock Can Kill
12
Cutting Can Produce Toxic Fumes
12
A Plasma Arc Can Cause Injury and Burns
13
Arc Rays Can Burn Eyes and Skin
13
Grounding Safety
13
Compressed Gas Equipment Safety
14
Gas Cylinders Can Explode if Damaged
14
Noise Can Damage Hearing
14
Pacemaker and Hearing Aid Operation
14
A Plasma Arc Can Damage Frozen Pipes
14
Additional Safety Information
14
SECTION B SÉCURITÉ
16
Identifier Les Consignes De Sécurité
16
Suivre Les Instructions De Sécurité
16
Danger Avertissement Précaution
16
Le Coupage Peut Provoquer Un Incendie Ou Une Explosion
16
Risque D'explosion Argon-Hydrogène Et Méthane
16
Détonation De L'hydrogène Lors Du Coupage De L'aluminium
16
Les Chocs Électriques Peuvent Être Fatals
17
Prévention Des Chocs Électriques
17
Le Coupage Peut Produire Des Vapeurs Toxiques
17
L'arc Plasma Peut Provoquer Des Blessures Ou Des Brûlures
18
Torches À Allumage Instantané
18
Les Rayons De L'arc Peuvent Brûler Les Yeux Et La Peau
18
Mise À La Masse Et À La Terre
18
Sécurité Des Bouteilles De Gaz Comprimé
19
Les Bouteilles De Gaz Comprimé Peuvent Exploser En Cas De Dommages
19
Le Bruit Peut Provoquer Des Problèmes Auditifs
19
Pacemakers Et Prothèses Auditives
19
Un Arc Plasma Peut Endommager Les Tuyaux Gelés
19
SECTION C SEGURIDAD
21
Reconocimiento De Información De Seguridad
21
Siga Las Instrucciones De Seguridad
21
Peligro Advertencia Precaución
21
Los Cortes Pueden Provocar Incendios O Explosiones
21
Peligro De Explosión Argón-Hidrógeno Y Metano
21
Detonación De Hidrógeno Con El Corte De Aluminio
21
Peligro
21
El Choque Elétrico Puede Provocar La Muerte
22
Prevención Ante El Electrochoque
22
Los Cortes Pueden Producir Humos Tóxicos
22
El Choque Eléctrico Puede Provocar La Muerte
22
El Arco De Plasma Puede Causar Lesiones Y Quemaduras
23
Antorchas De Encendido Instantáneo
23
Los Rayos Del Arco Pueden Producir Quemaduras En Los Ojos Y En La Piel
23
Seguridad De Toma a Tierra
23
Seguridad De Los Equipos De Gas Comprimido
24
Los Cilindros De Gas Pueden Explotar Si Están Dañados
24
El Ruido Puede Deteriorar La Audición
24
Operación De Marcapasos Yde Audífonos
24
Un Arco Plasma Puede Dañar Tubos Congelados
24
Section 1 Introduction
25
Read this First
26
Figure 1-1 MAX42 Power Unit, 208-240 VAC, 1 PH, 60 Hz
26
Safety
27
Warning - Instant-On Torches
27
Description
28
Power Unit
28
Major Subassemblies and Components
28
Front Panel Subassembly 029305
28
Pneumatic Subassembly 029351
28
Specifications
29
Power Unit
29
Disconnect Switch Box
29
PAC121T Trigger Torch
30
PAC121P Pushbutton Torch
30
PAC121M Machine Torch
30
Section 2 Theory of Operation
32
General
32
Principles of Operation
32
Figure 2-1 MAX42 Power Unit Block Diagram
32
Circuit Descriptions
33
Control Circuits
33
Power Circuits
34
Theory of Operation
35
Maintenance
37
General
37
Test Equipment & Tools
37
Visual Inspection
37
Checkout Procedures
37
Initial Resistance Checks
38
Corrective Maintenance Checks
42
Sequence of Operation
51
PAC121T Torch Parts Removal and Replacement
52
Torch Main Body Removal and Replacement
52
Torch Switch Removal and Replacement
53
Figure 3-1 PAC121T Torch Assembly
53
PAC121P Torch Parts Removal and Replacement
54
Torch Main Body Removal and Replacement
54
Torch Switch Removal and Replacement
54
Figure 3-2 PAC121P Torch Assembly
55
PAC121M Torch Parts Removal and Replacement
56
Torch Main Body Removal and Replacement
56
Figure 3-3 PAC121M Torch Assembly
57
Filter/Regulator Pressure Adjustment
58
Filter/Regulator Filter Cleaning or Replacement
58
Figure 3-4 Filter/Regulator Pressure Adjustment
59
Section 4 Parts List
60
Power Unit
60
MAX42 Power Unit 208-240 VAC, 1 PH, 60 Hz (071003)
61
Rear Panel Subassembly (029338)
61
Parts Lists
61
Bracket Subassembly, Air Pack Power Supply (029339)
67
Inverter Subsystem Assembly (029289)
69
Heatsink Subassembly (029331)
71
Bracket Assembly, Magnetic Tray (029328)
72
Input Capacitor Bank (029298)
72
Inductor, Power I/O (029293)
72
PAC121T Torch Assembly and Lead (25 Ft/7.63 M) - 071065
76
PAC121T Torch Assembly and Lead (50 Ft/15.25 M) - 071066
76
PAC121 Torch Assembly and Leads
76
Figure 4-12 PAC121T Torch Assembly and Leads
77
Parts List
77
PAC121P Torch Assembly and Lead (25 Ft/7.63 M) - 071069
78
PAC121P Torch Assembly and Lead (50 Ft/15.25 M) - 071070
78
Figure 4-13 PAC121P Torch Assembly and Leads
79
PAC121M Torch Assembly and Lead (25 Ft/7.63 M) - 071067
80
PAC121M Torch Assembly and Lead (50 Ft/15.25 M) - 071068
80
On/Off Pendant
80
Figure 4-14 PAC121M Torch Assembly with Leads and Optional On/Off Pendant
81
Figure 4-15 PAC121M Torch Assembly and Leads
81
Section 5 Wiring Diagrams & Schematics
82
Figure 5-3 Pneumatic System - Flow Diagram
82
General
83
MAX42 Service Manual
83

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