Beruflich Dokumente
Kultur Dokumente
Cutting System
Service Manual
804470 Revision 2
AMPS
60
40
30
80
100
AC
50
60
4.0
PSI
70
80
5.0
6.0
BAR
_
+
G3 S
E R IE
Service Manual
(P/N 804470)
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
Hypertherm Automation, LLC
5 Technology Drive, Suite 300
West Lebanon, NH 03755 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
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 UK, Ltd.
9 Berkeley Court, Manor Park
Runcorn, Cheshire, England WA7 1TQ
44 1928 579 074 Tel
44 1928 579 604 Fax
France
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (ETSO Technical Service)
00 800 49 73 7843 Tel (ETSO Technical Service
toll-free in Europe)
Japan
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
5/23/03
EMC INTRODUCTION
Hypertherm's CE-marked equipment is built
in compliance with standard EN50199. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN50199 may not be
adequate to completely eliminate interference when the affected equipment is in
close proximity or has a high degree of
sensitivity. In such cases it may be necessary to use other measures to further
reduce interference.
This plasma equipment is designed for use
only in an industrial environment.
INSTALLATION AND USE
The user is responsible for installing and
using the plasma equipment according to
the manufacturer's instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as
earthing the cutting circuit, see Earthing of
Workpiece. In other cases it could involve
constructing an electromagnetic screen
enclosing the power source and the work
complete with associated input filters. In all
cases electromagnetic disturbances must
be reduced to the point where they are no
longer troublesome.
ASSESSMENT OF AREA
Before installing the equipment the user
shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into
account:
a. Other supply cables, control cables,
signalling and telephone cables; above,
below and adjacent to the cutting equipment.
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
e. Health of the people around, for
example the use of pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.
Earthing of Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of its size and position, for example,
ship's hull or building steelwork, a connection
bonding the workpiece to earth may reduce
emissions in some, but not all instances.
Care should be taken to prevent the earthing
of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the connection of
the workpiece to earth should be made by a
direct connection to the workpiece, but in
some countries where direct connection is
not permitted, the bonding should be
achieved by suitable capacitances selected
according to national regulations.
Note. The cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be authorized by a person who is competent to
assess whether the changes will increase
the risk of injury, for example, by allowing
parallel cutting current return paths which
may damage the earth circuits of other
equipment. Further guidance is given in IEC
TC26 (sec)94 and IEC TC26/108A/CD Arc
Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding
area may alleviate problems of interference.
Screening of the entire plasma cutting
installation may be considered for special
applications
Cutting Cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor
level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should
be considered. However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a
shock by touching these metallic
components and the electrode at the same
time. The operator should be insulated from
all such bonded metallic components.
WARRANTY
WARNING
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any damage
caused by the use of other than genuine Hypertherm parts may
not be covered by the Hypertherm warranty.
WARNING
You are responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the Product in your
environment.
GENERAL
Hypertherm, Inc. warrants that its Products shall be free from
defects in materials and workmanship, if Hypertherm is notified
of a defect (i) with respect to the power supply within a period
of two (2) years from the date of its delivery to you, with the
exception of G3 Series power supplies, which shall be within a
period of three (3) years from the date of delivery to you, and
(ii) with respect to the torch and leads within a period of one (1)
year from its date of delivery to you. This warranty shall not
apply to any Product which has been incorrectly installed,
modified, or otherwise damaged. Hypertherm, at its sole
option, shall repair, replace, or adjust, free of charge, any
defective Products covered by this warranty which shall be
returned with Hypertherms prior authorization (which shall not
be unreasonably withheld), properly packed, to Hypertherms
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance and
freight prepaid. Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products covered by this
warranty, except those made pursuant to this paragraph or with
Hypertherms prior written consent. The warranty above is
exclusive and is in lieu of all other warranties, express,
implied, statutory, or otherwise with respect to the
Products or as to the results which may be obtained
therefrom, and all implied warranties or conditions of
quality or of merchantability or fitness for a particular
purpose or against infringement. The foregoing shall
constitute the sole and exclusive remedy for any breach
by Hypertherm of its warranty. Distributors/OEMs may offer
different or additional warranties, but Distributors/OEMs are
not authorized to give any additional warranty protection to you
or make any representation to you purporting to be binding
upon Hypertherm.
LIMITATION OF LIABILITY
In no event shall Hypertherm be liable to any person or
entity for any incidental, consequential, indirect, or
punitive damages (including but not limited to lost profits)
regardless of whether such liability is based on breach of
contract, tort, strict liability, breach of warranties, failure of
essential purpose or otherwise and even if advised of the
possibility of such damages.
LIABILITY CAP
In no event shall Hypertherms liability, whether such
liability is based on breach of contract, tort, strict liability,
breach of warranties, failure of essential purpose or
otherwise, for any claim action suit or proceeding arising
out of or relating to the use of the Products exceed in the
aggregate the amount paid for the Products that gave rise
to such claim.
INSURANCE
At all times you will have and maintain insurance in such
quantities and types, and with coverage sufficient and
appropriate to defend and to hold Hypertherm harmless in
the event of any cause of action arising from the use of the
Products.
TRANSFER OF RIGHTS
You may transfer any remaining rights you may have
hereunder only in connection with the sale of all or substantially
all of your assets or capital stock to a successor in interest who
agrees to be bound by all of the terms and conditions of this
Warranty.
PATENT INDEMNITY
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherms
specifications and in cases of designs, processes, formulae, or
combinations not developed or purported to be developed by
Hypertherm, Hypertherm will defend or settle, at its own
expense, any suit or proceeding brought against you alleging
that the use of the Hypertherm product, alone and not in
combination with any other product not supplied by
ii
9-01
TABLE OF CONTENTS
iii
0
TABLE OF CONTENTS
Section 2 Specifications
Specifications Power Supply .................................................................................................................................2-2
Power Connection............................................................................................................................................2-3
Engine Drives...................................................................................................................................................2-3
Duty Cycle........................................................................................................................................................2-4
Power Supply Dimensions and Weight .........................................................................................................2-4
Specifications T100 Torches ..................................................................................................................................2-5
Torch Dimensions .....................................................................................................................................................2-6
Symbols and Markings .............................................................................................................................................2-7
Section 3 Maintenance
Controls and Indicators .............................................................................................................................................3-2
Theory of Operation ..................................................................................................................................................3-3
General ............................................................................................................................................................3-3
Functional Description......................................................................................................................................3-3
Sequence of Operation.............................................................................................................................................3-4
Troubleshooting ........................................................................................................................................................3-5
Test Equipment ................................................................................................................................................3-5
Troubleshooting Procedures and Sequence ....................................................................................................3-5
Visual Inspection External .............................................................................................................................3-5
Visual Inspection Internal ..............................................................................................................................3-6
Resistance Checks ...................................................................................................................................................3-7
Troubleshooting Guide..............................................................................................................................................3-9
Voltage Checks.......................................................................................................................................................3-14
Component Replacement .......................................................................................................................................3-20
Power Cord Replacement ..............................................................................................................................3-20
Torch Installataion ..........................................................................................................................................3-21
Filter Element Replacement...........................................................................................................................3-23
Work Cable Replacement ..............................................................................................................................3-24
Capacitor Replacement..................................................................................................................................3-25
Heat Sink Component Replacement..............................................................................................................3-26
Section 4 Parts Power Supply
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
Section 5 Parts List Torch and Consumables
T100 Hand Torch Assembly ......................................................................................................................................5-2
T100M Machine Torch Assembly ..............................................................................................................................5-4
Torch Consumable Configurations............................................................................................................................5-6
Recommended Spare Parts .....................................................................................................................................5-8
Section 6 Wiring Diagrams
Timing Diagrams.......................................................................................................................................................6-2
Electrical Schematic .................................................................................................................................................6-4
iv
0
Section 1
SAFETY
In this section:
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 ..............................................................................................................1-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4
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
1-1
SAFETY
DANGER
WARNING
CAUTION
Fire Prevention
Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
Remove all flammables within 35 feet (10 m) of the
cutting area.
Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
Never cut containers with potentially flammable
materials inside they must be emptied and
properly cleaned first.
Ventilate potentially flammable atmospheres before
cutting.
When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
Explosion Prevention
Do not use the plasma system if explosive dust or
vapors may be present.
Do not cut pressurized cylinders, pipes, or any
closed container.
Do not cut containers that have held combustible
materials.
1-2
11-98
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with Aluminum Cutting
When cutting aluminum underwater, or with the
water touching the underside of the aluminum, free
hydrogen gas may collect under the workpiece and
detonate during plasma cutting operations.
Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
SAFETY
1-3
8-99
SAFETY
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
Arc Current
Up to 100 A
100-200 A
200-400 A
Over 400 A
Lens Shade
AWS (USA)
ISO 4850
No. 8
No. 11
No. 10
No. 11-12
No. 12
No. 13
No. 14
No. 14
GROUNDING SAFETY
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall
away when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or
local electrical codes.
1-4
5/6/02
Input Power
Be sure to connect the power cord ground wire to
the ground in the disconnect box.
If installation of the plasma system involves
connecting the power cord to the power supply, be
sure to connect the power cord ground wire
properly.
Place the power cord's ground wire on the stud first,
then place any other ground wires on top of the
power cord ground. Fasten the retaining nut tightly.
Tighten all electrical connections to avoid excessive
heating.
SAFETY
1-5
11-98
SAFETY
1.
WARNING LABEL
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician
understand the intent of these warning symbols as described.
The numbered text corresponds to the numbered boxes on
the label.
7.
110391 Rev A
1-6
8-99
Section 1a
SCURIT
1a-1
2/12/01
SCURIT
DANGER
AVERTISSEMENT
PRCAUTION
1a-2
2/12/01
AVERTISSEMENT
Risque dexplosion
argon-hydrogne et mthane
Lhydrogne et le mthane sont des gaz inflammables et
potentiellement explosifs. Conserver lcart de toute
flamme les bouteilles et tuyaux contenant des mlanges
base dhydrogne ou de mthane. Maintenir toute flamme
et tincelle lcart de la torche lors de lutilisation dun
plasma dargon-hydrogne ou de mthane.
AVERTISSEMENT
Dtonation de lhydrogne lors du
coupage de laluminium
Lors du coupage de laluminium sous leau, ou si leau
touche la partie infrieure de la pice daluminium, de
lhydrogne libre peut saccumuler sous la pice couper
et dtonner lors du coupage plasma.
Installer un collecteur daration au fond de la table eau
afin dliminer les risques de dtonation de lhydrogne.
Se rfrer lannexe du manuel pour plus de
renseignements sur les collecteurs daration.
SCURIT
1a-3
2/12/01
SCURIT
Courant de larc
Jusqu 100 A
100-200 A
200-400 A
Plus de 400 A
1a-4
5/6/02
Alimentation
Sassurer que le fil de terre du cordon dalimentation est
connect la terre dans le coffret du sectionneur.
Sil est ncessaire de brancher le cordon dalimentation
la source de courant lors de linstallation du systme,
sassurer que le fil de terre est correctement branch.
Placer tout dabord le fil de terre du cordon dalimentation
sur le plot de mise la terre puis placer les autres fils de
terre par-dessus. Bien serrer lcrou de retenue.
Sassurer que toutes les connexions sont bien serres
pour viter la surchauffe.
SCURIT
UN ARC PLASMA
PEUT ENDOMMAGER
LES TUYAUX GELS
PACEMAKERS ET
PROTHSES AUDITIVES
Les champs magntiques produits par les courants haute
tension peuvent affecter le fonctionnement des prothses
auditives et des pacemakers. Les personnes portant ce
type dappareil doivent consulter un mdecin avant de
sapprocher dun lieu o seffectue le coupage ou le
gougeage plasma.
Pour rduire les risques associs aux champs magntiques :
Garder loin de soi et du mme ct du corps le cble de
retour et le faisceau de la torche.
Faire passer le faisceau de la torche le plus prs possible
du cble de retour.
Ne pas senrouler le faisceau de la torche ou le cble de
retour autour du corps.
Se tenir le plus loin possible de la source de courant.
1a-5
2/12/01
SCURIT
tiquette de scurit
1.
110391 Rev A
1a-6
2/12/01
7.
Section 2
SPECIFICATIONS
In this section:
Specifications Power Supply .................................................................................................................................2-2
Power Connection............................................................................................................................................2-3
Engine Drives...................................................................................................................................................2-3
Duty Cycle........................................................................................................................................................2-4
Power Supply Dimensions and Weight .........................................................................................................2-4
Specifications T100 Torches ..................................................................................................................................2-5
Torch Dimensions .....................................................................................................................................................2-6
Symbols and Markings .............................................................................................................................................2-7
2-1
0
SPECIFICATIONS
Power Factor
IP codeDegree of protection
provided by enclosure
300 VDC
Drooping
30A 100A
160 VDC
U1 Volts AC rms
X
200-208 VAC 3PH
60%
230-240 VAC 3PH
70%
380-415 VAC 3PH
80%
480 VAC 3PH
80%
600 VAC 3PH
80%
14o to 104o F (-10o to 40o C)
PH
Hz
3
50-60
U1 Volts AC rms
I1-Amps rms
I1eff
200-208 VAC 3PH
53
41
230-240 VAC 3PH
46
38
380-415 VAC 3PH
27
24
480 VAC 3PH
22
20
600 VAC 3PH
21
19
U1 Volts AC rms
Harmonic
Displacement
Power Factor
Power Factor
200-208 VAC 3PH
0.94
0.98
230-240 VAC 3PH
0.94
0.98
380-415 VAC 3PH
0.94
0.99
480 VAC 3PH
0.94
0.99
600 VAC 3PH
0.78
0.99
U1 Volts AC rms, 3PH
Rsce
400 VAC
191
230 VAC
142
This equipment conforms to IEC 61000-3-12,
provided that Rsce min = 191 at 400VAC 3PH
and 142 at 230 VAC 3PH.
IP23CS*
IP International Protection
2 No ingress foreign objects >=12.5mm (0.5 in)
3 No harmful ingress spraying water
C AC line circuits protected against ingress of
tool >
=2.5 mm dia. x 100 mm long
(0.1 inch x 4.0 inch)
S fan stationary during water test
*WARNING: DO NOT OPERATE IN RAIN
Up to 15o incline.
Air
Nitrogen
Clean, moisture-free, oil-free
90-120 psig (6.2-8.3 bar) 550 scfh/9.2 scfm (260 l/min)
SPECIFICATIONS
Power Connection
The Powermax1650 is a universal power supply that configures itself to operate with AC voltages from 200 to 600
3PH (230-400 3PH for CE model). Use a line disconnect switch for each power supply so that the operator can turn
off the power supply quickly in an emergency. Locate the switch so it is easily accessible to the operator. The
interrupt level of the switch must be equal to or exceed the continuous rating of the fuses. Use slow-blow fuses
rated per local and national electrical codes.
Three Phase
Standard Model
200-208
230-240
400
480
600
53
46
27
22
21
75
72
42
34
33
Recommended Fuse
80
80
50
40
40
Input Voltage
CE Model
Three Phase
230
400
46
27
72
42
Recommended Fuse
80
50
Input Voltage
Engine Drives
When using an engine drive to power the Powermax1650:
The engine drive must be dedicated to powering the plasma cutting system.
Engine drive operation:
1. Set the engine drive output to 3 phase AC.
2. Plug the Powermax1650 power cord into the power outlet.
3. Set the engine drive to the maximum output (see table below).
Use unshielded consumables if you experience difficulty cutting thicker material (non-CE systems only).
Standard Unit
3 Phase, 50/60 hz, 200 600 VAC (480 VAC recommended for best performance)
CE Unit
3 Phase, 50/60 hz, 230 400 VAC (400 VAC recommended for best performance)
Engine Drive Rating
Performance
30 kw
100 A
22.5 kw
100 A
75 A
75 A
50 A
15 kw
2-3
0
SPECIFICATIONS
Duty Cycle
Duty cycle is the percentage of time, during a 10 minute period, that the power supply can cut continuously. The
diagram below depicts an 80% duty cycle.
Note: Refer to Specifications Power Supply to determine the duty cycle that corresponds with the input power.
8 minutes
cutting
2 minutes
resting
26.4 in
(671 mm)
124 lb
(56.2 kg)
AMPS
60
40
30
80
100
AC
50
60
4.0
2-4
0
PSI
70
80
5.0
25.8 in
(655 mm)
6.0
BAR
_
+
SPECIFICATIONS
Maximum capacity
Severance capacity
Gouging Capability
(metal removal rate on mild steel)
Weight
T100
T100M
2-5
0
SPECIFICATIONS
Torch Dimensions
T100 Hand Torch Dimensions
8.9" (226 mm)
4.2"
(107 mm)
2.55"
(65 mm)
1.5"
(38 mm)
1.00"
(25 mm)
1.00"
(25 mm)
15.47"
(393 mm)
2.35"
(60mm)
8"
(203 mm)
1.38"
(35 mm)
2-6
0
SPECIFICATIONS
An inverter-based power
source
l
O
Power is on
Power is off
Volt/amp curve, "drooping"
characteristic
2-7
0
SPECIFICATIONS
2-8
0
Section 3
MAINTENANCE
In this section:
Controls and Indicators .............................................................................................................................................3-2
Theory of Operation ..................................................................................................................................................3-3
General ............................................................................................................................................................3-3
Functional Description......................................................................................................................................3-3
Sequence of Operation.............................................................................................................................................3-4
Troubleshooting ........................................................................................................................................................3-5
Test Equipment ................................................................................................................................................3-5
Troubleshooting Procedures and Sequence ....................................................................................................3-5
Visual Inspection External .............................................................................................................................3-5
Visual Inspection Internal ..............................................................................................................................3-6
Resistance Checks ...................................................................................................................................................3-7
Troubleshooting Guide..............................................................................................................................................3-9
Voltage Checks.......................................................................................................................................................3-14
Component Replacement .......................................................................................................................................3-20
Power Cord Replacement ..............................................................................................................................3-20
Torch Installataion ..........................................................................................................................................3-21
Filter Element Replacement...........................................................................................................................3-23
Work Cable Replacement ..............................................................................................................................3-24
Capacitor Replacement..................................................................................................................................3-25
Heat Sink Component Replacement..............................................................................................................3-26
3-1
0
MAINTENANCE
Mode Switch
AMPS
60
40
80
30
100
AC
PSI
50
60
4.0
Indicator
LEDs
70
5.0
80
6.0
BAR
Pressure
Gauge
Pressure
Regulator
Indicator LEDs
AC
3-2
0
MAINTENANCE
Theory of Operation
General
Refer to Functional Description, Sequence of Operation and the system wiring diagram in Section 6.
Functional Description
AC power enters the system through the power switch S1 to the input diode bridge D24. The voltage from the diode
bridge supplies the Power Factor Correction (PFC) Boost Converter which provides a 750 VDC bus voltage. The
bus voltage then supplies the inverter and the flyback system power supply (DC to DC converter) on the power
board PCB2. The power board provides noise suppression and spike protection. A "soft start" is implemented via
the power board resistor and relay K1.
The PFC Boost Converter consists of an isolated gate bipolar transistor (IGBT) Q14, choke and control circuit. It provides
a 750 VDC bus voltage when input AC voltage is between 170 and 540 VAC. When the input voltage is above 540 VAC
the bus voltage will rise to Vin* 2.
The inverter consists of an IGBT Q13, the power transformer T2, a current sense transformer, and sections of the
power board. The inverter operates as a pulse-width, modulator-controlled bridge circuit, and is rectified by the
output diode.
The output circuitry consists of 2 current transfer sensors located on the power board, the pilot arc IGBT Q15 and
the output choke.
The control boards microprocessor monitors and regulates system operation and safety circuits. The current is set
to the desired value by adjusting the current adjustment knob. The system compares the set point to the output
current by monitoring the current sensor and adjusting the pulse width output of the inverter IGBT Q13.
The control board PCB3 includes a pilot arc control switch, allowing the operator to turn the pilot arc ON (useful
when cutting expanded metal), OFF (for maximum life of consumables), or increase the pilot arc to 30A (useful for
gouging or non-transferred-arc cutting).
3-3
0
MAINTENANCE
Sequence of Operation
System OFF
3-4
0
Arc extinguishes.
Post flow continues for 30 seconds.
Inverter starts.
Current flows through torch with nozzle and
electrode shorted.
Gas solenoid valve V1 opens.
Gas flow starts.
Torch "blows back" - nozzle and electrode
separate.
Pilot arc starts.
MAINTENANCE
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.
Test Equipment
Multimeter
Visual Inspection
External
Visual Inspection
Internal
Resistance Checks
Power ON
Troubleshooting
Guide
Voltage Checks
3-5
0
MAINTENANCE
WARNING
ELECTRIC SHOCK CAN KILL
Turn off the power and remove the input power plug from its receptacle before removing
the cover from the power supply. If the power supply is directly connected to a line
disconnect box, switch the line disconnect to OFF (O). In the U.S., use a "lock-out / tagout" procedure until the service or maintenance work is complete. In other countries,
follow appropriate national or local safety procedures.
Do not touch live electrical parts! If power is required for servicing, use extreme caution
when working near live electrical circuits. Dangerous voltages exist inside the power
supply that can cause serious injury or death.
Do not attempt to repair the power board or control board. Do not cut away or remove
any protective conformal coating from either board. To do so will risk a short circuit
between the AC input circuit and the output circuit and may result serious injury or
death.
3-6
0
MAINTENANCE
Resistance Checks
All resistance values must be taken with the power cord disconnected and all internal power supply wires attached.
Perform Visual Inspection Internal before continuing in this section.
If resistance values are not close to the values given in this section, isolate the problem by removing wires
attached to the resistance check points or component until the problem is found.
After the problem has been located and repaired, refer to the Sequence of Operation flow diagram in this
section to test the power unit for proper operation.
Resistance Check #1
1. With the power disconnected, set the ON/OFF switch S1 to ON.
2. Check resistance across input leads.
3. Check resistance from input leads to ground.
Note: All values are 15%.
2.4 M
2.4 M
2.4 M
>20 M
3-7
0
MAINTENANCE
Resistance Check #2
Remove the linkage bar as shown below.
Check each diode (connection 1 and 3) with an ohm meter in diode test mode.
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.
Linkage bar
3-8
1
MAINTENANCE
Troubleshooting Guide
WARNING
ELECTRIC SHOCK CAN KILL
Use extreme caution when working near live electrical circuits. Dangerous voltages exist
inside the power supply that can cause serious injury or death.
See warnings on page 3-7 before proceeding.
If no problems were found during the initial resistance checks and the power supply still does not operate correctly,
see the Troubleshooting Guide on the following pages.
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.
3-9
0
AC
AC
Faulty valve
MAINTENANCE
3-10
Problem
Turn power switch ON and
Power On LED does not
illuminate
3-11
MAINTENANCE
Worn-out consumables
Replace consumables
MAINTENANCE
3-12
MAINTENANCE
DIAGNOSTIC LED'S
P1
UP
GAS
STATUS
45
50
NORMAL
START
60
XFR
TRANSFER
SDF
IF
INVERTER INTERLOCK
(VISIBLE FOR 10 SEC. AFTER EVENT)
TSO
SP
SPARE
GOUGE
DOWN
55
CPA
MID
CURRENT
START
65
70
75
80
85
Problem
Start LED on control board
(PCB3) and Fault lamp are
illuminated
Cause
Shorted start wires or
depressed start trigger
switch
Solution
Check start wires (blue
and orange wires in torch)
for short.
SDF
START
Normal operation
N/A
Microprocessor failure
Arc transfer
IF
START
TSO
START
N/A
N/A
SP
3-13
0
MAINTENANCE
Voltage Checks
Voltage Check #1
Check input voltage to the input diode bridge.
The AC voltage between any 2 input wires should equal the line voltage.
Note: All values are 15%.
= Line Voltage*
= Line Voltage
= Line Voltage*
3-14
0
MAINTENANCE
Voltage Check #2
Check output voltage of the input diode bridge.
Output VDC = Line Voltage * 1.414
Note: All values are 15%.
3-15
0
MAINTENANCE
Voltage Check #3
Check voltage across IGBT module (Q14).
Note: All values are 15%.
750 VDC
3-16
0
MAINTENANCE
Voltage Check #4
Check voltage across IGBT module (Q13).
Note: All values are 15%.
750 VDC
375 VDC
375 VDC
3-17
0
MAINTENANCE
Voltage Check #5
Check voltage across power supply capacitors.
Note: All values are 15%.
375 VDC
3-18
0
MAINTENANCE
Resistance Check #3
Troubleshoot illuminated Torch Stuck Open LED on control board PCB3.
1. Check resistance between Q15 and J17. The value should be < 1 .
If not, check torch leads, torch head, and consumables.
2. Check resistance between Q15 and J17 with system in Gas Test mode. The value should be > 1 M.
If not, verify electrode and torch plunger move freely.
3. Pilot arc shorted check resistance between Q15 and J17 with torch removed. If value is < 1 K replace Pilot
Arc IGBT.
4. Pilot arc open use a jumper wire to jump J14 to Q15. Then attempt to fire the torch. If the torch fires replace
the Pilot Arc IGBT.
Note: All values are 15%.
J14
J17
3-19
0
MAINTENANCE
Component Replacement
WARNING
ELECTRIC SHOCK CAN KILL
Use extreme caution when working near live electrical circuits. Dangerous voltages exist
inside the power supply that can cause serious injury or death.
See warnings on page 3-7 before proceeding.
Standard Unit
CE Unit
L1
Black
Black (U)
L2
White
Blue (V)
L3
Red
Brown (W)
PE
Green
Green/Yellow
L3
Ground
#10
6 (152 mm)
L1
L2
L3
40
30
80
100
AC
50
60
4.0
PSI
70
80
5.0
6.0
BAR
Strain relief
_
+
Strain relief
inserts (2)
Ground (PE)
Plug Installation
The plug must be connected to the power cord by a licensed electrician.
3-20
0
MAINTENANCE
Torch Installation
OFF
ON
Open Easy Torch Removal (ETR) door and route lead through the end cap.
AMPS
60
40
30
80
100
AC
50
60
4.0
70
PSI
80
5.0
6.0
BAR
_
+
ETR
Door
End Cap
3-21
0
MAINTENANCE
Pull back quick-release collar and insert the leads gas fitting.
Quick Release
Collar
Slide quick-release collar foward to lock the gas fitting in place. 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.
3-22
0
MAINTENANCE
3-23
0
MAINTENANCE
Connect to J14
Strain
Relief
ETR
Barrier
Work
Cable
3-24
0
MAINTENANCE
Capacitor Replacement
Removal Refer to figure below.
Disconnect electrical power and gas supply before removing the power supply cover.
Remove screws securing capacitor to power board.
Remove capacitor from fan side of power supply.
Remove lower capacitor first. Then the upper capacitor may be tipped down and removed.
Installation Refer to figure below.
Align bleeder hole on capacitor with view hole
on power board.
Install new capacitor and secure with 2 screws.
Tighten screws to 30 inch pounds (36 kg cm).
Bleeder hole
View hole
3-25
0
MAINTENANCE
DC-340
PMX600.28
Thermal Pad
Notes:
1
Apply white thermal grease DC-340 (Part no. 027662) and torque to 8 in-lb (9 kg cm.)
2
Apply white thermal grease DC-340 (Part no. 027662) and torque to 35 in-lb (40 kg cm).
3
Apply grey thermal grease TC-330 (Part no. 128836) and torque to 35 in-lb (40 kg cm).
Note: grey thremal grease TC-330 is included with PFC IGBT Replacement Kit (Part no. 128745)
3-26
2
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
4-1
0
AMPS
60
40
30
80
100
AC
50
60
4.0
PSI
70
80
5.0
6.0
BAR
_
+
Item
1
2
3
4
5
6
7
8
9
4-2
0
Part
Number
Description
128750
128758
128766
128765
008965
110413
128735
123645
011096
128740
128762
128629
128742
Designator
Qty.
1
1
1
1
1
1
4
1
1
1
1
14
1
Item
Part
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
128736
128659
128801
128699
128810
128622
046116
108211
128665
128662
128737
123602
Designator
Qty.
PCB3
1
1
1
1
1
1
3 ft.
1
1
1
1
3
V1
PCB2
4-3
0
AMPS
60
40
30
80
100
AC
50
60
4.0
PSI
70
80
5.0
6.0
BAR
_
+
Item
1
2
3
4
5
4-4
3
Part
number
Description
128757
128763
128764
128706
128672
128761
Front caster
Rear axel
Rear wheel replacement
EMI filter PCB, CE only
Power switch CSA
Power switch CE
Designator
Quantity
PCB1
S1
2
1
2
1
1
Item
1
2
3
4
5
6
Part
Number
Description
128627
011093
011094
128749
128741
128739
128749
128683
Filter bowl
Air filter element
O-ring
Inductor, input choke
Capacitor
Power transformer
Inductor, output choke
Fan subassembly
Designator
L2
T2
L1
M1
Qty.
1
1
1
1
2
1
1
1
4-5
0
Item
Part
Number
Description
1
2
3
4
5
6
7
8
9
027662
128733
128747
128743
128744
128745
128746
128748
128734
129782
Designator
Qty.
Q13
PCB4
Q14
D24
1
1
1
1
1
1
1
1
1
1
4-6
2
4-7
0
4-8
0
Section 5
PARTS LIST - TORCH AND CONSUMABLES
In this section:
T100 Hand Torch Assembly ......................................................................................................................................5-2
T100M Machine Torch Assembly ..............................................................................................................................5-4
Torch Consumable Configurations............................................................................................................................5-6
Recommended Spare Parts .....................................................................................................................................5-8
5-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part Number
Description
059264*
059270*
128767
027889
058519
128639
075571
128768
128756
075586
002244
027254
128755
128752
128638
128642
Quantity
1
1
1
1
2
1
1
5
1
1
1
1
1
1
* Top assembly includes the following consumables (See page 5-6 for details of consumable parts):
220051
220037
220011
220048
220065
5-2
0
Swirl Ring
Electrode
Nozzle
Retaining Cap
Shield
1
1
1
1
1
5-3
0
1
2
3
4
5
6
7
8
9
10
11
12
13
Part Number
Description
059265*
059268*
059272*
128754
027889
058519
128639
075571
128768
128643
075004
128710
128753
128751
128759
128638
128645
Quantity
1
1
1
1
2
1
1
3
1
1
1
1
1
1
* Top assembly includes the following consumables (See page 5-6 for details of consumable parts):
220051
220037
220011
220048
220047
5-4
0
Swirl Ring
Electrode
Nozzle
Retaining Cap
Shield
1
1
1
1
1
5-5
0
Retaining Cap
Nozzle
120929
120928
120932
Electrode
Swirl Ring
Hand-Held, Shielded
40A
O-Ring
058519
60A
120929
120928
120931
120929
120928
120927
220065
220048
220011
120926
120925
220037
220051
80A
100A
O-Ring
058519
Gouging
60A
120977
120928
220059
80A
120977
120928
120978
120977
220048
220063
120926
120925
220037
220051
100A
5-6
0
Retaining Cap
Nozzle
120930
120928*
120932
Electrode
Swirl Ring
Mechanized, Shielded
40A
O-Ring
60A
058519
120930
120928*
120931
120930
120928*
120927
220047
220048*
220011
120926
120925
220037
220051
80A
Ohmic Sensing
Retaining Cap
100A
40A-80A
100A
220206*
220061*
** In CE countries, unshielded
consumables may only be used in
mechanized torch applications.
40A
Unshielded**
120979
120928
220006
O-Ring
60A
058519
120979
120928
220007
120979
120928
120980
120979
220048
220064
120926
120925
220037
220051
80A
100A
5-7
0
Description
058519
Torch O-Ring
027055
128756
128638
075586
002244
Safety Trigger
027254
Trigger Spring
128642
128767
128754
128768
027889
Retaining Clip
128639
075571
020620
120668
075004
059264
059270
128755
128752
059265
059268
059272
128753
128751
128759
128643
128645
5-8
0
Section 6
WIRING DIAGRAMS
In this section:
Timing Diagrams.......................................................................................................................................................6-2
Electrical Schematic .................................................................................................................................................6-4
6-1
0
Start
0
1 OF 2
2ms
1
Pilot
Arc
Switch
Inverter
Enable
(INV_EN)
013353
Debounced
Start
Digitized
XFR signal
valid
NORMAL MODE
t=0
1
2ms
3ms
>200 ms
1.
Setpoint
Icommand
30A
21.5A
0
2.17A/ms
3ms
13ms
30
Ipilot
(Amps)
21.5
10
0
3ms
13ms
30.0sec
1ms
Gas
Postflow
Consumable
Re-Seat
60
Pcritical(15)
Gas Pressure
at Torch
(psi)
Time
Constant
tdelay
250
Arc
Voltage
(volts)
225
210
160
0
1
Digitized
XFR signal
in DSP and
Machine Motion
6-2
0
If >5.0 sec
pilot arc time out
250
50
0.4
50
1.6
Time Constant
(msec)
I Work Lead
(amps)
tdelay
(msec)
2.17A/ms
30
Torch Lead
Length(feet)
I Setpoint
~
~ 10ms
typ
A
2 OF 2
013353
CPA OPERATION
NOTE: UNIT IS ALREADY IN TRANSFER MODE
Digitized
EA
~
~ 3FFh
MUST BE >10ms
1
PA
1ms
Setpoint
Setpoint
40A
30A
30A
21.5A
Icommand
1ms
Digitized
XFR signal
in DSP
Reattach
causes
transfer
If >10.00 sec
CPA timeout
I SETPOINT
2.17A/ms
I work lead 30A
1.6A
0.4A
6-3
0
POWER BD PCB2
PFC CHOKE
DOMESTIC UNIT
K1, K2
Vbus
SOFT START
IGBT
Q13
INVERTER
J9
S1
CORD
~
~
~
BLK
WHT
RED
GRN
(PE)
J7
129773
1
+
D24
INPUT
BRIDGE
VacR
AUX
C100
Vbus
CONTROL
GND
+24
+10
+5
T1
FLYBACK
SYSTEM
POWER
SUPPLY
J8
PFC
IGBT
Q14
YEL
PFC
CONTROL
CKT
18PA
COMPA
BRN
BRN
YEL
J13
18INV
-6INV
7.5 ohm
100W
P2
3
PE
T2
POWER
TRANSFORMER
30 OHM
100W
J6
+
1
C92
18T
COMT
18REG
-6
CE UNIT
S1
CORD
J10
J4
J1
BLK
BLU
J2
BRN
J3
FILTER
PCB1
MTG-9
15 ohm
100W
J5
PE
J6
AUX
GRN/YEL
(PE)
15 ohm
100W
J11
B
1
Y
+24
J3
U2
ULN2003A
042188
1
2
3
7
8
4B 4C
5B 5C
6B 6C
7B 7C
-V
+V
16
14
13
12
11
/PREFLOW
/MM
10
9
C10
0.10uF
50V
009994
P1
10
OUTA
12
UP
SDF
NORMAL
DOWN
IF
INVERTER INTERLOCK
(VISIBLE FOR 10 SEC. AFTER EVENT)
OUTPUT
INDUCTOR
OUTB
13
PILOT ARC
IGBT
14
CPA
MID
CURRENT
TRANSFER
R12
2.0K
009036
11
XFR
J12
FEEDBACK
CURRENT
SENSOR
IFB
Q1
IRLZ44N
55V
0.022ohm
109223
8
9
START
OUTPUT
DIODES
+24
DIAGNOSTIC LED'S
RT9
60V 0.20A
109024
/PA
/SSR
15
PCB3
CONTROL BD
2B 2C
1B 1C
3B 3C
GOUGE
C20
0.10uF
50V
009994
15
16
D8
1N5231B
5.1V
109109
R16
499
009414
NC
R6
2.21K
1/2W
009883
17
18
TRANSFER
SENSOR
CKT
ITF
19
TSO
/IOC
J14
20
WORK LEAD
21
R4
10
009115
+5
22
SP
SPARE
J17
23
24
25
C2
0.10uF
50V
009994
HST1
26
R5
10
009115
J18
+5
R106
10
009115
WHT
U20
27
3
28
COMT
C12
0.10uF
29
HST
30
GAS
STATUS
R9
10
009115
ELECTRODE
4
5
R107
10
009115
NOZZLE
6
7
31
KEY
45
50
55
60
65
70
75
80
85
32
+5
RED
+5
LOCKOUT
33
10
34
U22
C42
0.01uF
100VDC
009990
35
36
VACR
37
38
11
ORG
12
BLUE
START
CAP
COMT
C32
0.10uF
50V
009994
J19
+24
TP1
40
INPUT VOLTAGE
18T
WHT
RED
YEL
14
BLK
12
39
ITF
R47
100
009073
VIO
059267(CE)
200-600vac
230-400vac
3PH
3PH
IFB
008924
X
+24
J4
108171
3
Y
1
B
J5
R
1
R
J21
R
2
B
1
Y
J2
J1
2
B
1
R
J20
/MM
5
+24
GRN/YEL
MACHINE
INTERFACE
13
Vbus (Vac<540vac)
750
750
Vbus (Vac>541vac)
1.41 X Vac
NA
WIRE GROUP
129772
129775
123603
123603
005259
005259
FILTER (PCB1)
NA
041779
POWER BD (PCB2)
041783
041783
CONTROL BD (PCB3)
041790
041790
041789
041789
TIMING DIAGRAM
013353
013353
PRESSURE
SENSOR
SA
TEMP
SENSOR IN
XFMR
T2
HEATSINK
TEMP
SENSOR BD
PCB4
FAN
SA
CHASSIS
GND
GAS SOLENOID
SA
NOTES:
1. PIN 7 IS KEYING FEATURE
2. PIN 9 IS LOCKOUT FEATURE
013352
1 OF 1