Hypertherm MAX200 Service Manual - Manual (Page 42)

MAX200 Service Manual 3-1
1-99
Section 3
MAINTENANCE
In this section:
Introduction ...............................................................................................................................................................3-2
Routine Maintenance ................................................................................................................................................3-3
Torch and Torch Leads .....................................................................................................................................3-3
Torch Coolant ...................................................................................................................................................3-3
Power Supply ...................................................................................................................................................3-3
Theory of Operation: “Chopper” Power Supply ........................................................................................................3-4
Introduction ......................................................................................................................................................3-4
Circuit Description ............................................................................................................................................3-4
Theory of Operation: High Frequency ......................................................................................................................3-6
Introduction ......................................................................................................................................................3-6
Circuit Description ............................................................................................................................................3-6
Sequence of Events..................................................................................................................................................3-7
Initial Checks ..........................................................................................................................................................3-13
Troubleshooting ......................................................................................................................................................3-16
Test Procedures ......................................................................................................................................................3-30
Arc Transfer Test Procedure ..........................................................................................................................3-30
Chopper Module Test Procedure ...................................................................................................................3-31
Voltage Divider Test Procedure (Machine-Torch Systems) ............................................................................3-33
MAX200 Rev 1 90° Hand Torch Removal and Replacement .................................................................................3-34
Removal .........................................................................................................................................................3-34
Replacement ..................................................................................................................................................3-34
MAX200 Rev 1 90° Hand Torch Lead Set and Individual Torch Leads Removal and Replacement ......................3-36
Torch Lead Set ...............................................................................................................................................3-36
Removal .....................................................................................................................................................3-36
Replacement ..............................................................................................................................................3-36
Individual Torch Leads ...................................................................................................................................3-36
Removal .....................................................................................................................................................3-36
Replacement ..............................................................................................................................................3-38
MAX200 Rev 1 90° Hand Torch Lead Set Assemblies...................................................................................3-39
MAX200 Machine Torch Removal and Replacement .............................................................................................3-40
Removal .........................................................................................................................................................3-40
Replacement ..................................................................................................................................................3-40
MAX200 Machine Torch Lead Set and Individual Torch Leads Removal and Replacement ..................................3-42
Torch Lead Set ...............................................................................................................................................3-42
Removal .....................................................................................................................................................3-42
Replacement ..............................................................................................................................................3-42
Individual Torch Leads ...................................................................................................................................3-44
Removal .....................................................................................................................................................3-44
Replacement ..............................................................................................................................................3-44
PAC200T/E Torches Removal and Replacement ...................................................................................................3-46
Removal .........................................................................................................................................................3-46
Replacement ..................................................................................................................................................3-46
PAC200T/E Torch Lead Assembly Removal and Replacement..............................................................................3-48
Removal .........................................................................................................................................................3-48
Replacement ..................................................................................................................................................3-48
Increase or Decrease PAC200T/E Torch Lead Length ...........................................................................................3-50
Adjust Plasma Gas.........................................................................................................................................3-53