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Service manual – Hypertherm Powermax900 Service Manual User Manual

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T

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ONTENTS

Service Manual

iv

Section 3 MAINTENANCE .................................................................................... 3-1

INTRODUCTION ................................................................................................................................ 3-2
ROUTINE MAINTENANCE ................................................................................................................ 3-2

Bowl Draining/Filter Element Cleaning ........................................................................................ 3-2
Removal, Cleaning and Replacement of the Cooling Air Filter .................................................... 3-3

CONTROLS AND INDICATORS ........................................................................................................ 3-4
THEORY OF OPERATION ................................................................................................................ 3-5

General ........................................................................................................................................ 3-5
Functional Description ................................................................................................................. 3-6

SEQUENCE OF OPERATION ........................................................................................................... 3-7
TROUBLESHOOTING ....................................................................................................................... 3-8

Test Equipment ............................................................................................................................ 3-8
Troubleshooting Procedures ........................................................................................................ 3-8
Visual Inspection - External ......................................................................................................... 3-8
Visual Inspection - Internal .......................................................................................................... 3-9
Resistance Checks .................................................................................................................... 3-10

POWERMAX900 TROUBLESHOOTING GUIDE ............................................................................ 3-13

Voltage Checks .......................................................................................................................... 3-18
Power Board Test Points ........................................................................................................... 3-22

POWER BOARD .............................................................................................................................. 3-22
CONTROL BOARD .......................................................................................................................... 3-24

Control Board LEDs ................................................................................................................... 3-24

PAC125T TORCH PARTS REMOVAL AND REPLACEMENT ......................................................... 3-26

Torch Main Body Removal and Replacement ........................................................................... 3-26
Torch Switch Removal and Replacement .................................................................................. 3-27

PAC125M TORCH PARTS REMOVAL AND REPLACEMENT ........................................................ 3-28

Removal .................................................................................................................................... 3-28
Replacement ............................................................................................................................. 3-28

QUICK DISCONNECT O-RING REMOVAL AND REPLACEMENT ................................................ 3-30

Section 4 PARTS LIST – 208/240/480V ............................................................. 4-1

POWER SUPPLY - 208/240/480V ..................................................................................................... 4-2

Front ............................................................................................................................................ 4-2
Top and Right Side ...................................................................................................................... 4-4
Bottom and Left Side ................................................................................................................... 4-6
Rear ............................................................................................................................................. 4-8
Powermax900 Field Upgrade Kits and Optional Parts .............................................................. 4-10

POWER SUPPLIES - 208/240/480V, 1F/3F, 60 HZ ......................................................................... 4-10
RECOMMENDED SPARE PARTS - POWERMAX900- 208/240/480V ........................................... 4-11

Section 5 PARTS LIST - 200/230/400V .............................................................. 5-1

POWER SUPPLY - 200/230/400V ..................................................................................................... 5-2

Front ............................................................................................................................................ 5-2
Top and Right Side ...................................................................................................................... 5-4
Bottom and Left Side ................................................................................................................... 5-6
Rear ............................................................................................................................................. 5-8
Powermax900 Field Upgrade Kits and Optional Parts .............................................................. 5-10

POWER SUPPLIES - 200/230/400V, 1F/3F, 50/60 HZ .................................................................... 5-10
RECOMMENDED SPARE PARTS - POWERMAX900- 200/230/400V ........................................... 5-11