Hypertherm Powermax105 Service Manual Instruction Manuals and User Guides
We have 1 Instruction Manual and User Guide for Powermax105 Service Manual Hypertherm
Manuals 
| Recognized languages: | English |
|---|---|
| Pages: | 343 |
| Size: | 31.86 MB |
Show table of contents
Document Outline
- Section 1
- Specifications
- Safety information
- System description
- Where to find information
- Power supply dimensions
- Component weights (105 A systems)
- Powermax105 power supply ratings
- Duramax 75° hand torch dimensions
- Duramax 15° hand torch dimensions
- Duramax 180° full-length machine torch dimensions
- Duramax 180° mini machine torch dimensions
- Powermax105 cutting specifications
- Symbols and markings
- Noise levels
- IEC symbols
- Section 2
- Power Supply Setup
- Section 3
- Basic System Operations
- Section 4
- Hand Torch Setup
- Section 5
- Hand Cutting
- Section 6
- Machine Torch Setup
- Introduction
- Consumable life
- Machine torch components
- Converting a full-length machine torch to a mini machine torch
- Mount the torch
- Choose the machine torch consumables
- Machine torch consumables
- Mechanized shielded 105 A consumables
- Mechanized shielded 45 A, 65 A, 85 A consumables
- Mechanized shielded with ohmic 105 A consumables
- Mechanized shielded with ohmic 45 A, 65 A, 85 A consumables
- Mechanized unshielded 105 A consumables
- Mechanized unshielded 45 A, 65 A, 85 A consumables
- Gouging consumables
- FineCut® shielded consumables
- FineCut® unshielded consumables
- Install the machine torch consumables
- Aligning the torch
- Connecting the torch lead
- Using the cut charts
- Estimated kerf-width compensation
- 105 A Shielded consumables
- 105 A Shielded cutting (Mild Steel)
- 105 A Shielded cutting (Stainless Steel)
- 105 A Shielded cutting (Aluminum)
- 85 A Shielded consumables
- 85 A Shielded cutting (Mild Steel)
- 85 A Shielded cutting (Stainless Steel)
- 85 A Shielded cutting (Aluminum)
- 65 A Shielded consumables
- 65 A Shielded cutting (Mild Steel)
- 65 A Shielded cutting (Stainless Steel)
- 65 A Shielded cutting (Aluminum)
- 45 A Shielded consumables
- 45 A Shielded cutting (Mild Steel)
- 45 A Shielded cutting (Stainless Steel)
- 45 A Shielded cutting (Aluminum)
- FineCut® consumables
- FineCut (Mild Steel)
- FineCut (Stainless Steel)
- Low Speed FineCut (Mild Steel)
- Low Speed FineCut (Stainless Steel)
- 105 A Unshielded consumables
- 105 A Unshielded cutting (Mild Steel)
- 105 A Unshielded cutting (Stainless Steel)
- 105 A Unshielded cutting (Aluminum)
- 85 A Unshielded consumables
- 85 A Unshielded cutting (Mild Steel)
- 85 A Unshielded cutting (Stainless Steel)
- 85 A Unshielded cutting (Aluminum)
- 65 A Unshielded consumables
- 65 A Unshielded cutting (Mild Steel)
- 65 A Unshielded cutting (Stainless Steel)
- 65 A Unshielded cutting (Aluminum)
- 45 A Unshielded consumables
- 45 A Unshielded cutting (Mild Steel)
- 45 A Unshielded cutting (Stainless Steel)
- 45 A Unshielded cutting (Aluminum)
- Section 7
- Mechanized Cutting
- Connecting an optional remote-start pendant
- Connecting an optional machine interface cable
- Accessing raw arc voltage
- Connecting an optional RS485 serial interface cable
- Using the machine torch
- Setting up the torch and table
- Understand and optimize cut quality
- Piercing a workpiece using the machine torch
- Common machine-cutting faults
- Section 8
- Troubleshooting and System Tests
- Controls and indicators
- Theory of operation
- Troubleshooting preparation
- Initial resistance check
- 200-600 V CSA power supply overview
- 230-400 V CE, 380 V CCC/230-400 V CE power supply overview
- 380 V CCC, 400 V CE power supply overview
- 200-600 V CSA power supply overview (power board removed)
- 230-400 V CE, 380 V CCC/230-400 V CE power supply overview (power board removed)
- 380 V CCC, 400 V CE power supply overview (power board removed)
- Fault codes
- Troubleshooting guide
- System tests
- Test 1 – Voltage input
- Test 2 – DC Power Buss
- Test 3 – Output diodes
- Test 4 – Inverter and PFC temperature sensor
- Test 5 – Flyback circuit (DC minor voltages)
- Test 6 – Torch stuck open (TSO)/torch stuck closed (TSC)
- Test 7 – Start signal
- Test 8 – Torch cap switch
- Test 9 – Electronic regulator
- Test 10 – Pressure sensor
- Test 11 – Fan
- Test 12 – AUX switch
- Section 9
- Power Supply Component Replacement
- Replacing the air filter element
- Replacing the work lead connector
- Installing the optional filter kit
- Replacing the power supply cover
- Replacing the Mylar® barrier
- Installing the machine interface cable with voltage divider board
- Installing the machine interface cable
- Installing the RS485 serial interface cable
- Replacing the power cord
- Replacing the strain relief connector
- Replacing the power switch
- Replacing the control board
- Replacing the DSP board
- Replacing the power board
- Replacing the input diode bridge
- Replacing the output diode bridge
- Replacing the pilot arc IGBT
- Replacing the inverter IGBT module
- Replacing the PFC IGBT module
- Replacing the snubber resistor
- Replacing the damper resistor
- Replacing the thermal sensor
- Replacing the fan shroud
- Replacing the fan
- Replacing the pressure transducer
- Replacing the pressure switch
- Replacing the air filter subassembly
- Replacing the solenoid valve
- Replacing the gas tubing
- Replacing the bulk capacitors
- Replacing the torch quick disconnect receptacle
- Replacing the work lead receptacle
- Replacing the output inductor
- Replacing the transformer
- Replacing the PFC inductor
- Replacing the front end panel
- Replacing the rear end panel
- Installing the machine interface cable for raw arc voltage
- Section 10
- Torch Component Replacement
- Hand torch: Replacing the start switch
- Hand torch: Replacing the cap-sensor switch
- Hand torch: Replacing the handles
- Hand torch: Replacing the trigger
- Hand torch: Replacing the torch body
- Hand torch: Replacing the torch lead
- Hand torch: Replacing the quick disconnect housing
- Machine torch: Replacing the mounting sleeve
- Machine torch: Replacing the cap-sensor switch
- Machine torch: Replacing the torch body
- Machine torch: Replacing the coupler
- Machine torch: Replacing the gear rack
- Machine torch: Replacing the positioning sleeve
- Machine torch: Replacing the torch lead
- Machine torch: Replacing the quick disconnect housing
- Section 11
- Parts
- Power supply parts
- Heat sink assembly
- Duramax 75° hand torch replacement parts
- Duramax 15° hand torch replacement parts
- Hand torch consumables
- Duramax 180° full-length machine torch replacement parts
- Duramax 180° mini machine torch replacement parts
- Machine torch consumables
- Accessory parts
- Powermax105 labels
- Safety-critical parts
- Recommended spare parts
- Section 12
- Wiring Diagrams