Hypertherm Powermax125 Service Manua Manuale Utente Pagina 74
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74 Powermax125 Service Manual 808070
6 – Machine Torch Setup
Mechanized shielded with ohmic 105 A/125 A consumables
Mechanized shielded with ohmic 45 A and 65 A consumables
Gouging consumables
FineCut shielded consumables
220976
Shield
420156
Ohmic-sensing
retaining cap
220975
Nozzle
220971
Electrode
220997
Swirl ring
420168
Shield
420156
Ohmic-sensing
retaining cap
420158 (45 A)
420169 (65 A)
Nozzle
220971
Electrode
220997
Swirl ring
420112
Shield
220977
Retaining cap
420001
Nozzle
220971
Electrode
220997
Swirl ring
420152
Shield
420151
Nozzle
220971
Electrode
220997
Swirl ring
220977
Retaining cap
- Powermax125 1
- © 2014 Hypertherm, Inc 2
- Contents 10
- Introduction 15
- Installation and use 15
- Assessment of area 15
- Methods of reducing emissions 15
- Cutting cables 16
- Screening and shielding 16
- Warranty 17
- Attention 17
- Section 1 19
- Specifications 19
- Safety information 19
- Power supply dimensions 20
- 1 – Specifications 21
- Table 2 – Torch weights 21
- Table 3 – Work lead weights 21
- Symbols and markings 26
- Noise levels 27
- IEC symbols 28
- Section 2 29
- Power Supply Setup 29
- Unpack the Powermax system 29
- Position the power supply 30
- Prepare the electrical power 31
- 2 – Power Supply Setup 32
- Table 4 – 480 V CSA 32
- Table5 – 600V CSA 32
- Table6 – 400V CE 32
- Table 7 – 380 V CCC 33
- Prepare the gas supply 36
- Connect the gas supply 37
- Section 3 39
- Basic System Operations 39
- 3 – Basic System Operations 40
- Front controls and LEDs 40
- Gouge. Gouges metal plate 41
- Operating the Powermax 44
- Turn on the system 46
- Set the operating mode switch 47
- Check the indicators 47
- Section 4 51
- Hand Torch Setup 51
- Consumable life 51
- Hand torch components 52
- 4 – Hand Torch Setup 53
- Gouging consumables 53
- FineCut consumables 53
- Connecting the torch lead 55
- Section 5 57
- Hand Cutting 57
- Using the hand torch 57
- Operate the safety trigger 58
- Hand torch cutting guidelines 58
- 5 – Hand Cutting 59
- Pierce a workpiece 60
- Gouge a workpiece 62
- Gouge profile 63
- Typical gouging profile 63
- Varying the gouge profile 64
- 125 A gouging profile chart 64
- Table 9 – Metric 64
- Table 10 – English 65
- Common hand-cutting faults 66
- Section 6 67
- Machine Torch Setup 67
- Machine torch components 68
- Disassemble the machine torch 69
- 6 – Machine Torch Setup 70
- Mount the torch 72
- FineCut shielded consumables 74
- Aligning the torch 75
- Using the cut charts 77
- 125 A shielded consumables 80
- 105 A shielded consumables 84
- 65 A shielded consumables 88
- 45 A shielded consumables 92
- FineCut – mild steel 97
- FineCut – stainless steel 98
- Section 7 99
- Mechanized Cutting 99
- 7 – Mechanized Cutting 100
- Accessing raw arc voltage 104
- Using the machine torch 105
- Cut or bevel angle 106
- Figure 4 – Cut angles 106
- Common machine-cutting faults 107
- Controls and indicators 109
- Section 8 109
- Theory of operation 111
- Sequence of operation 112
- Troubleshooting preparation 113
- WARNING! 114
- Initial resistance check 115
- Figure 6 117
- IGBT test preparation 119
- CAUTION! 119
- Fault codes 128
- Run a gas test 130
- Figure 18 130
- Perform a cold restart 131
- Fault codes and solutions 131
- Troubleshooting guide 143
- System tests 149
- Test 1 – Voltage input 150
- Figure 20 150
- LV – incoming line voltage 150
- Figure 21 151
- Test 2 – DC power bus 152
- Figure 22 152
- Figure 23 153
- Test 3 – Output diodes 154
- Figure 24 155
- Table 12 156
- Figure 25 156
- Figure 26 157
- 1 2 3 4 5 157
- Figure 27 158
- Figure 28 159
- Test 7 – Start signal 160
- Figure 29 160
- Test 8 – Torch cap switch 161
- Test 10 – Pressure sensor 163
- Test 11 – Fan 164
- Test 12 – AUX switch 164
- Section 9 165
- Figure 31 166
- Remove the gas filter element 167
- Figure 33 169
- Figure 34 169
- Figure 35 169
- Figure 36 170
- Filter cover 171
- Remove the power supply cover 172
- Figure 39 172
- Remove the component barrier 173
- Figure 40 173
- Install the component barrier 173
- Remove the end panel bracket 174
- Figure 41 174
- Figure 43 176
- Figure 44 176
- Figure 45 177
- Figure 46 178
- Figure 49 180
- Set the voltage divider board 181
- Figure 50 181
- Figure 51 181
- Figure 52 183
- Figure 54 185
- Figure 55 185
- Figure 56 186
- Figure 57 186
- Disconnect the gas tube 188
- Connect the gas tube 189
- Strain relief on CE models 193
- Replacing the power switch 197
- Figure 67 198
- Label perforation 199
- Left edge of label 199
- Right edge of label 199
- Figure 70 200
- Replacing the control board 201
- Replacing the DSP board 203
- DSP back view 204
- DSP front view 204
- J1 J2 J3 J5 J6 205
- Install the power board 206
- J3 J2 J1 207
- Replacing the pilot arc IGBT 211
- Replacing the thermal sensor 214
- Replacing the fan shroud 216
- Replacing the pressure switch 221
- Figure 81 222
- Figure 83 224
- Replacing the gas tubing 227
- Figure 87 229
- C151C152 230
- Figure 89 231
- Figure 92 235
- Figure 94 237
- Replacing the output inductor 238
- Front panel mounting screws 239
- Install the output inductor 241
- Figure 98 243
- Replacing the transformer 244
- Figure 102 247
- Install the transformer 248
- Figure 103 248
- Remove the PFC inductor 249
- Figure 104 249
- Figure 105 250
- Replacing the front panel 252
- Figure 109 255
- Install the front panel 256
- Replacing the rear panel 257
- Figure 117 264
- Section 10 265
- Torch Component Replacement 265
- Hand torches 267
- Replacing the handle 269
- Figure 121 269
- Figure 122 270
- Figure 123 270
- Figure 126 272
- Cap-sensor switch wires 273
- Start switch wires 273
- Figure 129 274
- Figure 130 275
- Figure 131 275
- Replacing the torch body 276
- Figure 132 276
- Figure 133 277
- Replacing the start switch 278
- Figure 134 278
- Figure 135 278
- Figure 136 279
- Figure 137 280
- Replacing the torch lead 281
- Figure 138 281
- Figure 139 281
- Figure 140 282
- Figure 141 283
- Machine torches 284
- Replacing the mounting sleeve 285
- Figure 143 285
- Figure 144 287
- Figure 145 287
- Figure 146 288
- Figure 147 288
- Section 11 293
- Power supply parts 294
- 11 – Parts 296
- Hand torch consumables 303
- Machine torch consumables 306
- Accessory parts 307
- Powermax125 labels 308
- Safety-critical parts 310
- Recommended spare parts 313
- Section 12 315
- Wiring Diagrams 315
- Transfer PA current 316
- Pilot arc current 316
- Post flow 316
- 380V CCC 317
- 480V CSA 317
- 600V CSA 317
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