Hypertherm powermax1000

TABLE OF CONTENTS
powermax1000 Service Manual v
1
Check power switch .........................................................................................................................................3-8
Hypertherm IGBT tester ...................................................................................................................................3-9
Indicator LEDS and device tests ......................................................................................................................3-9
IGBT test preparation.....................................................................................................................................3-10
IGBT device test using the Hypertherm tester ...............................................................................................3-10
Troubleshoot the Hypertherm IGBT tester .....................................................................................................3-11
Schematic for building an IGBT tester............................................................................................................3-11
IGBT device test using non-Hypertherm tester ..............................................................................................3-12
Troubleshooting guide ............................................................................................................................................3-14
Control board LEDs........................................................................................................................................3-18
Test 1 – voltage input .....................................................................................................................................3-19
Test 2 – voltage balance ................................................................................................................................3-20
Test 3 – output diodes....................................................................................................................................3-21
Test 4 – pilot arc IGBT (Q8) ...........................................................................................................................3-22
Test 5 – inverter IGBT (Q6) and PFC IGBT (Q7) ...........................................................................................3-23
Test 6 – flyback circuit ....................................................................................................................................3-24
Test 7 – torch stuck open (TSO) ....................................................................................................................3-25
Test 8 – plasma start......................................................................................................................................3-26
Test 9 – torch cap sensor...............................................................................................................................3-26
Test 10 – gas solenoid ...................................................................................................................................3-27
Test 11 – incoming line voltage (VACR) .........................................................................................................3-27
Test 12 – pressure switch...............................................................................................................................3-27
Test 13 – fan...................................................................................................................................................3-27
Test 14 – AUX switch .....................................................................................................................................3-28
Test 15 – flyback circuit failure .......................................................................................................................3-28
T60 hand torch connector pinouts and assembly ...................................................................................................3-29
T60M machine torch connector pinouts and assembly ..........................................................................................3-30
Component replacement ........................................................................................................................................3-31
Power cord replacement ................................................................................................................................3-31
Torch replacement..........................................................................................................................................3-32
Filter element replacement.............................................................................................................................3-34
Work cable replacement ................................................................................................................................3-35
Capacitor replacement ...................................................................................................................................3-36
Heat sink component replacement.................................................................................................................3-37
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 – torch and consumables
T60 hand torch assembly .........................................................................................................................................5-2
T60M machine torch assembly.................................................................................................................................5-4