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TABLE OF CONTENTS

powermax1250 Service Manual v

Control board LEDs........................................................................................................................................3-20

est 1 – voltage input .....................................................................................................................................3-22

Test 2 – voltage balance ................................................................................................................................3-23

Test 3 – output diodes....................................................................................................................................3-24

Test 4 – pilot arc IGBT (Q8) ...........................................................................................................................3-25

Test 5 – inverter IGBT (Q6) and PFC IGBT (Q7) ...........................................................................................3-26

est 6 – flyback circuit ....................................................................................................................................3-27

Test 7 – torch stuck open (TSO) ....................................................................................................................3-28

Test 8 – plasma start......................................................................................................................................3-29

Test 9 – torch cap sensor...............................................................................................................................3-29

Test 10 – gas solenoid ...................................................................................................................................3-30

Test 11 – incoming line voltage (VACR) .........................................................................................................3-30

Test 12 – pressure switch...............................................................................................................................3-30

Test 13 – fan...................................................................................................................................................3-30

Test 14 – AUX switch .....................................................................................................................................3-31

Test 15 – flyback circuit failure .......................................................................................................................3-31

T60 hand torch connector pinout diagrams and assembly .....................................................................................3-32

T60M machine torch connector pinout diagrams and assembly ............................................................................3-33

Component replacement ........................................................................................................................................3-34

Power cord replacement ................................................................................................................................3-34

Torch replacement..........................................................................................................................................3-35

Filter element replacement.............................................................................................................................3-37

Work cable replacement ................................................................................................................................3-38

Capacitor replacement ...................................................................................................................................3-39

Power board removal and replacement .........................................................................................................3-40

Heat sink component replacement.................................................................................................................3-43

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

T80 hand torch assembly .........................................................................................................................................5-2

T80M achine torch assembly....................................................................................................................................5-4

T80 consumable configurations................................................................................................................................5-6

T80M consumable configurations.............................................................................................................................5-7

Recommended spare parts ......................................................................................................................................5-8

Section 6 WIRING DIAGRAMS

Timing diagrams .......................................................................................................................................................6-2

Electrical schematics

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6-5