Hypertherm powermax900 Service Manual

TABLE OF CONTENTS
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

Hypertherm powermax900 Specifications

General

Brand	Hypertherm
Model	powermax900
Category	Welding System
Language	English