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Powermax 85
Hypertherm Powermax 85 Service Manual
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8-6
Electrical schematic diagram (CE)
247
Table of Contents
Default Chapter
5
Assessment of Area
5
Mains Supply
5
Electromagnetic Compatibility
6
Maintenance of Cutting Equipment
6
Patent Indemnity
8
Safety Information
9
Table of Contents
11
Section 1
17
Specifications
17
Safety Information
18
System Description
18
Where to Find Information
19
Power Supply Dimensions
20
Component Weights
21
Powermax65 Power Supply Ratings
22
Powermax85 Power Supply Ratings
24
Duramax 75° Hand Torch Dimensions
26
Duramax 15° Hand Torch Dimensions
26
Duramax 180° Full-Length Machine Torch Dimensions
27
Duramax 180° Mini Machine Torch Dimensions
27
Powermax65 Cutting Specifications
28
Powermax85 Cutting Specifications
29
Symbols and Markings
30
IEC Symbols
31
Section 2
33
Power Supply Setup
33
Unpack the Powermax65 or Powermax85 System
34
Claims
34
Contents
35
Position the Power Supply
36
Prepare the Electrical Power
36
Install a Line-Disconnect Switch
37
Requirements for Grounding
37
Power Connection for the Powermax65
38
Single-Phase Power Cord (Not for CE Model)
39
Three-Phase Power Cord - Plug Installation
39
Power Connection for the Powermax85
40
Single-Phase Power Cord (Not for CE Model)
41
Single-Phase Power Cord Installation
42
Three-Phase Power Cord - Plug Installation
43
Extension Cord Recommendations
43
Extension Cord Specifications
44
Engine-Driven Generator Recommendations
45
Prepare the Gas Supply
46
Additional Gas Filtration
46
Connect the Gas Supply
47
Torch Setup
50
Introduction
50
Consumable Life
50
Copperplus™ Electrode for Duramax Torches
50
Hand Torch Setup
51
Choose the Hand Torch Consumables
52
Hand Torch Consumables
53
Install the Hand Torch Consumables
54
Machine Torch Setup
55
Converting a Full-Length Machine Torch to a Mini Machine Torch
56
Mount the Torch
58
Choose the Machine Torch Consumables
60
Machine Torch Consumables
60
Install the Machine Torch Consumables
63
Aligning the Torch
63
Connecting an Optional Remote-Start Pendant
64
Connecting an Optional Machine Interface Cable
65
Connecting the Torch Lead
70
Using the Cut Charts
71
Estimated Kerf-Width Compensation
72
85 A Shielded Consumables
74
65 A Shielded Consumables
78
45 A Shielded Consumables
82
Finecut ® Consumables
86
85 A Unshielded Consumables
91
65 A Unshielded Consumables
95
45 A Unshielded Consumables
99
Section 3
50
Section 4
103
Operation
103
Controls and Indicators
104
Rear Controls
104
Front Controls and Leds
104
Status Screen
106
Operating the Powermax65 or Powermax85
108
Connect the Electrical Power, Gas Supply, and Torch Lead
108
Attach the Work Lead to the Power Supply
109
Attach the Work Clamp to the Workpiece
110
Turn on the System
111
Set the Operating Mode Switch
111
Check the Indicators
112
Manually Adjusting the Gas Pressure
112
Adjusting the Current (Amperage)
113
Understanding Duty-Cycle Limitations
114
Using the Hand Torch
115
Operate the Safety Trigger
115
Hand Torch Cutting Hints
116
Start a Cut from the Edge of the Workpiece
117
Pierce a Workpiece
118
Gouge a Workpiece
119
Common Hand-Cutting Faults
122
Using the Machine Torch
123
Ensure the Torch and Table Are Set up Correctly
123
Understand and Optimize Cut Quality
123
To Pierce a Workpiece Using the Machine Torch
125
Common Machine-Cutting Faults
126
Section 5
127
Troubleshooting and System Tests
127
Controls and Indicators
129
Theory of Operation
130
General
130
200 - 600 V CSA 1- or 3-Phase Power Supply Functional Description
130
380/400 V CE 3-Phase Power Supply Functional Description
131
Sequence of Operation
132
Troubleshooting Preparation
133
Test Equipment
133
Troubleshooting Procedures and Sequence
133
External Inspection
135
Internal Inspection
135
Initial Resistance Check
135
Check the Power Switch
135
Hypertherm IGBT Tester
138
Indicator Leds and Device Tests
138
IGBT Test Preparation
139
IGBT Device Test Using the Hypertherm Tester
140
Troubleshoot the Hypertherm IGBT Tester
140
Schematic for Building an IGBT Tester
141
IGBT Device Test Using a Non-Hypertherm Tester
142
200 - 600 V CSA Power Supply Overview
143
380/400 V CE Power Supply Overview
144
CSA Power Supply Overview (Power Board Removed)
145
380/400 V CE Power Supply Overview (Power Board Removed)
146
Table of Contents
147
Fault Codes
147
Displaying the Service Screen
147
Important Fault Icons
148
Performing a Cold Restart
148
Fault Codes and Solutions
149
Troubleshooting Guide
158
System Tests
164
Test 1 - Voltage Input
165
Test 2 - DC Power Buss
166
Test 3 - Output Diodes
168
Test 4 - Inverter and PFC Temperature Sensor
169
Test 5 - Flyback Circuit (DC Minor Voltages)
172
Test 6 - Torch Stuck Open (TSO)
174
Test 7 - Start Signal
176
Test 8 - Torch Cap Switch
177
Test 9 - Electronic Regulator
178
Test 10 - Pressure Sensor
179
Test 11 - Fan
180
Test 12 - AUX Switch
181
Section 6
183
Component Replacement
183
Remove and Replace the Power Supply Cover and Mylar ® Barrier
184
Barrier
184
Remove the Power Supply Cover and Mylar Barrier
184
Replace the Mylar Barrier
185
Replace the Power Supply Cover
186
Replace the Power Cord
187
Replace the Power Cord (200 - 600 V 3-Phase CSA, 400 V 3-Phase CE)
187
Replace the Power Cord (200 - 480 V 1-Phase CSA)
192
Replace the Work Lead
193
Replace the Fan
194
Replace the Air Filter Element
196
Replace the Air Filter Subassembly
197
Replace the Power Board
199
Remove the DSP Board
199
Replace the Power Board (380/400V CE)
201
Replace the Power Board (200 - 600V CSA)
204
Install the DSP Board
207
Replace the Mylar Barrier and Power Supply Cover
208
Replace the Control Board
209
Replace the Heat Sink Components
211
65A Csa
212
85A Csa
214
Parts
218
Section 7
218
Power Supply Parts
218
Exterior Front
218
Exterior Rear
219
Interior, Power Board Side (200 - 600V CSA)
220
Interior, Power Board Side (380/400V CE)
221
Interior, Fan Side
222
Heat Sink Assembly
224
65A Csa
224
85A Csa
226
Duramax 75° Hand Torch Replacement Parts
228
Duramax 15° Hand Torch Replacement Parts
229
Hand Torch Consumables
230
Duramax 180° Full-Length Machine Torch Replacement Parts
231
Duramax 180° Mini Machine Torch Replacement Parts
233
Machine Torch Consumables
235
Accessory Parts
236
Powermax65 and Powermax85 Labels
237
Safety-Critical Parts
238
Recommended Spare Parts
240
Section 8
243
Wiring Diagrams
243
Cutting Timing Diagram Page 1 of 2
245
Cutting Timing Diagram Page 2 of 2
246
Electrical Schematic Diagram (CSA)
247
Electrical Schematic Diagram (CE)
248
Other manuals for Hypertherm Powermax 85
Operator's Manual
156 pages
Field Service Bulletin
16 pages
5
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Hypertherm Powermax 85 Specifications
General
Brand
Hypertherm
Model
Powermax 85
Category
Welding System
Language
English
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