Name: Hypertherm powermax1000
Brand: Hypertherm
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TABLE OF CONTENTS

powermax1000 Service Manual v

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