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Plasma Arc
Cutting System
Service Manual
803400 Revision 2
powermax600
Plasma Arc Cutting System
Service Manual
IM-340
(P/N 803400)
Hypertherm, Inc.
Hanover, NH USA
http://www.hypertherm.com
email:info@hypertherm.com
ELECTROMAGNETIC COMPATIBILITY
EMC INTRODUCTION
The CE power supplies have been built in
compliance with standard EN50199. To
ensure that the equipment works in a
compatible manner with other radio and
electronic systems, the equipment should
be installed and used in accordance with
the information below to achieve
electromagnetic compatibility.
The limits required by EN50199 may not
be adequate to completely eliminate
interference when the affected equipment
is in close proximity or has a high degree
of sensitivity. In such cases it may be
necessary to use other measures to
further reduce interference.
This plasma equipment should be used
only in an industrial environment. It may
be difficult to ensure electromagnetic
compatibility in a domestic environment.
Cutting Cables
The cutting cables should be kept as
short as possible and should be
positioned close together, running at or
close to the floor level.
Equipotential Bonding
Bonding of all metallic components in the
cutting installation and adjacent to it
should be considered. However, metallic
components bonded to the workpiece will
increase the risk that the operator could
receive a shock by touching these
metallic components and the electrode at
the same time. The operator should be
insulated from all such bonded metallic
components.
Earthing of Workpiece
Where the workpiece is not bonded to
earth for electrical safety, nor connected
to earth because of its size and position,
for example, ship's hull or building
steelwork, a connection bonding the
workpiece to earth may reduce
emissions in some, but not all instances.
Care should be taken to prevent the
earthing of the workpiece increasing the
risk of injury to users, or damage to other
electrical equipment. Where necessary,
the connection of the workpiece to earth
should be made by a direct connection to
the workpiece, but in some countries
where direct connection is not permitted,
the bonding should be achieved by
suitable capacitances selected
according to national regulations.
Note: The cutting circuit may or may not
be earthed for safety reasons. Changing
the earthing arrangements should only
be authorized by a person who is
competent to assess whether the
changes will increase the risk of injury, for
example, by allowing parallel cutting
current return paths which may damage
the earth circuits of other equipment.
Further guidance is given in IEC TC26
(sec)94 and IEC TC26/108A/CD Arc
Welding Equipment Installation and Use.
Screening and Shielding
Selective screening and shielding of
other cables and equipment in the
surrounding area may alleviate problems
of interference. Screening of the entire
plasma cutting installation may be
considered for special applications.
WARRANTY
WARNING
Genuine Hypertherm parts are the factoryrecommended replacement parts for your
Hypertherm system. Any damage caused by the use
of other than genuine Hypertherm parts may not be
covered by the Hypertherm warranty.
GENERAL
Hypertherm, Inc. warrants that products shall be free from
defects in materials and workmanship, under proper and
normal use for which such equipment is recommended, for
a period of two (2) years, except only with respect to the
torch, for which the warranty period shall be one (1) year,
from the date of its delivery to you.
Hypertherm, at its sole option, shall repair, replace, or
adjust, free of charge, any Products covered by this warranty which shall be returned with Hypertherm's prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm's place of business in Hanover,
New Hampshire, all costs, insurance and freight prepaid,
and which examination proves not to be free from defects in
materials and workmanship. Hypertherm shall not be liable
for any repairs, replacements, or adjustments of Products
covered by this warranty, except those made pursuant to
this paragraph or with Hypertherm's written consent. This
warranty shall not apply to any Product which has been
mishandled, incorrectly installed, modified or assembled by
you or any other person. Hypertherm shall be liable for
breach of this warranty only if it receives written notice of
such breach within the applicable warranty period specified
herein above. THE FOREGOING SHALL CONSTITUTE
THE SOLE REMEDY TO DISTRIBUTORS OR THEIR
CUSTOMERS FOR ANY BREACH BY HYPERTHERM OF
ITS WARRANTY.
PATENT INDEMNITY
Except only in cases of Products not manufactured by
Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm's specifications, and in cases of designs, processes, formulae or
combinations not developed or purported to be developed
by Hypertherm, Hypertherm agrees to indemnify, protect
and hold harmless Distributors and their customers against
any and all liability or claims in any manner imposed upon
or accruing against Distributors and their customers because of the use in or about the construction or operation of
equipment or any design, system, formula, combination,
article or material which infringes or alleges to infringe on
ii
any patent or other right. Distributors shall notify Hypertherm promptly upon learning of any action or threatened
action in connection with any such alleged infringement,
and each party may appoint its own counsel for any such
action or threatened action.
UPON RECEIPT
1. Verify that all parts and items on your order have been
received. Alert your distributor if any parts or items are
damaged or missing.
2. Inspect the power supply for any physical damage that
may have occurred during shipping. If there is evidence
of damage, refer to the Claims section below. All
communications regarding this equipment must include the model number and serial number located on
the back of the Powermax600.
3. Before setting up and operating the Powermax600,
read the Safety section of this manual.
CLAIMS
Claims for damage during shipment If your unit was
damaged during shipment, you must file a claim with the
carrier. Hypertherm will furnish you with a copy of the bill of
lading upon request. If you need additional assistance, call
Customer Service listed in the front of this manual, or your
authorized Hypertherm distributor.
Claims for defective or missing merchandise If any of
the merchandise is defective or missing, call your
authorized Hypertherm distributor. If you need additional
assistance, call Customer Service listed in the front of this
manual.
TABLE OF CONTENTS
Electromagnetic Compatibility .................................................................................................................................. i
Warranty
............................................................................................................................................................ ii
SECTION 1 - SAFETY
RECOGNIZE SAFETY INFORMATION ............................................................................................................... 1-2
FOLLOW SAFETY INSTRUCTIONS ................................................................................................................... 1-2
CUTTING CAN CAUSE FIRE OR EXPLOSION .................................................................................................. 1-2
ELECTRIC SHOCK CAN KILL ............................................................................................................................. 1-3
CUTTING CAN PRODUCE TOXIC FUMES ........................................................................................................ 1-3
PLASMA ARC CAN CAUSE INJURY AND BURNS ............................................................................................ 1-4
ARC RAYS CAN BURN EYES AND SKIN ........................................................................................................... 1-4
GROUNDING SAFETY ........................................................................................................................................ 1-4
COMPRESSED GAS EQUIPMENT SAFETY ...................................................................................................... 1-5
GAS CYLINDERS CAN EXPLODE IF DAMAGED .............................................................................................. 1-5
NOISE CAN DAMAGE HEARING ....................................................................................................................... 1-5
PACEMAKER AND HEARING AID OPERATION ................................................................................................ 1-5
ADDITIONAL SAFETY INFORMATION ............................................................................................................... 1-5
WARNING LABEL ................................................................................................................................................ 1-6
SECTION 1a - SCURIT
IDENTIFIER LES CONSIGNES DE SCURIT ................................................................................................ 1a-2
SUIVRE LES INSTRUCTIONS DE SCURIT ................................................................................................. 1a-2
LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION .................................................... 1a-2
LES CHOCS LECTRIQUES PEUVENT TRE FATALS .................................................................................. 1a-3
LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES ........................................................................ 1a-3
LARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRLURES ............................................ 1a-4
LES RAYONS DE LARC PEUVENT BRLER LES YEUX ET LA PEAU .......................................................... 1a-4
MISE LA MASSE ET LA TERRE ................................................................................................................. 1a-4
SCURIT DES BOUTEILLES DE GAZ COMPRIM ...................................................................................... 1a-5
LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES ......................... 1a-5
LE BRUIT PEUT PROVOQUER DES PROBLMES AUDITIFS ....................................................................... 1a-5
PACEMAKERS ET PROTHSES AUDITIVES .................................................................................................. 1a-5
TIQUETTE DE SCURIT .............................................................................................................................. 1a-6
SECTION 2 SPECIFICATIONS
SPECIFICATIONS, POWER SUPPLY ..................................................................................................................
SPECIFICATIONS, PAC123 TORCHES ...............................................................................................................
SETUP SPECIFICATIONS ...................................................................................................................................
INSTALL POWER CORD PLUG ...........................................................................................................................
CHECK REQUIRED INPUT VOLTAGE ................................................................................................................
S MARK (230/400 VOLT ONLY) .......................................................................................................................
GROUNDING REQUIREMENTS ..........................................................................................................................
POWER CORD / EXTENSION CORD ..................................................................................................................
GAS REQUIREMENTS .........................................................................................................................................
LINE VOLTAGE DISCONNECT BOX ...................................................................................................................
2-2
2-3
2-4
2-4
2-4
2-4
2-5
2-5
2-6
2-6
iii
TABLE OF CONTENTS
SECTION 3 MAINTENANCE
CONTROLS AND INDICATORS ........................................................................................................................... 3-2
INDICATOR LAMPS ............................................................................................................................................. 3-2
CONTROLS. ......................................................................................................................................................... 3-2
THEORY OF OPERATION ................................................................................................................................... 3-3
GENERAL ............................................................................................................................................................. 3-3
230/400 VOLT FUNCTIONAL DESCRIPTION ...................................................................................................... 3-4
208-240/480 VOLT FUNCTIONAL DESCRIPTION .............................................................................................. 3-6
SEQUENCE OF OPERATION .............................................................................................................................. 3-8
TROUBLESHOOTING .......................................................................................................................................... 3-9
TEST EQUIPMENT ............................................................................................................................................... 3-9
TROUBLESHOOTING PROCEDURES AND SEQUENCE .................................................................................. 3-9
VISUAL INSPECTION - EXTERNAL .................................................................................................................... 3-9
VISUAL INSPECTION - INTERNAL ................................................................................................................... 3-10
RESISTANCE CHECKS ...................................................................................................................................... 3-11
TROUBLESHOOTING GUIDE ............................................................................................................................ 3-14
VOLTAGE CHECKS ............................................................................................................................................ 3-21
COMPONENT REPLACEMENT ......................................................................................................................... 3-26
POWER CORD REPLACEMENT ....................................................................................................................... 3-26
TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT) ............................................... 3-27
AIR FILTER ELEMENT REPLACEMENT ........................................................................................................... 3-28
WORK CABLE REPLACEMENT ........................................................................................................................ 3-30
CAPACITOR REPLACEMENT ........................................................................................................................... 3-31
HEAT SINK COMPONENT REPLACEMENT ..................................................................................................... 3-32
SECTION 4 PARTS LIST - 400/230V CE
POWER SUPPLY EXTERIOR ...........................................................................................................................
POWER SUPPLY FRONT INTERIOR RIGHT SIDE ..........................................................................................
POWER SUPPLY BACK INTERIOR RIGHT SIDE ............................................................................................
POWER SUPPLY INTERIOR FAN SIDE ...........................................................................................................
POWER SUPPLY HEAT SINK ASSEMBLY .......................................................................................................
RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V .......................................................................
4-2
4-3
4-4
4-5
4-6
4-7
5-2
5-3
5-4
5-5
5-6
5-7
iv
SAFETY
Section 1
SAFETY
In this section:
Recognize Safety Information ................................................................................ 1-2
Follow Safety Instructions ...................................................................................... 1-2
Cutting Can Cause Fire or Explosion ..................................................................... 1-2
Electric Shock Can Kill ...........................................................................................1-3
Cutting Can Produce Toxic Fumes ......................................................................... 1-3
Plasma Arc Can Cause Injury and Burns ............................................................... 1-4
Arc Rays Can Burn Eyes and Skin ........................................................................ 1-4
Grounding Safety ...................................................................................................1-4
Compressed Gas Equipment Safety ...................................................................... 1-5
Gas Cylinders Can Explode if Damaged ................................................................ 1-5
Noise Can Damage Hearing .................................................................................. 1-5
Pacemaker and Hearing Aid Operation .................................................................. 1-5
Additional Safety Information ................................................................................. 1-5
Warning Label ........................................................................................................ 1-6
1-1
SAFETY
DANGER
WARNING
CAUTION
Fire Prevention
Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
Remove all flammables within 35 feet (10 m) of the
cutting area.
Quench hot metal or allow it to cool before handling
or before letting it touch combustible materials.
Never cut containers with potentially flammable
materials inside they must be emptied and
properly cleaned first.
Ventilate potentially flammable atmospheres before
cutting.
When cutting with oxygen as the plasma gas, an
exhaust ventilation system is required.
WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with Aluminum Cutting
Explosion Prevention
Do not use the plasma system if explosive dust or
vapors may be present.
Do not cut pressurized cylinders, pipes, or any
closed container.
Do not cut containers that have held combustible
materials.
1-2
11-98
SAFETY
1-3
8-99
SAFETY
Arc Current
Up to 100 A
100-200 A
200-400 A
Over 400 A
Lens Shade
AWS (USA)
ISO 4850
No. 8
No. 11
No. 10
No. 11-12
No. 12
No. 13
No. 14
No. 14
GROUNDING SAFETY
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall away
when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or local
electrical codes.
1-4
4-99
Input Power
Be sure to connect the power cord ground wire to
the ground in the disconnect box.
If installation of the plasma system involves connecting the power cord to the power supply, be sure to
connect the power cord ground wire properly.
Place the power cord's ground wire on the stud first,
then place any other ground wires on top of the
power cord ground. Fasten the retaining nut tightly.
Tighten all electrical connections to avoid excessive
heating.
SAFETY
COMPRESSED GAS EQUIPMENT SAFETY
Never lubricate cylinder valves or regulators with oil
or grease.
Use only correct gas cylinders, regulators, hoses and
fittings designed for the specific application.
Maintain all compressed gas equipment and associated parts in good condition.
Label and color-code all gas hoses to identify the
type of gas in each hose. Consult applicable national
or local codes.
2.
3.
4.
1-5
11-98
SAFETY
WARNING LABEL
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician
understand the intent of these warning symbols as described.
The numbered text corresponds to the numbered boxes on
the label.
1.
1-6
8-99
6.
7.
SCURIT
Section 1a
SCURIT
1a-1
08/99
SCURIT
IDENTIFIER LES CONSIGNES
DE SCURIT
Les symboles indiqus dans cette section sont utiliss pour
identifier les risques ventuels. Si vous trouvez un symbole
de scurit, que ce soit dans ce manuel ou sur
lquipement, soyez conscient des risques de blessures et
suivez les instructions correspondantes afin dviter ces
risques.
1a-2
08/99
AVERTISSEMENT
Risque dexplosion
Argon-hydrogne et mthane
Lhydrogne et le mthane sont des gaz inflammables et
potentiellement explosifs. Conserver lcart de toute
flamme les bouteilles et tuyaux contenant des mlanges
base dhydrogne ou de mthane. Maintenir toute flamme
et tincelle lcart de la torche lors de lutilisation dun
plasma dargon-hydrogne ou de mthane.
AVERTISSEMENT
Dtonation de lhydrogne lors du
coupage de laluminium
Lors du coupage de laluminium sous leau, ou si leau
touche la partie infrieure de la pice daluminium, de
lhydrogne libre peut saccumuler sous la pice couper
et dtonner lors du coupage plasma.
Installer un collecteur daration au fond de la table eau
afin dliminer les risques de dtonation de lhydrogne.
Se rfrer lannexe du manuel pour plus de
renseignements sur les collecteurs daration.
SCURIT
1a-3
08/99
SCURIT
Courant de larc
Jusqu 100 A
100-200 A
200-400 A
Plus de 400 A
1a-4
08/99
Alimentation
Sassurer que le fil de terre du cordon dalimentation est
connect la terre dans le coffret du sectionneur.
Sil est ncessaire de brancher le cordon dalimentation
la source de courant lors de linstallation du systme,
sassurer que le fil de terre est correctement branch.
Placer tout dabord le fil de terre du cordon dalimentation
sur le plot de mise la terre puis placer les autres fils de
terre par-dessus. Bien serrer lcrou de retenue.
Sassurer que toutes les connexions sont bien serres
pour viter la surchauffe.
SCURIT
PACEMAKERS ET
PROTHSES AUDITIVES
Les champs magntiques produits par les courants haute
tension peuvent affecter le fonctionnement des prothses
auditives et des pacemakers. Les personnes portant ce
type dappareil doivent consulter un mdecin avant de
sapprocher dun lieu o seffectue le coupage ou le
gougeage plasma.
Pour rduire les risques associs aux champs
magntiques :
Garder loin de soi et du mme ct du corps le cble de
retour et le faisceau de la torche.
Faire passer le faisceau de la torche le plus prs possible
du cble de retour.
Ne pas senrouler le faisceau de la torche ou le cble de
retour autour du corps.
Se tenir le plus loin possible de la source de courant.
1a-5
08/99
SCURIT
tiquette de scurit
Cette tiquette est appose sur certaines sources de courant. Il est
important que lutilisateur et le technicien de maintenance comprenne
la signification des symboles de scurit. Les numros de la liste
correspondent aux numros des images.
1.
1a-6
08/99
6.
7.
SPECIFICATIONS
Section 2
SPECIFICATIONS
In this section:
SPECIFICATIONS, POWER SUPPLY ......................................................................
SPECIFICATIONS, PAC123 TORCHES ...................................................................
SETUP SPECIFICATIONS........................................................................................
INSTALL POWER CORD PLUG ...............................................................................
CHECK REQUIRED INPUT VOLTAGE ....................................................................
S MARK (230/400 VOLT ONLY) ...........................................................................
GROUNDING REQUIREMENTS ..............................................................................
POWER CORD / EXTENSION CORD ......................................................................
GAS REQUIREMENTS .............................................................................................
LINE VOLTAGE DISCONNECT BOX .......................................................................
2-2
2-3
2-4
2-4
2-4
2-4
2-5
2-5
2-6
2-6
2-1
10-99
SPECIFICATIONS
Section 2 SPECIFICATIONS
300 VDC
20A 40A
140 VDC
50% (I2=40A, U2=140V)
Duty Cycle at 40 C
(See data tag on power supply for
more information on duty cycle)
Operating temperature
Nitrogen
99.995% pure
9.5 in
240 mm
47 lb
21 kg
17 in
430 mm
PMX600.14
2-2
11-99
SPECIFICATIONS
SPECIFICATIONS, PAC123 TORCHES
Maximum Cutting Capacity
40A PAC123T 5/8 inch / 16 mm @ 50% duty cycle
40A PAC123M 1/4 inch / 6 mm @ 50% duty cycle
28A PAC123M 1/8 inch / 3 mm @ 100% duty cycle
Gouging Capability
(metal removal rate)
Weight
3.5 pounds / 1.6 kg with 15 ft / 4.5 m lead
PAC123T
PAC123M
Dimensions
8.72" / 221 mm
8.5" / 216 mm
PAC123T
PAC123T.04
1.58"
40 mm
3.10"
79 mm
1.00"
25 mm
15.06"
383 mm
1.38"
35 mm
1.00"
25 mm
PAC123M.07
2-3
10-99
SPECIFICATIONS
S MARK (230/400 VOLT ONLY)
The S mark indicates that the power supply and torch are suitable for use in environments with increased
hazard of electrical shock. The hand torches must have shielded consumable parts to maintain S mark
compliance.
SETUP SPECIFICATIONS
Check Required Input Voltage
Look at U1 on the data plate to check input voltage requirements.
The data plate is on the back of the power supply. See Figure 2-4.
CO
2-4
10-99
SPECIFICATIONS
Power Cord / Extension Cord
Use a cord that is certified by national or local codes. The cord should be installed by a licensed electrician.
Refer to the length requirements listed below.
PMX600.02
< 10 ft
<3m
Input
Voltage
10-25 ft
3 7.5 m
25-50 ft
7.5 15 m
50-100 ft
15 30 m
100-150 ft
30 45 m
Phase
208-240 VAC
230 VAC
400 VAC
480 VAC
1
3
3
3
10
4
2.5
4
10
6
2.5
4
10
6
4
4
16
10
6
4
208-240 VAC
230 VAC
400 VAC
480 VAC
1
3
3
3
8
12
14
12
16
10
6
6
6
8
10
10
Grounding Requirements
To ensure personal safety, proper operation and to reduce electromagnetic interference (EMI), the
Powermax600 must be properly grounded:
The power supply chassis is electrically conductive and can present a shock hazard if it is not
properly grounded through the line voltage disconnect box.
The power supply must be properly grounded through the power cord according to national or
local electrical codes.
Three-phase service must use a 4-wire cord that includes a protective earth ground.
Also see Grounding Safety, in Section 1 of this manual.
2-5
10-99
SPECIFICATIONS
Line Voltage Disconnect Box
PMX600.04
Use a line disconnect box for each power supply so that the operator can turn the power supply off
quickly in an emergency situation. Locate the switch near the power supply so that it is easily
accessible to the operator. The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses. Use slow-blow fuses as listed below.
PMX600.03
Input
Voltage
208-240 VAC
230 VAC
400 VAC
480 VAC
Phase
1
3
3
3
Input Current
@ 5.6 kw Output
Recommended
Slow-Blow Fuse Size
46-40A
17A
9.7A
12A
100A
40A
25A
25A
Gas Requirements
Air must be filtered to remove all dirt, water and oil. Contaminants can damage the power supply, torch and
consummables.
The power supply will not power-up if the gas inlet pressure is below minimum.
CAUTION:
Do not exceed 120 psi / 8.3 bar pressure at the power supply
gas inlet. Damage to system may result from higher pressures.
2-6
10-99
MAINTENANCE
Section 3
MAINTENANCE
In this section:
CONTROLS AND INDICATORS ...............................................................................
INDICATOR LAMPS..................................................................................................
CONTROLS. .............................................................................................................
THEORY OF OPERATION .......................................................................................
GENERAL .................................................................................................................
230/400 VOLT FUNCTIONAL DESCRIPTION ..........................................................
208-240/480 VOLT FUNCTIONAL DESCRIPTION ..................................................
SEQUENCE OF OPERATION ..................................................................................
TROUBLESHOOTING ..............................................................................................
TEST EQUIPMENT ...................................................................................................
TROUBLESHOOTING PROCEDURES AND SEQUENCE ......................................
VISUAL INSPECTION - EXTERNAL ........................................................................
VISUAL INSPECTION - INTERNAL..........................................................................
RESISTANCE CHECKS ...........................................................................................
TROUBLESHOOTING GUIDE ..................................................................................
VOLTAGE CHECKS ..................................................................................................
COMPONENT REPLACEMENT ...............................................................................
POWER CORD REPLACEMENT .............................................................................
TORCH LEAD REPLACEMENT (MODELS WITHOUT QUICK DISCONNECT)......
AIR FILTER ELEMENT REPLACEMENT .................................................................
WORK CABLE REPLACEMENT ..............................................................................
CAPACITOR REPLACEMENT..................................................................................
3-2
3-2
3-2
3-3
3-3
3-4
3-6
3-8
3-9
3-9
3-9
3-9
3-10
3-11
3-14
3-21
3-26
3-26
3-27
3-28
3-30
3-31
3-1
10-99
MAINTENANCE
CONTROLS AND INDICATORS
Indicator Lamps
Green POWER IS ON
When illuminated, indicates that AC voltage is supplied to the power supply
and that the ON/OFF switch is in the ON position.
Green SYSTEM READY
When illuminated, indicates that circuits are activated and that all fault
conditions are clear (none of the yellow lamps are illuminated).
Yellow LOW LINE VOLTAGE
When illuminated, indicates that the AC line voltage is: 1) below operating
limits ,or 2) is missing 1 phase (230V and 400V systems only).
Yellow LOW GAS PRESSURE
When illuminated, indicates that the incoming gas pressure is below operating limits.
Yellow TORCH PARTS ARE LOOSE OR REMOVED
When illuminated, indicates that the torch consumables are loose or not
installed.
Yellow HIGH TEMPERATURE
When illuminated, indicates that the power supply temperature has exceeded operating limits.
Current
Adjustment
Knob
ON
OFF
Pilot Arc
Control Switch
(208-240, 480V)
PMX600.05
ON (I)/OFF (0)
Switch
3-2
11-99
MAINTENANCE
THEORY OF OPERATION
General
Refer to Functional Description, Figures 3-2.1 and 3-2.2, Sequence of Operation and the
system wiring diagram.
3-3
10-99
3-4
10-99
The control board microprocessor monitors and regulates system operation and safety
circuits. The current is set to the desired value by adjusting the current adjust potentiometer. The system compares the set point to the output current by monitoring the current
sensor and adjusting the pulse width output of the inverter IGBT Q2.
The output circuitry consists of 2 current transfer sensors located on the power board, the
pilot arc IGBT Q3 and the output choke L2.
The inverter consists of several components: an isolated gate bipolar transistor (IGBT Q2),
the power transformer (T2), a current sense transformer (LEM), power factor choke and
sections of the power board. The inverter operates as a pulse width modulator controlled
bridge circuit and is rectified by the output diode D2.
Three phase AC power enters the system through the power switch S1 and supplies the
EMI filter board PCB1. The filter board provides noise suppression and spike protection.
The DC voltage output from the diode bridge D1 supplies the inverter and supplies the
flyback system power supply (DC to DC converter) on the power board PCB2. A soft start
is implemented via power board resistor RT5 and relay K1.
MAINTENANCE
S1
PCB1
EMI Filter
Board
Filter
~
~
D1
Input
Diode
Bridge
Regulator
TS1 TS2
LED8
Start
L1
T2
Power
xfmr
~
~
D2
Output
Diode
Start Switch
Cap Switch
V1
Soleniod
Valve (gas)
Q2
IGBT
Module
On Rear of Board
PS1
Pressure
Switch (gas)
M1
PCB2
Power
Board
Gas Test
Current Adjust
LED6 LED7
Over Temp
Cap Off
Low Pres
Low Volt
O.K.
Power
LEDs
Component
Q3
PA
IGBT
L2
Work
Nozzle
Electrode
Air/Gas
to
Torch
xfer
sensors
TB1
Designator
Workpiece
Torch
MAINTENANCE
3-5
10-99
3-6
10-99
The control board PCB3 includes a pilot arc control switch, allowing the operator to turn the
pilot arc ON (useful when cutting expanded metal) or OFF for maximum consumable life.
The control board microprocessor monitors and regulates system operation and safety
circuits. The current is set to the desired value by adjusting the current adjust potentiometer. The system compares the set point to the output current by monitoring the current
sensor and adjusting the pulse width output of the inverter IGBT Q2.
The output circuitry consists of 2 current transfer sensors located on the power board, the
pilot arc IGBT Q3 and the output choke L2.
The inverter consists of several components: an isolated gate bipolar transistor (IGBT Q2),
the power transformer (T2), a current sense transformer (LEM), power factor choke and
sections of the power board. The inverter operates as a pulse width modulator controlled
bridge circuit and is rectified by the output diode D2.
AC power enters the system through the power switch S1 to the input diode bridge D18.
The DC voltage output from the diode bridge D1 supplies the inverter and supplies the
flyback system power supply (DC to DC converter) on the power board PCB2. The power
board provides noise suppression and spike protection. A soft start is implemented via
power board resistor RT5 and relay K1.
MAINTENANCE
S1
Filter
~
~
D18
Input
Diode
Bridge
Regulator
TS1 TS2
LED8
Start
T2
Power
xfmr
~
~
D2
Output
Diode
Start Switch
Cap Switch
V1
Soleniod
Valve (gas)
Q2
IGBT
Module
On Rear of Board
PS1
Pressure
Switch (gas)
M1
PCB2
Power
Board
Pilot Arc
Switch
Gas Test
Current Adjust
LED6 LED7
Over Temp
Cap Off
Low Pres
Low Volt
O.K.
Power
LEDs
Component
Q3
PA
IGBT
L2
Work
Nozzle
Electrode
Air/Gas
to
Torch
xfer
sensors
TB1
Designator
Workpiece
Torch
MAINTENANCE
3-7
10-99
MAINTENANCE
Sequence of Operation
System off
3-8
10-99
Arc extinguishes.
Post flow continues for 10
seconds.
MAINTENANCE
TROUBLESHOOTING
The complexity of the circuits require that service technicians have a working knowledge of inverter
power supply theory. In addition to being technically qualified, technicians must perform all testing
with safety in mind.
If questions or problems arise during servicing, call the Hypertherm Technical Services Department
at the phone numbers listed in the front of this manual.
Test Equipment
Multimeter
Visual Inspection
External
Visual Inspection
Internal
Resistance Checks
Power ON
Troubleshooting
Guide
Voltage Checks
3-9
10-99
MAINTENANCE
WARNING
ELECTRIC SHOCK CAN KILL
Turn off the power and remove the input power plug from its receptacle
before removing the cover from the power supply. If the power supply is
directly connected to a line disconnect box, switch the line disconnect to
OFF (O). In the U.S., use a "lock-out / tag-out" procedure until the service
or maintenance work is complete. In other countries, follow appropriate
national or local safety procedures.
Do not touch live electrical parts! If power is required for servicing, use
extreme caution when working near live electrical circuits. Dangerous
voltages exist inside the power supply that can cause serious injury or
death.
Do not attempt to repair the power board or control board. Do not cut away
or remove any protective conformal coating from either board. To do so
will risk a short circuit between the AC input circuit and the output circuit
and may result serious injury or death.
3-10
10-99
MAINTENANCE
Resistance Checks
All resistance values were taken with the power cord disconnected and all internal power supply
wires attached. Perform Visual Inspection - Internal before continuing in this section.
If your resistance values are not close to the values given in this section, isolate the problem
by removing wires attached to the resistance check points or component until the problem is
found.
After the problem has been located and repaired, refer to the Sequence of Operation flow
diagram in this section to test the power unit for proper operation.
2.5M
208V - 240V
>50M
480V
3.5 - 4.5M
>50M
PMX600-SM.01
Figure 3-3 Resistance Check #1 - Across Input Leads and Input to Ground
3-11
10-99
MAINTENANCE
Resistance Check #2 - Figure 3-4
> 10M
> 10M
PMX600.20
3-12
10-99
MAINTENANCE
Resistance Check #3 - Figure 3-5
6 to 9 K
+
4 to 7 K
+
208-240V and 480V
PMX600.21
3-13
10-99
MAINTENANCE
Troubleshooting Guide
WARNING
ELECTRIC SHOCK CAN KILL
Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.
See warnings on page 3-6 before proceeding.
If no problems were found during the initial resistance checks and the power supply still does not
operate correctly, follow the Troubleshooting Guide.
Note: The Troubleshooting Guide provides most probable cause and solutions. Study the system
wiring diagram and understand the theory of operation before troubleshooting. Before purchasing a
major replacement component, verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility.
3-14
10-99
Problem
1.1 Verify incoming voltage is correct.
Solution
No or improper voltage
applied to unit
Cause
MAINTENANCE
3-15
10-99
3-16
10-99
ON
ON
Insufficient air
pressure
Solution
Faulty air pressure switch. 6.3a 230V & 400V System only: If supply
39 psi (2.5 bar) is required pressure is above 39 psi (2.5 bar), check
to activate the pressure
continuity on J14, pins 3 & 4 on power board. If
switch.
open continuity, replace switch.
Defective power
board (PCB2)
Improper line voltage
Faulty valve
5. Voltage LED
illuminates
Shorted internal
components
Depressed torch trigger or
shorted start signal
Cause
Over voltage
condition
Problem
MAINTENANCE
Problem
ON
ON
Defective heatsink
temperature switch TS1
(check when system is
cool, at least 15 min after
use)
Defective power
transformer (T2)
temperature sensor TS2
(check when system is
cool, at least 15 min after
use)
Solution
Consumables not
installed, installed
improperly, or damaged
Cause
MAINTENANCE
3-17
10-99
3-18
10-99
Damaged control
board (PCB3)
Overuse or improperly
installed consumables
Damaged torch or
lead assembly
Worn or bad
consumables
Cause
Problem
Solution
MAINTENANCE
Problem
Overuse of consumables
Moisture or contaminates
in air line
Undersized electrical
supply installation:
- Breaker/fuse
- Supply wire
- Extension cord
Power board (PCB2)
failure
Inverter fault or
interlock
Cause
Worn consumables
Solution
MAINTENANCE
3-19
10-99
3-20
10-99
Problem
Solution
Incorrect operation
Current adjustment set too 11.1 Verify current adjust knob is at proper
low
setting (turn to max, full clockwise).
Poor work lead connection 12.1 Verify work lead is attached to workpiece
and workpiece is free of rust, paint, etc.
Cause
MAINTENANCE
MAINTENANCE
Voltage Checks
WARNING
ELECTRIC SHOCK CAN KILL
Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.
See warnings on page 3-6 before proceeding.
Before performing voltage checks, complete Visual Inspection - Internal, Resistance Checks and
the troubleshooting guide.
Connect the power cord into the line voltage disconnect switch box or plug into a properly
grounded outlet.
Connect the gas supply to the power supply.
Switch the power supply on.
3-21
10-99
MAINTENANCE
Voltage Check #1 - Figure 3-5
8
= Line Voltage
= Line Voltage
= Line Voltage
10
= Line Voltage*
= Line Voltage
= Line Voltage*
*480V Only
PMX600.22
3-22
10-99
MAINTENANCE
Voltage Check #2 - Figure 3-6
230 VAC
400 VAC
208-240 VAC
480 VAC
Output at Bridge
325 VDC
565 VDC
300-330 VDC
660 VDC
15
14
PMX600.23
3-23
10-99
MAINTENANCE
Voltage Check #3 - Figure 3-7
230 VAC
400 VAC
208-240 VAC
480 VAC
A
160
280
165
330
B
160
280
165
330
C
325
565
330
660
B
A
B
A
+
PMX600.24
3-24
10-99
MAINTENANCE
Voltage Check #4 - Figure 3-8
230 VAC
400 VAC
208-240 VAC
480 VAC
290 VDC
290 VDC
165-165 VDC
330 VDC
PMX600.25
3-25
10-99
MAINTENANCE
COMPONENT REPLACEMENT
WARNING
ELECTRIC SHOCK CAN KILL
BLUE
BLACK
400V
YELLOW
GREEN
208V - 240V
BLACK
480V
WHITE
BLACK
WHITE
RED
GREEN
GREEN
PMX600.12
3-26
10-99
MAINTENANCE
Torch Lead Replacement (For models without quick disconnect)
Disconnect electrical power and gas supply before removing the old torch lead.
3-27
10-99
MAINTENANCE
Air Filter Element Replacement
Removal
3-28
10-99
MAINTENANCE
Air Filter Element Replacement (continued)
Installation - Refer to Figure 3-13.
Install the new filter element into the filter housing.
Secure with screw and retainer.
Install the filter bowl and O-ring into the filter housing.
3-29
10-99
MAINTENANCE
Work Cable Replacement
Disconnect electrical power and gas supply before removing the old work cable.
CAUTION:
Early Configuration
PMX600.15
3-30
10-99
MAINTENANCE
Capacitor Replacement
Removal - Refer to Figure 3-15.
Disconnect electrical power and gas supply before removing the power supply cover.
Remove screws securing capacitor to PC board.
Remove capacitor from fan side of power supply.
Capacitor Identification
Installation - Refer to Figure 3-15.
Check capacitor identification and install as
shown below.
Power
Supply
208/240V
Capacitor
Marking
250V 6800uf
230V
250V 4700uf
400V
400V 1800uf
480V
450V 1500uf
Correct Installation
+ Positive
+ Positive
3-31
11-99
MAINTENANCE
Heat Sink Component Replacement
Installation - Refer to Figure 3-16.
Install components to the heat sink as shown
below.
Thermal Pad
129529exploded.eps
Thermal Grease
DC-120
A
PMX600.28
Reference
Notes:
A
Apply thermal grease and Torque to 20 in-lb / 23 kg cm
B
Apply thermal grease and Torque to 8 in-lb / 9 kg cm
C
Torque to 8 in-lb / 9 kg cm
3-32
11-99
Section 4
PARTS LIST - 400/230V
In this section:
POWER SUPPLY EXTERIOR ..................................................................................................... 4-2
POWER SUPPLY FRONT INTERIOR RIGHT SIDE .................................................................... 4-3
POWER SUPPLY BACK INTERIOR RIGHT SIDE ...................................................................... 4-4
POWER SUPPLY INTERIOR FAN SIDE ..................................................................................... 4-5
POWER SUPPLY HEAT SINK ASSEMBLY ................................................................................. 4-6
RECOMMENDED SPARE PARTS - POWERMAX600- 230/400V ................................................. 4-7
4-1
11-99
4-2
10-99
Item
Part
Number
Description
1
2
3
4
5
6
7
8
001669
001668
110242
129488
008965
110261
110258
110996
Designator
Qty.
1
1
1
1
1
1
1
1
PM
X60
0.2
Early Configuration
Item
1
2
3
4
Part
Number
Description
041593
108090
129374
123375
Designator
PCB3
V1
Qty.
1
1
1
1
4-3
10-99
Item
1
2
3
4
5
4-4
10-99
Part
Number
Description
003193
003195
041566
041587
129368
129410
008389
108107
109070
Designator
S1
S1
PCB1
PCB1
Qty.
1
1
1
1
1
1
1
1
1
Item
1
2
3
4
5
6
7
8
9
10
Part
Number
Description
005112
022027
014232
014234
014238
009999
109118
014231
014241
011083
011086
011087
129366
Pressure Switch
Pressure gauge
Inductor, output choke .80MH 40A
Power transformer, 400V
Power transformer, 230V
Capacitor, 1800/1900UF, 400V
Capacitor, 1800/1900UF, 230V
Inductor, input choke 5MH 11A, 400V
Inductor, input choke 5MH 11A, 230V
Filter regulator subassembly
Air filter element
O-ring
Fan subassembly
Designator
PS1
L2
T2
T2
L1
L1
M1
Qty.
1
1
1
1
1
2
2
1
1
1
1
1
1
4-5
10-99
DC-120
PMX600.28
4-6
11-99
Item
Part
Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
109088
129406
009849
109080
005222
109079
009849
109067
109090
109134
041568
041607
008903
027662
Output diode
EMI suppression capacitor
Resistor, 20 OHM
IGBT, pilot arc
Temp switch
IGBT module
Resistor, 20 OHM
MOV
Input diode bridge, 400V
Input diode bridge, 230V
Power PCB, 400V
Power PCB, 230V
Thermal pad
Thermal grease, 5 oz. tube
Designator
D2
Q3
TS1
Q2
D1
D1
PCB2
PCB2
Qty.
1
1
2
1
1
1
1
1
1
1
1
1
3
5 places
Description
Page
4-7
11-99
Blank
4-8
Section 5
PARTS LIST - 208-240/480V
In this section:
POWER SUPPLY EXTERIOR ..................................................................................................... 5-2
POWER SUPPLY FRONT INTERIOR RIGHT SIDE .................................................................... 5-3
POWER SUPPLY CIRCUIT BREAKER AND POWER CABLE ................................................... 5-4
POWER SUPPLY INTERIOR FAN SIDE ..................................................................................... 5-5
POWER SUPPLY HEAT SINK ASSEMBLY ................................................................................. 5-6
RECOMMENDED SPARE PARTS - POWERMAX600- 208-240/480V .......................................... 5-7
5-1
11-99
5-2
10-99
Item
Part
Number
Description
1
2
3
4
5
6
7
8
001669
001668
110271
129594
008965
010287
110276
110996
Designator
Qty.
1
1
1
1
1
1
1
1
PMX
600
Item
1
2
3
4
5
Part
Number
Description
041654
108090
129534
129533
123375
.27
Designator
PCB3
V1
Qty.
1
1
1
1
1
5-3
10-99
208V - 240V
480V
Item
1
2
3
5-4
10-99
Part
Number
Description
003193
003202
023519
129530
108124
108122
Designator
S1
S1
Qty.
1
1
1
1
1
1
Item
1
2
3
4
5
6
7
8
9
Part
Number
Description
005112
022027
014232
014252
014251
109179
109187
011083
011086
011087
129366
027654
Pressure Switch
Pressure gauge
Inductor, output choke .80MH 40A
Power transformer, 480V
Power transformer, 208-230V
Capacitor, 1800/1900UF 450V, 480V
Capacitor, 1800/1900UF 250V, 208-230V
Filter regulator subassembly
Air filter element
O-ring
Fan subassembly, 480V
Fan assembly, 208-230V
Designator
PS1
L2
T2
T2
M1
M1
Qty.
1
1
1
1
1
2
2
1
1
1
1
1
5-5
10-99
12952
DC-120
PMX600.28
Item
1
2
3
4
5
6
7
8
9
10
5-6
11-99
Part
Number
Description
109088
009849
109080
005222
109079
109183
009849
109175
109174
041652
041650
008903
027662
Output diode
Resistor, 20 OHM
IGBT, pilot arc
Temp switch
IGBT module, 480V
IGBT module, 208-240V
Resistor, 20 OHM
Input diode bridge, 480V
Input diode bridge, 208-240V
Power PCB, 480V
Power PCB, 208-240V
Thermal pad
Thermal grease, 5 oz. tube
Designator
D2
Q3
TS1
Q2
Q2
D18
D18
PCB2
PCB2
Qty.
1
2
1
1
1
1
1
1
1
1
1
3
5 places
Description
Page
5-7
11-99
Blank
5-8
Section 6
PARTS LIST - TORCH AND CONSUMABLES
In this section:
PAC123T HAND TORCH ASSEMBLY (NO QUICK DISCONNECT) .................................................... 6-2
PAC123T HAND TORCH ASSEMBLY (WITH QUICK DISCONNECT) ................................................ 6-4
PAC123M MACHINE TORCH ASSEMBLY (NO QUICK DISCONNECT) ............................................. 6-6
PAC123M MACHINE TORCH ASSEMBLY (WITH QUICK DISCONNECT) ......................................... 6-8
TORCH CONSUMABLES ................................................................................................................... 6-10
RECOMMENDED SPARE PARTS - PAC123 TORCH ....................................................................... 6-11
6-1
10-99
1
2
3
4
5
6
7
8
9
9
9
Quantity
PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect)
PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)
PAC123T Hand Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect)
Handle, 2 Sides
1
Safety Trigger
1
Replacement Start Switch (switch and wire splices)
1
Trigger Spring
1
Retaining Ring, Gutcha
1
Screws, P/S, # 4 X 1/2, PH, RND, S/B
5
Torch Main Body with Safety Switch
1
O-Ring: BUNA 90 Duro .614X.070
1
Replacement Hand Torch Lead, 15 ft / 4.5 m
1
Replacement Hand Torch Lead, 25 ft / 7.5 m
1
Replacement Hand Torch Lead, 50 ft / 15 m
1
6-2
10-99
Electrode
Swirl Ring
Retaining Cap
Nozzle
Shield
1
1
1
1
1
23
C1
PA
6-3
10-99
1
2
3
4
5
6
7
8
9
9
9
Quantity
PAC123T Hand Torch Assembly with 15 ft / 4.5 m Lead and Quick Disconnect
PAC123T Hand Torch Assembly with 25 ft / 7.5 m Lead and Quick Disconnect
PAC123T Hand Torch Assembly with 50 ft / 15 m Lead and Quick Disconnect
Handle, 2 Sides
1
Safety Trigger
1
Replacement Start Switch (switch and wire splices)
1
Trigger Spring
1
Retaining Ring, Gutcha
1
Screws, P/S, # 4 X 1/2, PH, RND, S/B
5
Torch Main Body with Safety Switch
1
O-Ring: BUNA 90 Duro .614X.070
1
Replacement Hand Torch Lead, 15 ft / 4.5 m
1
Replacement Hand Torch Lead, 25 ft / 7.5 m
1
Replacement Hand Torch Lead, 50 ft / 15 m
1
6-4
10-99
Electrode
Swirl Ring
Retaining Cap
Nozzle
Shield
1
1
1
1
1
*
*
2
T.0
23
C1
PA
*
*
6-5
10-99
1
2
3
3
3
4
5
6
7
Quantity
PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead (No Quick Disconnect)
PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead (No Quick Disconnect)
PAC123M Machine Torch Assembly with 50 ft / 15 m Lead (No Quick Disconnect)
Sleeve, Machine Torch
1
Sleeve, Torch Position
1
Replacement Torch Lead, 15 ft / 4.5 m
1
Replacement Torch Lead, 25 ft / 7.5 m
1
Replacement Torch Lead, 50 ft / 15 m
1
Snap Ring
1
Torch Main Body with Safety Switch
1
O-Ring: BUNA 90 Duro 0.614 X 0.070 inch
1
On/Off Pendant with Lead, 25 ft / 7.5 m
On/Off Pendant with Lead, 50 ft / 15 m
On/Off Pendant with Lead, 75 ft / 23 m
6-6
10-99
Electrode
Swirl Ring
Retaining Cap
Nozzle
Shield
1
1
1
1
1
*
Included with replacement
lead assembly.
PA
C
12
3M
.0
6-7
10-99
1
2
3
3
3
4
5
6
7
Quantity
PAC123M Machine Torch Assembly with 15 ft / 4.5 m Lead and Quick Disconnect
PAC123M Machine Torch Assembly with 25 ft / 7.5 m Lead and Quick Disconnect
PAC123M Machine Torch Assembly with 50 ft / 15 m Lead and Quick Disconnect
Sleeve, Machine Torch
1
Sleeve, Torch Position
1
Replacement Torch Lead w/Quick Disconnect, 15 ft / 4.5 m
1
Replacement Torch Lead w/Quick Disconnect, 25 ft / 7.5 m
1
Replacement Torch Lead w/Quick Disconnect, 50 ft / 15 m
1
Snap Ring
1
Torch Main Body with Safety Switch
1
O-Ring: BUNA 90 Duro 0.614 X 0.070 inch
1
On/Off Pendant with Lead, 25 ft / 7.5 m
On/Off Pendant with Lead, 50 ft / 15 m
On/Off Pendant with Lead, 75 ft / 23 m
6-8
10-99
Electrode
Swirl Ring
Retaining Cap
Nozzle
Shield
1
1
1
1
1
*
*
.04
PA
C
3M
12
6-9
10-99
Shield
Retaining Cap
120828
120600
120608
120600
Nozzle
Electrode
Swirl Ring
120826
Hand
Cutting
120831
120573
Gouging
120827
120576
120600
120826
Machine
Cutting
Deflector
120303
120600
120606
120574
Unshielded*
6-10
10-99
Description
6-11
10-99
Blank
6-12
WIRING DIAGRAMS
Section 7
WIRING DIAGRAMS
In this section:
Electrical Schematic: 230/400V ..................................................... 013335
Electrical Schematic: 208-240/480V .............................................. 013337
7-1
10-99
POWER FACTOR
CHOKE (L1)
WHT
W14
J7
POWER
CORD
FILTER
X TURNS
109070
3 PHASE
INPUT
VOLTAGE
BLK
W2 BLU
W1
BRN
J6
K1
S1
CIRCUIT
BREAKER
W3
WHT
IGBT
MODULE
SOFT START
PCB1
W7
W6
W5
J3
J2
EMI
FILTER
BOARD
J1
+
J9
J8
W10
J7
J6
W9
J5
J4
W8
PE
W4
GRN/YEL
~
~
~
Q2
D2
RT5
OUTPUT BRIDGE
109088
J4
VDC
1
+
D1
INPUT
BRIDGE
T2
POWER
TRANSFORMER
C11
+24
+12
+5
T1
FLYBACK
SYSTEM
POWER
SUPPLY
CONTROL
GND
YEL
P4
3
PE
BRN
YEL
009849
J13
18PA
20 OHM
COMPA
18INV
COMINV
009849/2
J3
20 OHM
C24
18T
COMT
20 OHM
J8
18REG
FAULT CODES
RC
MOV
J9
W13
STATUS
W12
W11
SYSTEM OKAY
OFF
ON
ON
ON
OFF
ON
TRANSFER SENSOR
5 TURNS
LINE
VOLTAGE
SENSE
3 TURNS
W16
109160
J10
TB1
WORK LEAD
W17
C
J1
NOZZLE
Q3
PILOT
ARC
IGBT
108071
+12
+5
L2
ELECTRODE
W19
E
OUTPUT CHOKE
014232
TP1
008924
3
4
PCB3
CONTROL BOARD
1
2
3
4
5
6
7
6
7
START
POWER
LED6 LED7 LED8
O.K.
042188
U11
OUTA
10
OUTB
1B
2B
3B
4B
5B
6B
7B
1C
2C
3C
4C
5C
6C
7C
-V
+V
16
15
14
13
12
11
10
/SSR
/GAS
/PA
/SPARE
+5
9
+24
C50
.1UF
50V
009994
ULN2003A
11
12
LOW VOLTAGE
U4
13
CURRENT
LOW PRESSURE
RT2
R3
/CAPON
J2
SPAREIN
RT2
COMT
14
/START
18T
15
+5
16
CAP OFF
BLU
ORG
VIO
CAP SWITCH
START
/VOK
HSTEMPOK
17
RT6
RT1
R26
GASOK
18
OVER TEMP
OFF
J11
OFF
LEM
J12
LED6
W18
OVER
VOLTAGE
TRIP
W15
LED7
4.7 NF
129406
J5
~
~
BRN
U3
19
(FRONT)
TFRI
COMT
20
041593
R54
21
22
23
24
086000
086007
INPUT VOLTAGE
400vac, 3
230vac, 3
003193
003195
041566
041587
109090
109134
041568
041607
TP2
R42
R41
008924
25
IFB
26
IOCA
R4
R5
+24
014231
014241
014234
014238
009999/2
109118/2
109079
109061
TIMING DIAGRAM
013333
013333
540
310
VDC
J14
GAS
SWITCH
PS1
HEATSINK
THERMAL
SWITCH
TS1
J15
RED
BLK
BLK
J16
RED
BLK
J17
RED
TS2
GAS
SOLENOID
V1
FAN
M1
SENSOR IN
POWER TRANSFORMER
208/240V (086021)
480V (086022)
K1,K2
S1
CIRCUIT
BREAKER
S1
CIRCUIT
BREAKER
RED
W3
W2
WHT
BLK
W5
W4
~
~
~
W1
BLK
D18
INPUT
BRIDGE
PE
GRN
W7
~
~
~
W5
W4
Q2
D2
RT3
OUTPUT BRIDGE
109088
J4
VDC
1
+
D18
INPUT
BRIDGE
T2
POWER
TRANSFORMER
C51
T1
FLYBACK
SYSTEM
POWER
SUPPLY
CONTROL
GND
+24
+12
+5
YEL
P1
3
PE
BRN
YEL
009849
J13
18PA
20 OHM
COMPA
18INV
COMINV
009849/2
J3
20 OHM
C50
18T
COMT
20 OHM
J5
J8
18REG
208/240V UNIT ONLY
W18
OVER
VOLTAGE
TRIP
W14
~
~
BRN
RC
MOV
J9
LEM
TRANSFER SENSOR
5 TURNS
W16
J18
W8
TB1
WORK LEAD
W17
C
J1
1
2
NOZZLE
Q3
PILOT
ARC
IGBT
108071
+12
+5
ELECTRODE
W19
E
OUTPUT CHOKE
014232
U1
1
2
3
4
5
6
7
6
7
4
5
OUTA
10
OUTB
042188
1B
2B
3B
4B
5B
6B
7B
1C
2C
3C
4C
5C
6C
7C
-V
+V
16
15
14
13
12
11
10
/SSR
/GAS
/PA
/SPARE
+5
9
+24
C8
.1UF
50V
009994
ULN2003A
11
LOW VOLTAGE
U4
13
RT2
R6
/CAPON
12
J2
SPAREIN
15
ORG
CAP SWITCH
+5
16
/VOK
RT4
RT1
R8
GASOK
18
START
VIO
HSTEMPOK
17
OVER TEMP
ORG
/START
18T
CAP OFF
BLU
R12
COMT
14
START
POWER
U3
J18
CONT. PA
(FRONT)
WHT
WHT
PCB3
CONTROL BOARD
CURRENT
TP1
008924
LOW PRESSURE
RED
L2
PE
GRN
W1
W6
208/240
1
VDC
W2
480
3
W7
WHT
IGBT
MODULE
SOFT START
+
19
TFRI
COMT
20
R55
041654
21
22
23
24
TP2
R57
R58
008924
25
IFB
26
IOCA
R56
R59
+24
086021
086022
INPUT VOLTAGE
208/240vac, 1
480vac, 3
CORD
129530
023519
J14
W12
003202
003193
109174
109175
LED7
LED6
STATUS
041650
041652
OFF
OFF
SYSTEM OKAY
014251
014252
OFF
ON
BULK CAPS
109187/2
109179/2
109183
109079
ON
OFF
TIMING DIAGRAM
013333
013333
ON
ON
330
660
FAULT CODES
GAS
SWITCH
PS1
J15
RED
BLK
VDC
BLK
OR WHT
J16
RED
BLK
J17
RED
W13
HEATSINK
THERMAL
SWITCH
TS1
TS2
GAS
SOLENOID
V1
FAN
M1
SENSOR IN
POWER TRANSFORMER
013-3-337 REV. B