Hypertherm Powermax125 Service Manua User Manual
Powermax125, Plasma arc cutting system service manual
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Table of contents
Document Outline
- Contents
- Electromagnetic Compatibility (EMC)
- Warranty
- Specifications
- Safety information
- Powermax125 System description
- Power supply dimensions
- Component weights (125 A systems)
- Hypertherm power supply ratings
- Duramax Hyamp 85° hand torch dimensions
- Duramax Hyamp 15° hand torch dimensions
- Duramax Hyamp 180° full-length machine torch dimensions
- Duramax Hyamp 180° mini machine torch dimensions
- Powermax125 cutting specifications
- Symbols and markings
- Power Supply Setup
- Basic System Operations
- Hand Torch Setup
- Hand Cutting
- Machine Torch Setup
- Introduction
- Consumable life
- Machine torch components
- Disassemble the machine torch
- Convert a full-length machine torch to a mini machine torch
- Mount the torch
- Choose the machine torch consumables
- Machine torch consumables
- Install the machine torch consumables
- Aligning the torch
- Connecting the torch lead
- Using the cut charts
- Estimated kerf-width compensation
- 125 A shielded consumables
- 125 A shielded cutting – mild steel
- 125 A shielded cutting – stainless steel
- 125 A shielded cutting – aluminum
- 105 A shielded consumables
- 105 A shielded cutting – mild steel
- 105 A shielded cutting – stainless steel
- 105 A shielded cutting – aluminum
- 65 A shielded consumables
- 65 A shielded cutting – mild steel
- 65 A shielded cutting – stainless steel
- 65 A shielded cutting – aluminum
- 45 A shielded consumables
- 45 A shielded cutting – mild steel
- 45 A shielded cutting – stainless steel
- 45 A shielded cutting – aluminum
- FineCut consumables
- FineCut – mild steel
- FineCut – stainless steel
- Mechanized Cutting
- Connecting an optional remote-start pendant
- Connecting the machine interface cable
- Accessing raw arc voltage
- Connecting an optional RS-485 serial interface cable
- Using the machine torch
- Setting up the torch and table
- Understand and optimize cut quality
- Piercing a workpiece using the machine torch
- Common machine-cutting faults
- Troubleshooting and System Tests
- Controls and indicators
- Theory of operation
- Troubleshooting preparation
- Initial resistance check
- IGBT device test using a non-Hypertherm tester
- Fault codes
- Troubleshooting guide
- System tests
- Test 1 – Voltage input
- Test 2 – DC power bus
- Test 3 – Output diodes
- Test 4 – Inverter temperature sensor
- Test 5 – Flyback circuit (DC minor voltages)
- Test 6 – Torch stuck open/torch stuck closed
- Test 7 – Start signal
- Test 8 – Torch cap switch
- Test 9 – Electronic regulator
- Test 10 – Pressure sensor
- Test 11 – Fan
- Test 12 – AUX switch
- Power Supply Component Replacement
- Installing a machine interface cable for raw arc voltage
- Disconnect the power and gas supply
- Replacing the gas filter element
- Replacing the work lead connector
- Installing the optional filter kit
- Replacing the power supply cover
- Replacing the component barrier
- Replacing the end panel bracket
- Replacing the machine interface cable with voltage divider board
- Installing the machine interface cable
- Installing the RS-485 serial interface cable
- Disconnect the gas tube
- Connect the gas tube
- Replacing the power cord and strain relief
- Replacing the power switch
- Replacing the control board
- Replacing the DSP board
- Replacing the power board
- Replacing the input diode bridge
- Replacing the output diode bridge
- Replacing the pilot arc IGBT
- Replacing the inverter IGBT module
- Replacing the snubber resistor
- Replacing the thermal sensor
- Replacing the fan shroud
- Replacing the fan
- Replacing the pressure transducer
- Replacing the pressure switch
- Replacing the gas filter assembly
- Replacing the solenoid valve
- Replacing the gas tubing
- Replacing the bulk capacitors
- Replacing the torch quick disconnect receptacle
- Replacing the work lead receptacle
- Replacing the output inductor
- Replacing the transformer
- Replacing the PFC inductor
- Replacing the front panel
- Replacing the rear panel
- Torch Component Replacement
- Parts
- Power supply parts
- Duramax Hyamp 85° hand torch replacement parts
- Duramax Hyamp 15° hand torch replacement parts
- Hand torch consumables
- Duramax Hyamp 180° full-length machine torch replacement parts
- Duramax Hyamp 180° mini machine torch replacement parts
- Machine torch consumables
- Accessory parts
- Powermax125 labels
- Safety-critical parts
- Recommended spare parts
- Wiring Diagrams