Hypertherm MAX42 User manual

Plasma Arc
Cutting System
Service Manual
SM116
801160 – Rev. 2
MAX42®

MAX42
Service Manual
(P/N 801160)
for systems beginning with serial number
MX42-8553
Revision 2 – May 1995
© Copyright 1995 Hypertherm, Inc.
All Rights Reserved
Hypertherm and MAX are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com

6/15/05
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.ser[email protected] (Customer Service Email)
Hypertherm Automation
5 Technology Drive, Suite 300
West Lebanon, NH 03784 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik, GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
No. 19 Kaki Bukit Road 2
K.B. Warehouse Complex
Singapore 417847, Republic of Singapore
65 6 841 2489 Tel
65 6 841 2490 Fax
65 6 841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 1308-09, Careri Building
432 West Huai Hai Road
Shanghai, 200052
PR China
86-21 5258 3330/1 Tel
86-21 5258 3332 Fax
Hypertherm
Branch of Hypertherm, UK, UC
PO Box 244
Wigan, Lancashire, England WN8 7WU
00 800 3324 9737 Tel
00 800 4973 7329 Fax
00 800 4973 7843 (Technical Service)
France (Representative office)
15 Impasse des Rosiers
95610 Eragny, France
00 800 3324 9737 Tel
00 800 4973 7329 Fax
Hypertherm S.r.l.
Via Torino 2
20123 Milano, Italia
39 02 725 46 312 Tel
39 02 725 46 400 Fax
39 02 725 46 314 (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9
4704 SE Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 49 73 7843 Tel (Technical Service)
Japan (Representative office)
1952-14 Yata-Natsumegi
Mishima City, Shizuoka Pref.
411-0801 Japan
81 0 559 75 7387 Tel
81 0 559 75 7376 Fax
HYPERTHERM BRASIL LTDA.
Rua Jati, 33
CEP 07180-350 Cumbica
Guarulhos, SP - Brasil
55 11 6482 1087 Tel
55 11 6482 0591 Fax

WARRANTY
MAX42 Service Manual Page i
ATTENTION
Genuine Hypertherm parts are the factory-recommended replacement parts
for your Hypertherm system. Any damage caused by the use of other than
genuine Hypertherm parts is not covered by the Hypertherm warranty.

WARRANTY
Page ii MAX42 Service Manual
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 or to a customer by you, BUT IN NO EVENT SHALL THIS WARRANTY
EXTEND BEYOND 36 MONTHS FROM THE DATE OF ORIGINAL DELIVERY TO YOU BY HYPER-
THERM.
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 FOREGO-
ING 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 any patent or other right. Distributors shall notify HYPERTHERM promptly upon learn-
ing 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.
DISCLAIMER OF OTHER WARRANTIES
HYPERTHERM MAKES NO WARRANTIES REGARDING PRODUCTS MANUFACTURED BY IT OR
OTHERS (INCLUDING WITHOUT IMPLIED LIMITATION WARRANTIES AS TO MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE), EITHER EXPRESS OR IMPLIED, EXCEPT AS
PROVIDED HEREIN. This warranty is in lieu of any and all warranties, express or implied, by law or
otherwise; and Distributors are not authorized to give any other warranty purporting to be binding
upon HYPERTHERM upon resale of Products to their customers. IN NO EVENT shall HYPER-
THERM be liable for incidental or consequential damages or injury to the person or property of
anyone by reason of any defect in any Equipment sold hereunder.

TABLE OF CONTENTS
MAX42 Service Manual
SECTION a SAFETY .................................................................................................................... a-1
Recognize Safety Information .......................................................................................................... a-2
Follow Safety Instructions ................................................................................................................ a-2
Cutting Can Cause Fire or Explosion ............................................................................................... a-2
Electric Shock Can Kill ..................................................................................................................... a-3
Cutting Can Produce Toxic Fumes .................................................................................................. a-3
A Plasma Arc Can Cause Injury and Burns ..................................................................................... a-4
Arc Rays Can Burn Eyes and Skin .................................................................................................. a-4
Grounding Safety ............................................................................................................................. a-4
Compressed Gas Equipment Safety ................................................................................................ a-5
Gas Cylinders Can Explode If Damaged ......................................................................................... a-5
Noise Can Damage Hearing ............................................................................................................ a-5
Pacemaker and Hearing Aid Operation ........................................................................................... a-5
A Plasma Arc Can Damage Frozen Pipes ....................................................................................... a-5
Additional Safety Information ........................................................................................................... a-5
SECTION b SÉCURITÉ ................................................................................................................ b-1
Identifier les consignes de sécurité .................................................................................................. b-2
Suivre les instructions de sécurité.................................................................................................... b-2
Danger Avertissement Précaution ................................................................................................. b-2
Le coupage peut provoquer un incendie ou une explosion ............................................................. b-2
Prévention des incendies, Prévention des explosions .............................................................. b-2
Risque d’explosion argon-hydrogène et méthane ..................................................................... b-2
Détonation de l’hydrogène lors du coupage de l’aluminium ...................................................... b-2
Les chocs électriques peuvent être fatals ........................................................................................ b-3
Prévention des chocs électriques .............................................................................................. b-3
Le coupage peut produire des vapeurs toxiques ............................................................................. b-3
L’arc plasma peut provoquer des blessures ou des brûlures........................................................... b-4
Torches à allumage instantané ................................................................................................. b-4
Les rayons de l’arc peuvent brûler les yeux et la peau .................................................................... b-4
Protection des yeux, Protection de la peau, Zone de coupage ................................................. b-4
Mise à la masse et à la terre ............................................................................................................ b-4
Câble de retour, Table de travail, Alimentation ......................................................................... b-4
Sécurité des bouteilles de gaz comprimé ........................................................................................ b-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ....................................... b-5
Le bruit peut provoquer des problèmes auditifs ............................................................................... b-5
Pacemakers et prothèses auditives ................................................................................................. b-5
Un arc plasma peut endommager les tuyaux gelés ......................................................................... b-5
SECTION c SEGURIDAD ............................................................................................................. c-1
Reconocimiento de información de seguridad ................................................................................. c-2
Siga las instrucciones de seguridad................................................................................................. c-2
Peligro Advertencia Precaución ..................................................................................................... c-2
Los cortes pueden provocar incendios o explosiones ..................................................................... c-2
Prevención ante el fuego, Prevención ante explosiones ........................................................... c-2
Peligro de explosión argón-hidrógeno y metano ....................................................................... c-2
Detonación de hidrógeno con el corte de aluminio ................................................................... c-2
El choque elétrico puede provocar la muerte................................................................................... c-3
Prevención ante el electrochoque ............................................................................................. c-3
Los cortes pueden producir humos tóxicos...................................................................................... c-3
El arco de plasma puede causar lesiones y quemaduras ............................................................... c-4
Page iii

TABLE OF CONTENTS
MAX42 Service Manual
Antorchas de encendido instantáneo ........................................................................................ c-4
Los rayos del arco pueden producir quemaduras en los ojos y en la piel ....................................... c-4
Protección para los ojos, Protección para la piel, Área de corte ............................................... c-4
Seguridad de toma a tierra............................................................................................................... c-4
Cable de trabajo, Mesa de trabajo, Potencia primaria de entrada ............................................ c-4
Seguridad de los equipos de gas comprimido ................................................................................. c-5
Los cilindros de gas pueden explotar si están dañados .................................................................. c-5
El ruido puede deteriorar la audición ............................................................................................... c-5
Operación de marcapasos y de audífonos ...................................................................................... c-5
Un arco plasma puede dañar tubos congelados.............................................................................. c-5
SECTION 1 INTRODUCTION ....................................................................................................... 1-1
Read This First ................................................................................................................................. 1-2
Safety ............................................................................................................................................... 1-3
Warning - Instant-On Torches .......................................................................................................... 1-3
Description ....................................................................................................................................... 1-4
Power Unit ................................................................................................................................. 1-4
Major Subassemblies and Components .................................................................................... 1-4
Specifications ................................................................................................................................... 1-5
Power Unit ................................................................................................................................. 1-5
Disconnect Switch Box .............................................................................................................. 1-5
PAC121T Trigger Torch ............................................................................................................ 1-6
PAC121P Pushbutton Torch ..................................................................................................... 1-6
PAC121M Machine Torch ......................................................................................................... 1-6
SECTION 2 THEORY OF OPERATION......................................................................................... 2-1
General .............................................................................................................................................2-2
Principles of Operation ......................................................................................................................2-2
Circuit Descriptions ...........................................................................................................................2-3
Control Circuits ...........................................................................................................................2-3
Power Circuits ............................................................................................................................2-4
SECTION 3 MAINTENANCE......................................................................................................... 3-1
General ............................................................................................................................................. 3-2
Test Equipment & Tools .................................................................................................................... 3-2
Visual Inspection ............................................................................................................................... 3-2
Checkout Procedures........................................................................................................................ 3-2
Initial Resistance Checks ........................................................................................................... 3-3
Corrective Maintenance Checks................................................................................................. 3-7
Sequence of Operation............................................................................................................. 3-16
PAC121T Torch Parts Removal and Replacement......................................................................... 3-18
Torch Main Body Removal and Replacement .......................................................................... 3-18
Torch Switch Removal and Replacement ................................................................................ 3-19
PAC121P Torch Parts Removal and Replacement ........................................................................ 3-20
Torch Main Body Removal and Replacement .......................................................................... 3-20
Torch Switch Removal and Replacement ................................................................................ 3-20
PAC121M Torch Parts Removal and Replacement ........................................................................ 3-22
Torch Main Body Removal and Replacement .......................................................................... 3-22
Filter/Regulator Pressure Adjustment ............................................................................................. 3-24
Filter/Regulator Filter Cleaning or Replacement ............................................................................. 3-24
Page iv

TABLE OF CONTENTS
MAX42 Service Manual
SECTION 4 PARTS LIST ............................................................................................................... 4-1
Power Unit......................................................................................................................................... 4-2
MAX42 Power Unit 208-240 VAC, 1 PH, 60 Hz (071003) .......................................................... 4-2
Enclosure, Left Half (002183/001216) ........................................................................................ 4-5
Front Panel Subassembly (029305) ........................................................................................... 4-6
Rear Panel Subassembly (029338) ............................................................................................ 4-7
Pneumatic Subassembly (029351)............................................................................................. 4-8
Bracket Subassembly, Air Pack Power Supply (029339) ........................................................... 4-9
Inverter Subsystem Assembly (029289) ................................................................................... 4-11
Heatsink Subassembly (029331).............................................................................................. 4-13
Bracket Assembly, Magnetic Tray (029328) ............................................................................. 4-14
Input Capacitor Bank (029298) ................................................................................................. 4-16
Inductor, Power I/O (029293) ................................................................................................... 4-17
PAC121 Torch Assembly and Leads .............................................................................................. 4-18
PAC121T Torch Assembly and Lead (25 Ft/7.63 M) - 071065 ................................................ 4-18
PAC121T Torch Assembly and Lead (50 Ft/15.25 M) - 071066 .............................................. 4-18
PAC121P Torch Assembly and Lead (25 Ft/7.63 M) - 071069 ................................................ 4-20
PAC121P Torch Assembly and Lead (50 Ft/15.25 M) - 071070 .............................................. 4-20
PAC121M Torch Assembly and Lead (25 Ft/7.63 M) - 071067................................................ 4-22
PAC121M Torch Assembly and Lead (50 Ft/15.25 M) - 071068.............................................. 4-22
On/Off Pendant......................................................................................................................... 4-22
SECTION 5 WIRING DIAGRAMS & SCHEMATICS ..................................................................... 5-1
General ............................................................................................................................................. 5-2
ILLUSTRATIONS
Figure 1-1 MAX42 Power Unit, 208-240 VAC, 1 PH, 60 Hz .......................................................... 1-2
Figure 2-1 MAX42 Power Unit Block Diagram .............................................................................. 2-2
Figure 3-1 PAC121T Torch Assembly .......................................................................................... 3-19
Figure 3-2 PAC121P Torch Assembly ......................................................................................... 3-21
Figure 3-3 PAC121M Torch Assembly ......................................................................................... 3-23
Figure 3-4 Filter/Regulator Pressure Adjustment ........................................................................ 3-25
Figure 4-1 MAX42 Power Unit 208-240 VAC, 1 PH, 60 Hz - Exploded View .......................... 4-3/4-4
Figure 4-2 Enclosure, Left Half - Exploded View ........................................................................... 4-5
Figure 4-3 Front Panel Subassembly - Exploded View ................................................................. 4-6
Figure 4-4 Rear Panel Subassembly - Exploded View.................................................................. 4-7
Figure 4-5 Pneumatic Subassembly - Exploded View................................................................... 4-8
Figure 4-6 Bracket Subassembly, Air Pack Power Supply - Exploded View ............................... 4-10
Figure 4-7 Inverter Subsystem Assembly - Exploded View ......................................................... 4-12
Figure 4-8 Heatsink Subassembly - Explode View...................................................................... 4-13
Figure 4-9 Bracket Assembly, Magnetic Tray - Explode View ..................................................... 4-15
Figure 4-10 Input Capacitor Bank - Exploded View....................................................................... 4-16
Figure 4-11 Inductor, Power I/O - Exploded View ......................................................................... 4-17
Figure 4-12 PAC121T Torch Assembly and Leads ....................................................................... 4-19
Figure 4-13 PAC121P Torch Assembly and Leads ....................................................................... 4-21
Figure 4-14 PAC121M Torch Assembly with Leads and Optional On/Off Pendant ...................... 4-23
Figure 4-15 PAC121M Torch Assembly and Leads ...................................................................... 4-23
Figure 5-1 Power Unit 208-240, 1 PH, 60 Hz - Wiring Diagram .............................................. 5-3/5-4
Figure 5-2 Inverter 208-240, 1 PH, 60 Hz - Wiring Diagram ................................................... 5-5/5-6
Page v

TABLE OF CONTENTS
MAX42 Service Manual
Page vi
Figure 5-3 Pneumatic System - Flow Diagram .............................................................................. 5-7
Figure 5-4 Inverter I/O PC BD Assy, PCB1 - Schematic Diagram ................................................ 5-8
Figure 5-5 Inverter Power Supply PC BD Assy, PCB2 - Schematic Diagram ............................... 5-9
Figure 5-6 Input Rectifier PC BD Assy, PCB3 - Schematic Diagram .......................................... 5-10
Figure 5-7 Capacitor Packs 1 and 2 PC BD Assys, PCB4 and PCB5 - Schematic Diagrams .... 5-11
Figure 5-8 FET Pack Snubber 1 and 2, PC BD Assy, PCB6 - Schematic Diagram .................... 5-12
Figure 5-9 FET Pack Snubber 3 and 4, PC BD Assy, PCB7 - Schematic Diagram .................... 5-13
Figure 5-10 FET Packs 1 and 2 - Schematic Diagrams ................................................................ 5-14
Figure 5-11 FET Packs 3 and 4 - Schematic Diagrams ................................................................ 5-15
Figure 5-12 Inverter Modulator PC BD Assy, PCB12 - Schematic Diagram (2 Sheets) ............... 5-16
Figure 5-13 Control Power Supply PC BD Assy, PCB13 - Schematic Diagram ........................... 5-18
Figure 5-14 Control PC BD Assy, PCB14 - Schematic Diagram (2 Sheets) ................................. 5-19
Figure 5-15 Pilot Arc Controller PC BD Assy, PCB15 - Schematic Diagram ................................ 5-21
TABLE
Table 1-1 Major Subassemblies & Components of the MAX42 Power Unit ................................ 1-4

Hypertherm Plasma Systems a-1
Section a
SAFETY
In this section:
Recognize Safety Information...................................................................................................................................a-2
Follow Safety Instructions.........................................................................................................................................a-2
Cutting Can Cause Fire or Explosion .......................................................................................................................a-2
Electric Shock Can Kill..............................................................................................................................................a-3
Cutting Can Produce Toxic Fumes ...........................................................................................................................a-3
A Plasma Arc Can Cause Injury and Burns ..............................................................................................................a-4
Arc Rays Can Burn Eyes and Skin ...........................................................................................................................a-4
Grounding Safety......................................................................................................................................................a-4
Compressed Gas Equipment Safety ........................................................................................................................a-5
Gas Cylinders Can Explode If Damaged ..................................................................................................................a-5
Noise Can Damage Hearing.....................................................................................................................................a-5
Pacemaker and Hearing Aid Operation ....................................................................................................................a-5
A Plasma Arc Can Damage Frozen Pipes ................................................................................................................a-5
Additional Safety Information....................................................................................................................................a-5