Hypertherm SmartSYNC 059719, Procedure Manual

Page 1: ...SmartSYNC Torches Service Parts and Procedures Guide 810460 REVISION 0 ENGLISH ...

Page 2: ...pertherm Inc and may be registered in the United States and other countries All other trademarks are the property of their respective holders Environmental stewardship is one of Hypertherm s core values www hypertherm com environment 2022 Hypertherm Inc 100 Associate owned ...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com SmartSYNC Torches Service Parts and Procedures Guide 810460 REVISION 0 ENGLISH Original instructions August 2022 ...

Page 4: ... 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 0 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service technicalservice emeia hypertherm com Technical Service Hypertherm Shanghai Trading Co Ltd B301 495 ShangZhong Road Shanghai 200231 PR China 86 21 80231122 Tel 86 21 80231120 Fax 86 21 80231128 Tel Technical Service techsupport...

Page 5: ... vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden käsikirja 80943C ja radiotaajuusvaroitusten käsikirja 80945C Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa Sähköiset kopiot ovat myös verkkosivustollamme Monet käyttöoppaat ovat myös saatavissa useilla kielillä www hypertherm com docs FR FRANÇAIS FRENCH AVERTISSEMENT Avant d utiliser tout équipement ...

Page 6: ...ránke www hypertherm com docs SL SLOVENŠČINA SLOVENIAN OPOZORILO Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka v Priročniku za varnost in skladnost 80669C v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom 80943C in v Priročniku Opozorilo o radijskih frekvencah 80945C Izvodi priročnikov so lahko izdelku priloženi v elektron...

Page 7: ...gth machine torch parts 20 Full length machine torch assemblies 20 Full length machine torch exterior parts 21 Full length machine torch body and O ring 22 Full length machine torch switches and PCB 23 Full length machine torch lead and terminal screw 24 Mini machine and 180 robotic torch parts 25 Mini machine and 180 robotic torch assemblies 25 Mini machine and 180 robotic torch exterior parts 26...

Page 8: ...ndle or shell 41 Get a photograph of the torch 41 4 Hand Torch Part Replacement Procedures 43 Disassemble the hand torch 44 Before you begin 44 Remove the components from the torch handle 44 Disconnect the torch components 46 Assemble the hand torch 49 Connect the torch components 49 Install the torch components into the torch handle 52 Do a check of the component positions and wire routing 58 Ins...

Page 9: ...machine or robotic torch 82 Connect the torch components 82 Install the torch components into the torch shell 86 Do a check of the component positions and wire routing 89 Install the left side of the torch shell 91 7 Torch Lead Replacement Procedures 93 Replace the torch quick disconnect shell 93 Before you begin 93 Remove the torch quick disconnect shell 93 Install the torch quick disconnect shel...

Page 10: ...10 810460 Service Parts and Procedures SmartSYNC ...

Page 11: ...ollowing 1 Get the serial number for your torch from the data plate that is on the torch 2 Contact your Hypertherm distributor or authorized repair facility 3 Contact the nearest Hypertherm office shown in the front of this manual For related information refer to the following documents Powermax65 85 105 SYNC Troubleshooting Guide 810430 Powermax65 85 SYNC Service Parts and Procedures Guide 810440...

Page 12: ...Before You Begin 1 12 810460 Service Parts and Procedures SmartSYNC ...

Page 13: ...5 85 105 SYNC Parts Guide 810490 To find part numbers with kit contents refer to the following Hand torch parts on page 14 Full length machine torch parts on page 20 Mini machine and 180 robotic torch parts on page 25 90 and 45 robotic torch parts on page 30 To see a list of parts in order by part number refer to Find torch replacement parts by part number on page 35 NOTICE Genuine Hypertherm part...

Page 14: ...assembly with 15 m 50 foot lead 1 059728 75 hand torch assembly with 23 m 75 foot lead 2 059723 15 hand torch assembly with 7 6 m 25 foot lead 2 059724 15 hand torch assembly with 15 m 50 foot lead 2 059725 15 hand torch assembly with 23 m 75 foot lead The torch assembly does not include a cartridge For a full list of the cutting and gouging cartridges available refer to the Powermax65 85 105 SYNC...

Page 15: ...torch 101452 Handle for 15 hand torch 075714 Screws for torch handle 7 3 428863 Kit Quick disconnect shell shell with button does not include torch lead or connector 420565 Shell for torch quick disconnect 220681 Latch with red button 127197 Lever for latch 075714 Screws for shell 4 4 428148 Kit Screws for torch handle or quick disconnect shell 075714 Screws for torch handle or quick disconnect sh...

Page 16: ...orch lock slider for 75 or 15 hand torch 229846 Torch lock slider for 75 or 15 hand torch with yellow and green label 3 428156 Kit Trigger 002554 Trigger 027254 Spring for trigger 005684 Start switch 075714 Screws for torch handle 7 4 428182 Kit Spring for trigger 027254 Spring for trigger 5 Can also be ordered separately as kit 428182 quantity 5 Can also be ordered separately as kit 428958 quanti...

Page 17: ...rew 1 4 inch for pilot arc wire 075714 Screws for torch handle 7 027055 Silicone lubricant 7 4 ml 0 25 fl oz 330103 Thread locker 0 5 ml 0 017 fl oz 4 428857 Kit Body for 15 hand torch 420630 Main body replacement for 15 hand torch 075903 Terminal screw 1 4 inch for pilot arc wire 075714 Screws for torch handle 7 027055 Silicone lubricant 7 4 ml 0 25 fl oz 330103 Thread locker 0 5 ml 0 017 fl oz C...

Page 18: ...6 m 25 foot Kit Lead for hand torch 15 m 50 foot Kit Lead for hand torch 23 m 75 foot 229849 Lead for kit 428852 7 6 m 25 foot 229850 Lead for kit 428853 15 m 50 foot 229851 Lead for kit 428854 23 m 75 foot 210735 Data plate SmartSYNC torch not shown 210729 Label SmartSYNC torch lead not shown 075903 Terminal screw 1 4 inch for pilot arc wire 330103 Thread locker 0 5 ml 0 017 fl oz Can also be ord...

Page 19: ...art switch for hand torch 2 428869 Kit Radio frequency RF torch PCB for hand torch 141463 RF torch PCB for hand torch 3 428877 Kit Clip for RF wires 104912 Clip for RF wires 2 4 428865 Kit Cap sensor switch for 75 hand torch 005710 Cap sensor switch for 75 hand torch 5 428864 Kit Cap sensor switch for 15 hand torch 005722 Cap sensor switch for 15 hand torch 3 4 2 1 3 5 2 1 1 2 3 4 5 ...

Page 20: ...sembly with 7 6 m 25 foot lead 1 059720 Full length machine torch assembly with 10 7 m 35 foot lead 1 059721 Full length machine torch assembly with 15 m 50 foot lead 1 059722 Full length machine torch assembly with 23 m 75 foot lead The torch assembly does not include a cartridge For a full list of the cutting and gouging cartridges available refer to the Powermax65 85 105 SYNC Parts Guide 810490...

Page 21: ...t shell shell with button does not include torch lead or connector 420565 Shell for torch quick disconnect 220681 Latch with red button 127197 Lever for latch 075714 Screws for shell 4 3 428703 Kit Removable gear rack with screws 420504 Gear rack for full length machine torch 075418 Screws for gear rack 2 4 428148 Kit Screws for torch handle or quick disconnect shell 075714 Screws for torch handle...

Page 22: ...8021 O ring for any SmartSYNC torch 5 3 428859 Kit Body for full length machine torch 420544 Main body replacement for full length machine torch 075903 Terminal screw 1 4 inch for pilot arc wire 075714 Screws for torch handle 7 027055 Silicone lubricant 7 4 ml 0 25 fl oz Can also be ordered separately as part number 075903 quantity 1 Can also be ordered separately as kit 428148 quantity 7 Can also...

Page 23: ...PCB for full length mini machine or robotic torch 141466 RF torch PCB for full length mini machine or robotic torch 3 428868 Kit Switch assembly for torch lock slider for full length machine torch 005712 Switch assembly for torch lock slider for full length machine torch 4 428872 Kit Torch lock slider for full length machine torch 229848 Torch lock slider for full length machine torch with yellow ...

Page 24: ...ull length machine torch 10 7 m 35 foot Kit Lead for full length machine torch 15 m 50 foot Kit Lead for full length machine torch 23 m 75 foot 229853 Lead for kit 428848 7 6 m 25 foot 229854 Lead for kit 428849 10 7 m 35 foot 229855 Lead for kit 428850 15 m 50 foot 229856 Lead for kit 428851 23 m 75 foot 210735 Data plate SmartSYNC torch not shown 210729 Label SmartSYNC torch lead not shown 07590...

Page 25: ... Mini machine and 180 robotic torch assembly with 4 6 m 15 foot lead 1 059734 Mini machine and 180 robotic torch assembly with 7 6 m 25 foot lead 1 059735 Mini machine and 180 robotic torch assembly with 15 m 50 foot lead The torch assembly does not include a cartridge For a full list of the cutting and gouging cartridges available refer to the Powermax65 85 105 SYNC Parts Guide 810490 1 ...

Page 26: ...mini machine and180 robotic torch 075714 Screws for shell 5 2 428863 Kit Quick disconnect shell shell with button does not include torch lead or connector 420565 Shell for torch quick disconnect 220681 Latch with red button 127197 Lever for latch 075714 Screws for shell 4 3 428148 Kit Screws for torch shell 075714 Screws for torch handle or quick disconnect shell 7 Can also be ordered separately a...

Page 27: ...d robotic torch 4 6 m 15 foot Kit Lead for mini machine and robotic torch 7 6 m 25 foot Kit Lead for mini machine and robotic torch 15 m 50 foot 229966 Lead for kit 428901 4 6 m 15 foot 229967 Lead for kit 428900 7 6 m 25 foot 229969 Lead for kit 428903 15 m 50 foot 210735 Data plate SmartSYNC torch not shown 210729 Label SmartSYNC torch lead not shown 075903 Terminal screw 1 4 inch for pilot arc ...

Page 28: ...tch for mini machine and180 robotic torch 2 428870 Kit RF torch PCB for full length mini machine or robotic torch 141466 RF torch PCB for full length mini machine or robotic torch 3 428899 Kit Jumper wire for RF torch PCB for mini machine or robotic torch 005724 Jumper wire for RF torch PCB for mini machine or robotic torch 4 428877 Kit Clip for RF wires 104912 Clip for RF wires 2 Does not include...

Page 29: ...for any SmartSYNC torch 5 3 428860 Kit Body for mini machine and180 robotic torch 420754 Main body replacement for mini machine and180 robotic torch 075903 Terminal screw 1 4 inch for pilot arc wire 075714 Screws for torch handle 5 027055 Silicone lubricant 7 4 ml 0 25 fl oz Can also be ordered separately as part number 075903 quantity 1 Can also be ordered separately as kit 428148 quantity 7 Can ...

Page 30: ...orch assembly with 15 m 50 foot lead 1 059767 90 robotic torch assembly with 23 m 75 foot lead 2 059729 45 robotic torch assembly with 7 6 m 25 foot lead 2 059730 45 robotic torch assembly with 15 m 50 foot lead 2 059766 45 robotic torch assembly with 23 m 75 foot lead The torch assembly does not include a cartridge For a full list of the cutting and gouging cartridges available refer to the Power...

Page 31: ... for 45 robotic torch 101480 Shell for 45 robotic torch 075714 Screws for shell 5 3 428863 Kit Quick disconnect shell shell with button does not include torch lead or connector 420565 Shell for torch quick disconnect 220681 Latch with red button 127197 Lever for latch 075714 Screws for shell 4 4 428148 Kit Screws for torch shell 075714 Screws for torch handle or quick disconnect shell 7 Can also b...

Page 32: ...tic torch 7 6 m 25 foot Kit Lead for mini machine and robotic torch 15 m 50 foot Kit Lead for mini machine and robotic torch 23 m 75 foot 229967 Lead for kit 428900 7 6 m 25 foot 229969 Lead for kit 428903 15 m 50 foot 229970 Lead for kit 428904 23 m 75 foot 210735 Data plate SmartSYNC torch not shown 210729 Label SmartSYNC torch lead not shown 075903 Terminal screw 1 4 inch for pilot arc wire Can...

Page 33: ...ini machine or robotic torch 2 428870 Kit Torch RF PCB for full length mini machine or robotic torch 141466 RF torch PCB for full length mini machine or robotic torch 3 428899 Kit Jumper wire for RF torch PCB for mini machine or robotic torch 005724 Jumper wire for RF torch PCB for mini machine or robotic torch 4 428877 Kit Clip for RF wires 104912 Clip for RF wires 2 Does not include RF torch PCB...

Page 34: ...r 90 robotic torch 075903 Terminal screw 1 4 inch for pilot arc wire 075714 Screws for torch handle 5 027055 Silicone lubricant 7 4 ml 0 25 fl oz 4 428861 Kit Body for 45 robotic torch 420755 Main body replacement for 45 robotic torch 075903 Terminal screw 1 4 inch for pilot arc wire 075714 Screws for torch handle 5 027055 Silicone lubricant 7 4 ml 0 25 fl oz Can also be ordered separately as part...

Page 35: ...Page 059719 20 059720 20 059721 20 059722 20 059723 14 059724 14 059725 14 059726 14 059727 14 059728 14 059729 30 059730 30 059731 30 059732 30 059733 25 059734 25 059735 25 059766 30 059767 30 075903 18 24 27 32 428148 15 21 26 31 428156 16 428182 16 428703 21 428848 24 428849 24 428850 24 428851 24 428852 18 428853 18 428854 18 428855 15 428856 15 428857 17 428858 17 428859 22 428860 29 ...

Page 36: ...21 26 31 428864 19 428865 19 428866 23 428867 28 33 428868 23 428869 19 428870 23 28 33 428871 16 428872 23 428873 16 428874 21 428877 19 23 28 33 428896 26 428897 31 428898 31 428899 28 33 428900 27 32 428901 27 428903 27 32 428904 32 428950 17 22 29 34 428958 19 528066 17 22 29 34 ...

Page 37: ... of the following If you already have the kit continue with this section If you need to order the kit refer to Service Parts on page 13 Get the tools Assorted TORX screwdrivers Blade screwdriver Clamp Grounded wrist strap or similar grounding accessory Anti static container to store PCB Eye protection 1 4 inch 3 8 inch 1 2 inch and 5 8 inch wrenches for torch body or torch lead replacement only ...

Page 38: ... get a serious electric shock if electric power is not disconnected Electric shock can seriously injure or kill you All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 80669C for more safety information CAUTION Wear eye protection The trigger spring can eject from the right side of the torc...

Page 39: ...t the power switch on the plasma power supply to OFF O 3 Disconnect the power cord from the power source 4 Disconnect the gas supply Remove the Hypertherm cartridge Turn the cartridge counter clockwise to remove the cartridge 1 2 3 4 NOTICE To prevent damage to the cap sensor switch always remove the cartridge before you start any replacement procedure ...

Page 40: ... torch handle is the side with the screws 2 Put a clamp on the torch lead to hold the torch in position Put the clamp 150 mm 300 mm 6 inches 12 inches from the torch handle or shell Figure 1 75 hand torch with clamp This figure shows a 75 hand torch but the procedure is the same for all torches Figure 2 Full length machine torch with clamp This figure shows a full length machine torch but the proc...

Page 41: ... torch handle 2 Lift the left side of the torch handle away from the torch For a hand torch do not let the trigger spring eject from the torch handle 3 Remove the left side of the torch handle Get a photograph of the torch If possible get a photograph of the torch components in their correct positions You can use the photograph as a reference as you replace parts ...

Page 42: ...Prepare to Do the Part Replacement 3 42 810460 Service Parts and Procedures SmartSYNC ...

Page 43: ... example shows a 15 torch The components are the same for the 75 torch 75 torch 7 8 9 1 2 3 4 5 6 9 10 11 1 Amperage adjustment control 2 Trigger and trigger spring 3 Torch lead 4 Torch body 5 Torch lock slider 6 Start switch 7 Radio frequency RF wire and clip 8 RF torch PCB 9 Cap sensor switch 10 Pilot terminal screw 11 Gas fitting ...

Page 44: ...e the torch Only remove and disconnect the components and wires that you must for each replacement part Before you begin Complete the procedures in Prepare to Do the Part Replacement on page 37 1 Disconnect the power from the cutting system on page 39 2 Remove the Hypertherm cartridge on page 39 3 Put a clamp on the torch lead on page 40 4 Remove the left side of the torch handle or shell on page ...

Page 45: ...trigger spring eject from the torch handle 3 Carefully lift the torch lead body PCB and attached wires from the right side of the torch handle Use a screwdriver as a lever under the torch body to help you remove the torch body Do not bend the gas tube Do not pinch wires between the screwdriver and the torch handle 4 Remove the torch lock slider 5 Lift the RF wire out of the RF wire routing post an...

Page 46: ...ts 8 Pull the cap sensor switch off of the cap sensor switch mounting stud Disconnect the torch components 1 Remove the wire connector from the start switch Push the plastic lever and pull the wire connector out of the start switch 2 Remove the 6 wire connector from the receptacle on the RF torch PCB Do not pull the wires Refer to Figure 4 on page 47 for location 75 hand torch 15 hand torch ...

Page 47: ...ce or push the wire into the receptacle before you pull it out Refer to Figure 4 on page 47 for location a Remove the blue and black cap sensor switch wires from the receptacle b Remove the 2 red RF wires from the receptacle Figure 4 RF torch PCB connections for hand torch 4 Put the RF torch PCB in an anti static container unless you are replacing the RF torch PCB 5 Remove the pilot terminal screw...

Page 48: ...commends that you use some heat to loosen the gas fitting Do not overheat the torch wires 5 8 inch 1 2 inch NOTICE To prevent damage to the torch always use 2 wrenches to loosen or tighten the gas fitting NOTICE Do not bend the gas tube If you bend the gas tube you will not be able to install the torch body in the torch handle again because it will not fit correctly NOTICE To prevent damage to the...

Page 49: ...essary to fully disassemble the torch to the do the part replacement procedure Do only the steps that are applicable Connect the torch components 1 Apply a small quantity of thread locker to the first 2 or 3 threads of the gas fitting on the torch body Do not get thread locker on the conical surface of the fitting 2 Attach the torch body to the torch lead as follows a Tighten the gas fitting with ...

Page 50: ...to 6 78 N m 60 lbf in Do not tighten too much Make sure that the torch body and torch lead stay aligned 1 2 1 1 Flat sides of the torch body 2 White wires 5 8 inch 1 2 inch NOTICE To prevent damage to the torch always use 2 wrenches to loosen or tighten the gas fitting NOTICE Do not bend the gas tube If you bend the gas tube you will not be able to install the torch body in the torch handle again ...

Page 51: ...en to 1 13 N m 10 lbf in 4 Install the wires into the 2 pin receptacles on the RF torch PCB Refer to Figure 5 on page 51 for location a Push both wires of the cap sensor switch into the 2 pin receptacle at the same time b Push both red RF wires into the 2 pin receptacle at the same time 5 Install the 6 wire connector into the receptacle on the RF torch PCB Refer to Figure 5 on page 51 for location...

Page 52: ...ear a click Install the torch components into the torch handle 1 Put the cap sensor switch onto the cap sensor mounting stud in the right side of the torch handle 75 hand torch 15 hand torch NOTICE Keep the cap sensor switch flat in relation to the torch handle especially with the 15 torch The fit is tight and you can break the cap sensor switch if you use force ...

Page 53: ...dures 810460 53 2 Push the metal lever against the start switch and then push the start switch onto the mounting studs in the torch handle 3 Align the RF torch PCB with the PCB mounting posts in the right side of the torch handle and push the PCB loosely into the torch handle ...

Page 54: ...lock slider switch on the RF torch PCB is in the lock position 6 Put the torch lock slider on the torch lock slider switch with the yellow lock X label pointing to the torch body Make sure that the torch lock slider switch aligns with the recess in the bottom of the torch lock slider 7 Hold the torch lock slider in position and push the RF torch PCB fully into the torch handle 1 2 1 Pilot arc wire...

Page 55: ... body fully into the torch handle 11 Push the torch lead fully into the torch handle Push the gas hose fitting flange onto the support in the handle Align the torch lead strain relief with the recess in the handle and push the strain relief into position 12 Push the RF wire clip onto the torch body Make sure that the RF wire clip points up and that the prong of the RF wire clip is between the 2 mo...

Page 56: ...r spring on the mounting stud in the trigger 15 Fully compress the trigger spring Keep the trigger spring compressed as you push the trigger assembly into the torch handle Do not let the trigger spring eject from the torch handle 1 2 3 4 1 2 3 4 75 hand torch 15 hand torch 1 RF wire 2 RF wire clip 3 2 mounting studs 4 Routing post 1 2 3 1 Trigger spring 2 Mounting stud 3 Trigger assembly ...

Page 57: ...tabs of the amperage adjustment control into the 2 recesses in the torch handle b Align the switch recess on the amperage adjustment control with the amperage adjustment switch on the RF torch PCB Then put the amperage adjustment control into position on the RF torch PCB and in the handle 1 2 3 4 1 2 tabs 2 2 recesses 3 Switch recess 4 Amperage adjustment switch ...

Page 58: ...components are in the correct positions in the right side of the torch handle Compare the appearance of the torch components with the photograph you got on page 41 or with Figure 6 Figure 7 and Figure 8 Figure 6 75 hand torch components in correct positions Figure 7 15 hand torch components in correct positions 2 Make sure that the routing of all of the wires is correct as shown ...

Page 59: ...res 4 SmartSYNC Service Parts and Procedures 810460 59 Figure 8 Wire routing in correct positions 1 5 3 4 5 2 3 3 75 hand torch 15 hand torch 1 RF torch PCB wires 2 Cap sensor switch wires 3 Pilot arc wire 4 Start switch wires 5 RF wires ...

Page 60: ... the torch handle onto the torch at the torch body end of the torch Continue to push the left and right sides of the torch handle fully together 2 Make sure that no wires are pinched between the handles Make sure that the handles stay aligned NOTICE Do not cause damage to the wires inside the torch as you install the left side of the torch handle 1 2 1 Torch body end of the left torch handle 2 Tor...

Page 61: ... with the 7 screws Install the screws in the following sequence a The middle of the torch b The torch body end of the torch c The torch lead end of the torch 4 Tighten the screw in the middle of the torch handle again 5 Do a Check of the Torch Assembly on page 97 1 2 3 4 1 Middle of the torch 2 Torch body end of the torch 3 Torch lead of the torch 4 Middle of the torch ...

Page 62: ...Hand Torch Part Replacement Procedures 4 62 810460 Service Parts and Procedures SmartSYNC ...

Page 63: ...es Figure 9 Full length machine torch components 7 8 9 1 2 3 4 5 6 10 7 1 Torch lead 2 Torch body 3 Radio frequency RF torch PCB 4 Cap sensor switch 5 Torch lock slider 6 Switch assembly for torch lock slider 7 RF wires and clip 8 RF torch PCB wires and connector 9 Pilot terminal screw 10 Gas fitting ...

Page 64: ...cement part Before you begin Complete the procedures in Prepare to Do the Part Replacement on page 37 1 Disconnect the power from the cutting system on page 39 2 Remove the Hypertherm cartridge on page 39 3 Put a clamp on the torch lead on page 40 4 Remove the left side of the torch handle or shell on page 41 5 Get a photograph of the torch on page 41 Remove the components from the torch shell 1 C...

Page 65: ... and Procedures 810460 65 3 Lift the RF wire out of the RF wire routing post and the RF wire clip 4 Remove the RF wire clip 5 Pull the cap sensor switch off of the cap sensor switch mounting stud 6 Pull the switch assembly for the torch lock slider off of the switch mounting stud ...

Page 66: ...Figure 10 on page 66 for location a Remove the blue and black cap sensor switch wires from the receptacle b Remove the 2 red RF wires from the receptacle 3 One wire at a time remove the blue and black torch lock switch wires from the notch in the RF torch PCB Then pull the torch lock switch connector out of the receptacle Use your fingernails to pull out the connector Do not pull the wires Refer t...

Page 67: ...s and Procedures 810460 67 5 Remove the pilot terminal screw 6 Use a 1 4 inch wrench and a 3 8 inch wrench to disconnect the gas fitting Do not strip the gas fitting 3 8 inch 1 4 inch NOTICE To prevent damage to the torch always use 2 wrenches to loosen or tighten the gas fitting ...

Page 68: ... disassemble the torch to the do the part replacement procedure Do only the steps that are applicable Connect the torch components 1 Attach the torch body to the torch lead as follows a Tighten the gas fitting with your hand b Put the torch body and torch lead on a flat surface c Make sure that the flat sides of the torch body point up and that the RF wire is in the correct position as shown d Mak...

Page 69: ...o not tighten too much Do not strip the gas fitting 2 Install the pilot terminal screw as follows a Make sure that the routing of the pilot arc wire is correct b Align the ring terminal of the pilot arc wire with the slot in the torch body c Attach the pilot arc wire to the torch body with the pilot terminal screw Tighten to 1 13 N m 10 lbf in 3 8 inch 1 4 inch NOTICE To prevent damage to the torc...

Page 70: ...ch PCB Refer to Figure 11 on page 70 for location a Push both wires of the cap sensor switch into the 2 pin receptacle at the same time b Push both red RF wires into the 2 pin receptacle at the same time 5 Install the 6 wire connector into the receptacle on the RF torch PCB Refer to Figure 11 on page 70 for location Figure 11 RF torch PCB connections for full length machine torch 5 1 2 3 4 6 6 1 6...

Page 71: ...ght side of the torch shell Keep the cap sensor switch flat in relation to the torch shell 3 Align the RF torch PCB with the PCB mounting posts in the shell and push the PCB into the torch shell 4 Put the torch body and lead loosely into position in the shell 5 Put the torch lock switch wires into the shell Hold them down with your finger 6 Push the cap sensor wires into the shell 7 Push the pilot...

Page 72: ... shown 10 Push the torch body fully into the torch shell 11 Align the torch lead strain relief with the recess in the shell and push the strain relief into position 12 Install the torch lock slider into the torch shell with the yellow lock X label pointing to the torch body 2 3 4 1 1 RF torch PCB wires 2 Cap sensor wires 3 Pilot arc wire 4 Torch lock switch wires ...

Page 73: ...rtSYNC Service Parts and Procedures 810460 73 13 Push the RF wire clip onto the torch body Make sure that the RF wire clip points up 14 Put the RF wire through the routing post and into the slot in the RF wire clip 2 3 1 1 RF wire 2 RF wire clip 3 Routing post ...

Page 74: ...e right side of the torch shell Compare the appearance of the torch components with the photograph you got on page 41 or with Figure 12 Figure 13 Figure 12 Full length machine torch components in correct positions 2 Make sure that the routing of all of the wires is correct as shown Figure 13 Wire routing in correct positions 2 1 3 4 5 3 2 1 RF torch PCB wires 2 Cap sensor switch wires 3 Pilot arc ...

Page 75: ...ch at the torch body end of the torch Continue to push the left and right sides of the torch shell fully together 2 Make sure that no wires are pinched between the shells Make sure that the torch lock switch is aligned correctly and can move freely Make sure that the shells stay aligned NOTICE Do not cause damage to the wires inside the torch as you install the left side of the torch shell 1 2 1 T...

Page 76: ... a The middle of the torch b The torch body end of the torch c The torch lead end of the torch 4 Tighten the screw in the middle of the torch shell again 5 Make sure that the seam between the left and right sides of the torch shell is even Make sure that the torch lock slider moves freely 6 Do a Check of the Torch Assembly on page 97 1 2 3 4 1 Middle of the torch 2 Torch body end of the torch 3 To...

Page 77: ...c Torch Part Replacement Procedures Figure 14 Mini machine 180 robotic torch components 7 8 1 2 3 4 5 6 5 1 Torch lead 2 Torch body 3 Radio frequency RF torch PCB 4 Cap sensor switch 5 RF wires and clip 6 RF torch PCB wires and connector 7 Pilot terminal screw 8 Gas fitting ...

Page 78: ...nnect the components and wires that you must for each replacement part Before you begin Complete the procedures in Prepare to Do the Part Replacement on page 37 1 Disconnect the power from the cutting system on page 39 2 Remove the Hypertherm cartridge on page 39 3 Put a clamp on the torch lead on page 40 4 Remove the left side of the torch handle or shell on page 41 5 Get a photograph of the torc...

Page 79: ...e of the torch shell Use a screwdriver as a lever under the torch body to help you remove the torch body Do not bend the gas tube or torch lead Do not pinch wires between the screwdriver and the torch shell 2 Lift the RF wire out of the RF wire routing post and the RF wire clip 3 Remove the RF wire clip 4 Pull the cap sensor switch off of the cap sensor switch mounting stud 90 robotic torch 45 rob...

Page 80: ...be necessary to use some force or push the wire into the receptacle before you pull it out Refer to Figure 16 on page 80 for location a Remove the blue and black cap sensor switch wires from the receptacle b Remove the 2 red RF wires from the receptacle 3 Pull the jumper wire connector out of the receptacle Do not pull on the wire Refer to Figure 16 on page 80 for location Figure 16 RF torch PCB c...

Page 81: ... a 5 8 inch wrench to disconnect the gas fitting Do not strip the gas fitting 5 8 inch 1 2 inch 5 8 inch 1 2 inch NOTICE To prevent damage to the torch always use 2 wrenches to loosen or tighten the gas fitting NOTICE Do not bend the gas tube If you bend the gas tube you will not be able to install the torch body in the torch shell again because it will not fit correctly ...

Page 82: ...installation of all of the torch components into the right side of the torch shell and how to connect all of the wires It is not always necessary to fully disassemble the torch to the do the part replacement procedure Do only the steps that are applicable Connect the torch components 1 Attach the torch body to the torch lead a Tighten the gas fitting with your hand b Put the torch body and torch l...

Page 83: ...at sides of the torch body point up and that the RF wire is in the correct position as shown d Make sure that the white wires of the torch lead are on the opposite side from the RF torch PCB and that the RF torch PCB wires point to the PCB 1 3 1 1 3 1 4 4 2 2 1 Flat sides of the torch body 2 RF wire 3 White wires 4 RF torch PCB wires ...

Page 84: ... in Make sure that the torch body and torch lead stay aligned Do not tighten too much Do not strip the gas fitting 5 8 inch 1 2 inch 5 8 inch 1 2 inch NOTICE To prevent damage to the torch always use 2 wrenches to loosen or tighten the gas fitting NOTICE Do not bend the gas tube If you bend the gas tube you will not be able to install the torch body in the torch shell again because it will not fit...

Page 85: ...he receptacle Refer to Figure 17 on page 85 for location 4 Install the wires into the 2 pin receptacles on the RF torch PCB Refer to Figure 17 on page 85 for location a Push both wires of the cap sensor switch into the 2 pin receptacle at the same time b Push both red RF wires into the 2 pin receptacle at the same time 5 Install the 6 wire connector into the receptacle on the RF torch PCB Refer to...

Page 86: ...cap sensor switch flat in relation to the torch shell 2 Align the RF torch PCB with the PCB slot in the shell and push the PCB into the torch shell 3 Put the torch body and lead loosely into position in the shell 4 Push the cap sensor wires into the shell Make sure that the wires go around the stud 5 Push the pilot arc wire below the torch body and lead in the shell 6 Push the RF torch PCB wires i...

Page 87: ...hat the routing of all the wires is correct as shown 8 Push the torch body fully into the torch shell 9 Align the torch lead strain relief with the recess in the shell and push the strain relief into position 2 3 1 2 1 3 Mini machine 180 robotic torch 45 robotic torch 1 RF torch PCB wires 2 Cap sensor wires 3 Pilot arc wire ...

Page 88: ...SmartSYNC 10 Push the RF wire clip onto the torch body Make sure that the RF wire clip points up 11 Put the RF wire through the routing post and into the slot in the RF wire clip 2 3 1 Mini machine 180 robotic torch 45 robotic torch 90 robotic torch 2 3 1 2 3 1 1 RF wire 2 RF wire clip 3 Routing post ...

Page 89: ...tions in the right side of the torch shell Compare the appearance of the torch components with the photograph you got on page 41 or with Figure 18 Figure 19 and Figure 20 Figure 18 Mini machine and 180 robotic torch components in correct positions Figure 19 90 robotic torch components in correct positions Figure 20 45 robotic torch components in correct positions 2 Make sure that the routing of al...

Page 90: ...and Procedures SmartSYNC Figure 21 Wire routing in correct positions 1 4 2 3 2 3 Mini machine 180 robotic torch 45 robotic torch 90 robotic torch 2 3 2 3 Mini machine 180 robotic torch 45 robotic torch 4 4 1 2 3 1 RF torch PCB wires 2 Cap sensor switch wires 3 Pilot arc wire 4 RF wires ...

Page 91: ... of the torch shell fully together 2 Make sure that no wires are pinched between the shells Make sure that the shells are still aligned 3 Attach the left side of the torch shell to the right side of the torch shell with the 5 screws Install the screws in the following sequence a The middle of the torch b The torch body end of the torch c The torch lead end of the torch NOTICE Do not cause damage t...

Page 92: ...artSYNC 4 Tighten the screw in the middle of the torch shell again 5 Make sure that the seam between the left and right sides of the torch shell is even 6 Do a Check of the Torch Assembly on page 97 1 2 3 4 1 Middle of the torch 2 Torch body end of the torch 3 Lead end of the torch 4 Middle of the torch ...

Page 93: ... begin Complete the following procedures 1 Disconnect the power from the cutting system on page 39 2 Disconnect the torch page 95 3 Put a clamp on the torch lead on page 40 Remove the torch quick disconnect shell 1 Remove the 4 screws from the torch quick disconnect shell 2 Remove the torch quick disconnect shell The shell is 2 pieces ...

Page 94: ...e latch out of the torch quick disconnect housing 4 Remove the lever from the torch quick disconnect housing Install the torch quick disconnect shell 1 Put the latch with the red button into the torch quick disconnect housing 2 Hold the latch up and put the lever under the latch 3 Push the lever into the torch quick disconnect housing until it clicks into place 4 Put the 2 new torch quick disconne...

Page 95: ...h the torch quick disconnect shell 7 Connect the torch page 95 Replace the torch assembly with lead 1 Disconnect the power from the cutting system on page 39 2 Disconnect the torch Push the red button on the torch quick disconnect and pull the connector out of the receptacle on the front panel of the plasma power supply 3 Connect the torch Push the torch quick disconnect into the receptacle The co...

Page 96: ...Torch Lead Replacement Procedures 7 96 810460 Service Parts and Procedures SmartSYNC ...

Page 97: ...ng components to make sure that the torch is assembled correctly 1 Torch lock switch Unlock the torch You must hear a click 2 Trigger Pull the trigger You must hear a click 3 Cap sensor tab in torch body Use a blade screwdriver to push down the cap sensor tab inside the torch body You must hear a click 1 2 3 ...

Page 98: ...Do a Check of the Torch Assembly 8 98 810460 Service Parts and Procedures SmartSYNC ...