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powermax
105
Service Manual 8-1
Section 8
TROUBLESHOOTING AND SYSTEM TESTS
In this section:
Controls and indicators .........................................................................................................................................................................8-3
Theory of operation .................................................................................................................................................................................8-4
General ...........................................................................................................................................................................................8-4
200-600 V CSA 3-phase power supply functional description .......................................................................................8-4
230-400 V CE, 380 V CCC/230-400 V CE 3-phase power supply functional description ....................................8-5
400 V CE, 380 V CCC 3-phase power supply functional description ........................................................................... 8-5
Sequence of operation ................................................................................................................................................................8-6
Troubleshooting preparation ................................................................................................................................................................8-7
Test equipment .............................................................................................................................................................................8-7
Troubleshooting procedures and sequence ..........................................................................................................................8-7
External inspection .......................................................................................................................................................................8-9
Internal inspection ........................................................................................................................................................................8-9
Initial resistance check ...........................................................................................................................................................................8-9
Check the power switch ............................................................................................................................................................. 8-9
Hypertherm IGBT tester .......................................................................................................................................................... 8-12
Indicator LEDs and device tests ............................................................................................................................................ 8-12
IGBT test preparation ............................................................................................................................................................... 8-13
IGBT device test using the Hypertherm tester ................................................................................................................... 8-14
Troubleshoot the Hypertherm IGBT tester .......................................................................................................................... 8-14
Schematic for building an IGBT tester ................................................................................................................................. 8-15
IGBT device test using a non-Hypertherm tester .............................................................................................................. 8-16
200-600 V CSA power supply overview ....................................................................................................................................... 8-17
230-400 V CE, 380 V CCC/230-400 V CE power supply overview .................................................................................... 8-18
380 V CCC, 400 V CE power supply overview ........................................................................................................................... 8-19
- Plasma arc cutting systems 1
- Service Manual 3
- (P/N 807580) 3
- Introduction 5
- Installation and use 5
- Assessment of area 5
- Methods of reducing emissions 5
- Cutting cables 6
- Equipotential bonding 6
- Earthing of the workpiece 6
- Screening and shielding 6
- Attention 7
- WARRANTY 7
- W-2 Compliance Information 8
- Service Manual 10
- Section 1 19
- SPECIFICATIONS 19
- Safety information 20
- System description 20
- Where to find information 21
- Power supply dimensions 22
- SpecificationS 23
- Service Manual 1-5 23
- 1-6 powermax 24
- Service Manual 1-7 25
- 1-8 powermax 26
- Service Manual 1-9 27
- 1-10 powermax 28
- Symbols and markings 29
- Noise levels 29
- IEC symbols 30
- Service Manual 2-1 31
- Service Manual 2-3 33
- Service Manual 2-5 35
- Service Manual 2-7 37
- Service Manual 2-9 39
- Service Manual 2-11 41
- Service Manual 2-13 43
- Section 3 45
- BASIC SYSTEM OPERATIONS 45
- Basic system OperatiOns 47
- Service Manual 3-3 47
- Service Manual 3-5 49
- Service Manual 3-7 51
- Service Manual 3-9 53
- Turn ON the system 53
- Set the operating mode switch 53
- Service Manual 3-11 55
- Section 4 57
- HAND TORCH SETUP 57
- Hand torch components 59
- Connecting the torch lead 63
- Section 5 65
- HAND CUTTING 65
- Hand torch cutting hints 67
- Pierce a workpiece 69
- Hand Cutting 71
- Service Manual 5-7 71
- Gouge profile 71
- Section 6 73
- MACHINE TORCH SETUP 73
- Consumable life 75
- Service Manual 6-5 77
- Mount the torch 79
- Service Manual 6-11 83
- Service Manual 6-15 87
- Service Manual 6-17 89
- 105 A Shielded consumables 89
- Service Manual 6-19 91
- Service Manual 6-21 93
- 85 A Shielded consumables 93
- Service Manual 6-23 95
- Service Manual 6-25 97
- 65 A Shielded consumables 97
- Service Manual 6-27 99
- Service Manual 100
- Machine Torch SeTup 101
- Service Manual 6-29 101
- 45 A Shielded consumables 101
- Service Manual 6-31 103
- Service Manual 6-33 105
- consumables 105
- Service Manual 6-35 107
- FineCut (Stainless Steel) 107
- Service Manual 6-37 109
- Service Manual 6-39 111
- Service Manual 6-41 113
- Service Manual 6-43 115
- Service Manual 6-45 117
- Service Manual 6-47 119
- Service Manual 6-49 121
- Service Manual 6-51 123
- Service Manual 6-53 125
- Section 7 127
- MECHANIZED CUTTING 127
- Mechanized cutting 129
- Service Manual 7-3 129
- Service Manual 7-5 131
- Accessing raw arc voltage 133
- Service Manual 7-9 135
- Common machine-cutting faults 137
- Section 8 139
- Controls and indicators 141
- Service Manual 8-5 143
- Troubleshooting preparation 145
- Initial resistance check 147
- Service Manual 8-11 149
- Service Manual 8-13 151
- IGBT test preparation 151
- Service Manual 8-15 153
- Service Manual 8-17 155
- Service Manual 8-19 157
- Service Manual 8-21 159
- Fault codes 161
- Service Manual 8-25 163
- Fault codes and solutions 163
- Service Manual 8-27 165
- Service Manual 8-29 167
- Service Manual 8-31 169
- Service Manual 8-33 171
- Service Manual 8-35 173
- Service Manual 8-37 175
- Service Manual 8-39 177
- Service Manual 8-41 179
- Service Manual 8-43 181
- Test 1 – Voltage input 181
- Service Manual 8-47 185
- J19J20J21J22 186
- Service Manual 8-49 187
- Service Manual 8-51 189
- Install a test 191
- Service Manual 8-55 193
- Test 8 – Torch cap switch 193
- Service Manual 8-57 195
- Test 10 – Pressure sensor 195
- Service Manual 8-59 197
- Test 12 – AUX switch 197
- Section 9 199
- 9-2 powermax 200
- Replacing the power cord 203
- Replacing the power switch 204
- Replacing the control board 204
- Replacing the DSP board 204
- Replacing the power board 205
- Replacing the pilot arc IGBT 206
- Replacing the PFC IGBT module 207
- Replacing the damper resistor 208
- Replacing the thermal sensor 208
- Replacing the fan shroud 208
- Replacing the fan 209
- Replacing the pressure switch 209
- Replacing the solenoid valve 210
- Replacing the gas tubing 210
- Replacing the bulk capacitors 211
- Replacing the output inductor 212
- Replacing the transformer 212
- Replacing the PFC inductor 212
- Replacing the front end panel 213
- Replacing the rear end panel 213
- Power switch 214
- Gas supply 214
- Service Manual 9-17 215
- 9-18 powermax 216
- Service Manual 9-19 217
- 9-20 powermax 218
- Remove the component barrier 219
- Remove the power supply cover 219
- Remove the end panel bracket 220
- Service Manual 9-23 221
- 9-24 powermax 222
- Set the voltage divider board 224
- Service Manual 9-27 225
- 9-28 powermax 226
- Service Manual 9-29 227
- 9-30 powermax 228
- Service Manual 9-31 229
- Disconnect the gas tube 230
- Connect the gas tube 230
- Remove the power cord 231
- 9-34 powermax 232
- Service Manual 9-35 233
- Replace the power switch 234
- Service Manual 9-37 235
- 9-38 powermax 236
- Replace the control board 237
- Remove the DSP board 238
- Remove the power board 239
- 9-42 powermax 240
- Service Manual 9-43 241
- 9-44 powermax 242
- Service Manual 9-45 243
- Replace the pilot arc IGBT 244
- Replace the PFC IGBT module 245
- Replace the damper resistor 246
- Replace the snubber resistor 246
- Replace the thermal sensor 247
- Install the power board 251
- Install the DSP board 252
- Remove the fan shroud 253
- Install the fan shroud 253
- Replace the fan 254
- Service Manual 9-57 255
- Replace the pressure switch 256
- Service Manual 9-59 257
- 9-60 powermax 258
- Replace the solenoid valve 259
- 9-62 powermax 260
- Replace the gas tubing 261
- Replace the bulk capacitors 262
- Service Manual 9-65 263
- 9-66 powermax 264
- Service Manual 9-67 265
- 9-68 powermax 266
- Service Manual 9-69 267
- Replace the output inductor 268
- Service Manual 9-71 269
- 9-72 powermax 270
- Service Manual 9-73 271
- Replace the transformer 272
- Service Manual 9-75 273
- 9-76 powermax 274
- Replace the PFC inductor 275
- 9-78 powermax 276
- Service Manual 9-79 277
- Replace the front end panel 278
- Service Manual 9-81 279
- 9-82 powermax 280
- Service Manual 9-83 281
- Replace the rear end panel 282
- Service Manual 9-85 283
- 9-86 powermax 284
- Service Manual 9-87 285
- Install the power cord 286
- Service Manual 9-89 287
- Install the end panel bracket 288
- Install the component barrier 289
- 9-92 powermax 290
- Section 10 291
- TORCH COMPONENT REPLACEMENT 291
- Torch componenT replacemenT 293
- Service Manual 10-3 293
- 293
- 293
- 293
- Service Manual 10-5 295
- 295
- 295
- 295
- Torch componenT replacemenT 296
- 10-6 powermax 296
- 296
- Service Manual 10-7 297
- WARNING 297
- 297
- Remove the left handle 298
- Install the left handle 298
- Remove the trigger and spring 299
- Remove the start switch 300
- Replace the start switch 300
- Remove the right handle 301
- Replace the cap-sensor switch 301
- Replace the torch body 302
- Replace the torch lead 303
- Install the right handle 304
- Service Manual 10-15 305
- Remove the mounting sleeve 306
- Remove the cap-sensor switch 306
- Remove the torch body 306
- Separate the torch components 306
- Service Manual 10-17 307
- Replace the gear rack 308
- Replace the coupler 308
- Install the torch body 309
- Install the cap-sensor switch 309
- Install the mounting sleeve 309
- Connect the torch components 309
- 10-20 powermax 310
- Section 11 311
- Power supply parts 312
- 11-4 powermax 314
- Service Manual 11-9 319
- Heat sink assembly 320
- Hand torch consumables 325
- Service Manual 11-17 327
- Service Manual 11-19 329
- Machine torch consumables 330
- Accessory parts 331
- Powermax105 labels 331
- Safety-critical parts 332
- Item Part number Description 333
- Recommended spare parts 336
- Service Manual 11-27 337
- 11-28 powermax 338
- Section 12 339
- WIRING DIAGRAMS 339
- Wiring Diagrams 340
- 12-2 powermax 340
- Powermax Generic Timing Chart 341
- PMX105 CSA 342
- PMX105 230-400V CE 342
- PMX105 380V CCC/230-400V CE 342
- PMX105 380V CCC 343
- PMX105 400V CE 343
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