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TroubleshooTing and sysTem TesTs
powermax
105
Service Manual 8-11
J27
WORK
LEAD
J26
RED
J18
ORG
J17
J32
J28
RED
Measure resistance from All models
Work lead (J27) to nozzle (black wire) 230 kΩ
Work lead (J27) to electrode (red wire) 9 kΩ
Electrode (red wire) to nozzle (black wire) 230 kΩ
Output to ground > 20 MΩ
If no problems were found during the visual inspection or the initial resistance check, and the power supply still does not
operate correctly, see the Troubleshooting guide.
Note: Troubleshooting guide later is this section provides most probable causes and solutions. Study the system
wiring diagram and understand the theory of operation before troubleshooting. Before purchasing any major
replacement component, verify the problem with Hypertherm Technical Service or the nearest Hypertherm
repair facility.
Black wires
Red wire J28
Work lead J27
- 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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