Hypertherm Powermax30 Service Manual - Manual (Page 40)

powermax30
Service Manual 3-1
Section 3
MAINTENANCE
In this section:
Controls and indicators .............................................................................................................................................3-2
Front controls and LEDs ..................................................................................................................................3-2
Rear controls....................................................................................................................................................3-2
Theory of operation...................................................................................................................................................3-3
General ............................................................................................................................................................3-3
Functional description ......................................................................................................................................3-3
Sequence of operation .....................................................................................................................................3-4
Troubleshooting preparation .....................................................................................................................................3-5
Test equipment.................................................................................................................................................3-5
Troubleshooting procedures and sequence .....................................................................................................3-5
External inspection...........................................................................................................................................3-5
Internal inspection ............................................................................................................................................3-6
Initial resistance check..............................................................................................................................................3-7
Power supply overview .............................................................................................................................................3-8
Troubleshooting guide ..............................................................................................................................................3-9
Control board LEDs ................................................................................................................................................3-12
Use the Error and Reset LEDs to troubleshoot..............................................................................................3-13
System tests ...........................................................................................................................................................3-14
Test 1 – voltage input .....................................................................................................................................3-15
Test 2 – power board voltage checks.............................................................................................................3-16
Test 3 – VBUS and voltage balance...............................................................................................................3-17
Test 4 – solenoid valve...................................................................................................................................3-18
Test 5 – torch stuck open (TSO) ....................................................................................................................3-19
Test 6 – plasma start ......................................................................................................................................3-20
Test 7 – torch cap sensor ...............................................................................................................................3-20
Test 8 – fan.....................................................................................................................................................3-21
Test 9 – pressure switch.................................................................................................................................3-21
Component replacement ........................................................................................................................................3-22
Remove an endcap ........................................................................................................................................3-22
Replace the torch lead ...................................................................................................................................3-24
Replace the work lead....................................................................................................................................3-26
Replace the power cord (CSA) ......................................................................................................................3-27
Replace the power cord (CE).........................................................................................................................3-28
Replace the fan ..............................................................................................................................................3-30
Replace the air filter element .........................................................................................................................3-31
Replace the air filter/regulator ........................................................................................................................3-32
Replace the control board ..............................................................................................................................3-33
Replace the power board ...............................................................................................................................3-34
Replace the base ...........................................................................................................................................3-37