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10
Powermax30 XP Service Manual 808150 Revision 1
Contents
Control board LEDs ..................................................................................................................................................................... 69
Use the control board Error and Reset LEDs to troubleshoot ................................................................................... 70
Reset LED ...................................................................................................................................................................... 70
Error LED ........................................................................................................................................................................ 71
System tests .................................................................................................................................................................................. 71
Test 1 – voltage input .......................................................................................................................................................... 74
Test 2 – power board voltage checks ............................................................................................................................. 76
Test 3 – VBUS and voltage balance ................................................................................................................................ 78
Test 4 – solenoid valve ........................................................................................................................................................ 80
Test 5 – torch stuck open or torch stuck closed .......................................................................................................... 81
Test 6 – plasma start ........................................................................................................................................................... 82
Test 7 – torch cap-sensor .................................................................................................................................................. 84
Test 8 – fan ............................................................................................................................................................................ 85
Test 9 – pressure switch .................................................................................................................................................... 86
6
Power Supply Component Replacement ............................................................................. 87
Disconnect the power and gas supply .................................................................................................................................... 87
Replacing the power supply cover ........................................................................................................................................... 88
Replacing the component barrier ............................................................................................................................................. 90
Detaching and reattaching the front panel ............................................................................................................................. 92
Detaching and reattaching the rear panel .............................................................................................................................. 95
Replacing the power cord and strain relief ............................................................................................................................. 98
Replacing the power switch .................................................................................................................................................... 105
Replacing the control board .................................................................................................................................................... 107
Replacing the power board ...................................................................................................................................................... 109
Replacing the fan ........................................................................................................................................................................ 116
Replacing the drain hose, gas supply hoses, and 90° fitting ........................................................................................... 119
Replacing the wire group ......................................................................................................................................................... 123
Replacing the solenoid valve ................................................................................................................................................... 130
Replacing the torch lead and strain relief ............................................................................................................................. 133
Replacing the pressure switch ................................................................................................................................................ 139
Replacing the air filter/regulator and pressure switch assembly ..................................................................................... 141
Replacing the air inlet fittings .................................................................................................................................................. 146
Replacing the air filter bowl and air filter element ............................................................................................................... 148
Replacing the front panel .......................................................................................................................................................... 152
Replacing the rear panel ........................................................................................................................................................... 156
Replacing the base .................................................................................................................................................................... 160
Replacing the magnetics assembly ........................................................................................................................................ 162
Replacing the work lead and ground clamp ......................................................................................................................... 167
