Hypertherm Powermax45 Service Manual - Manual (Page 9)

Table of ConTenTs
powermax
45 Service Manual iii
Pierce a workpiece ..........................................................................................................................................................................4-9
Gouge a workpiece .....................................................................................................................................................................4-10
Common hand-cutting faults .....................................................................................................................................................4-12
How to use the machine torch .............................................................................................................................................................4-12
Ensure the torch and table are set up correctly ....................................................................................................................4-12
Understand and optimize cut quality ........................................................................................................................................4-13
To pierce a workpiece using the machine torch ...................................................................................................................4-14
Common machine-cutting faults ...............................................................................................................................................4-15
SeCTIoN 5
TRoUbleSHooTINg ANd SySTeM TeSTS
Theory of operation ....................................................................................................................................................................................5-2
General ..............................................................................................................................................................................................5-2
200–240 V CSA and 230 V CE 1-phase power supply functional description..............................................................5-2
400 V CE 3-phase power supply functional description .......................................................................................................5-2
480 V CSA 3-phase power supply functional description ....................................................................................................5-3
Sequence of operation ...................................................................................................................................................................5-4
Troubleshooting preparation ...................................................................................................................................................................5-5
Test equipment ................................................................................................................................................................................5-5
Troubleshooting procedures and sequence .............................................................................................................................5-5
External inspection ..........................................................................................................................................................................5-6
Internal inspection ...........................................................................................................................................................................5-6
Initial resistance check ..............................................................................................................................................................................5-7
200–240 V CSA and 230 V CE power supply overview ................................................................................................................5-8
400 V CE power supply overview .........................................................................................................................................................5-9
480 V CSA power supply overview ...................................................................................................................................................5-10
Troubleshooting guide ...........................................................................................................................................................................5-11
Control Board LEDs ...............................................................................................................................................................................5-16
Use the control board Error and Reset LEDs to troubleshoot ...........................................................................................5-17
System tests.............................................................................................................................................................................................5-18
Test 1 – voltage input ..................................................................................................................................................................5-18
Test 2 – power board voltage checks .....................................................................................................................................5-19
Test 3 – VBUS and voltage balance .......................................................................................................................................5-20
Test 4 – solenoid valve ...............................................................................................................................................................5-24
Test 5 – torch stuck open (TSO) or torch stuck closed (TSC) ........................................................................................5-25
Test 6 – plasma start ...................................................................................................................................................................5-26
Test 7 – torch cap sensor ..........................................................................................................................................................5-27
Test 8 – fan ....................................................................................................................................................................................5-27
Test 9 – pressure transducer ....................................................................................................................................................5-28
Test 10 – power switch trip coil ...............................................................................................................................................5-28