Hypertherm Powermax 125 Service Manual

12 Powermax125 Service Manual 808070
Contents
IGBT device test using a non-Hypertherm tester ............................................................................................................... 122
Fault codes ................................................................................................................................................................................... 128
Important fault icons ........................................................................................................................................................... 128
Displaying the service screen .......................................................................................................................................... 128
Run a gas test ..................................................................................................................................................................... 130
Perform a cold restart ........................................................................................................................................................ 131
Fault codes and solutions ................................................................................................................................................. 131
Fault code format – 0-00-0 ...................................................................................................................................... 131
Fault code format – 0-nn-n ...................................................................................................................................... 132
Fault code format – 1-nn-n ...................................................................................................................................... 138
Fault code format – 2-nn-n ...................................................................................................................................... 138
Fault code format – 3-nn-n ...................................................................................................................................... 139
Torch-related faults – continuity check ................................................................................................................. 142
Troubleshooting guide ............................................................................................................................................................... 143
System tests ................................................................................................................................................................................ 149
Test 1 – Voltage input ....................................................................................................................................................... 150
Test 2 – DC power bus .................................................................................................................................................... 152
Resistance check ........................................................................................................................................................ 152
Voltage check .............................................................................................................................................................. 152
Test 3 – Output diodes ..................................................................................................................................................... 154
Test 4 – Inverter temperature sensor ............................................................................................................................. 154
For operational fault codes 0-40-2 and 0-40-3 or power board faults 2-10-0 and 2-10-1 ................... 155
Test 5 – Flyback circuit (DC minor voltages) ............................................................................................................... 156
Test 6 – Torch stuck open/torch stuck closed ............................................................................................................ 158
Test 7 – Start signal ........................................................................................................................................................... 160
Test 8 – Torch cap switch ................................................................................................................................................ 161
Test 9 – Electronic regulator ........................................................................................................................................... 162
Test 10 – Pressure sensor ............................................................................................................................................... 163
Test 11 – Fan ...................................................................................................................................................................... 164
Test 12 – AUX switch ....................................................................................................................................................... 164
9 Power Supply Component Replacement ........................................................................... 165
Installing a machine interface cable for raw arc voltage .................................................................................................... 166
Disconnect the power and gas supply .................................................................................................................................. 166
Replacing the gas filter element .............................................................................................................................................. 167
Replacing the work lead connector ....................................................................................................................................... 169
Installing the optional filter kit .................................................................................................................................................. 170
Replacing the power supply cover ......................................................................................................................................... 172
Replacing the component barrier ........................................................................................................................................... 173
Replacing the end panel bracket ............................................................................................................................................ 174

Hypertherm Powermax 125 Specifications

General

Brand	Hypertherm
Model	Powermax 125
Category	Welding System
Language	English