Hypertherm Powermax 125 Service Manual

Powermax125 Service Manual 808070 161
8 – Troubleshooting and System Tests
Test 8 – Torch cap switch
Symptom: Fault code 0-50 and the cap-sensor switch icon appear on the operator screen.
1. Confirm that the retaining cap is in place.
2. Remove the torch from the power supply and check the resistance between pin 5 and pin 7 in the torch lead plug.
a. If the resistance is very high, check for opens in the torch leads and cap-sensor switch.
b. If the resistance is approximately 0 Ω:
 Reconnect the torch.
 Measure for continuity between pin 1 and pin 2 at J17 on the power board.
 If there is no continuity, inspect and perform a resistance test on the torch disconnect.
c. If there is no problem with the leads or switch, test the circuit boards.
 Turn OFF the machine and disconnect the power.
 Put a jumper wire between J20 pins 1 and 2.
 Reconnect the power and turn on the machine.
 If the cap-sensor switch icon is not displayed, verify the DSP board by replacing it with a known
working board. If the DSP is not the problem, replace the power board.

Hypertherm Powermax 125 Specifications

General

Output Current	30-125 A
Input Power	15.2 kW
Open Circuit Voltage	300 VDC
Gas Supply	Clean, dry, oil-free air or nitrogen
Input Power Cable Length	10 ft (3 m)
Rated Output Current	125 A
Gas Type	Air or nitrogen
Cutting Capacity	1-1/4 inch (32 mm)
Pierce Capacity	1 inch (25 mm)
Input Voltage	200-600 V, 3-PH
Duty Cycle	100% @ 125 A
Certifications	CSA
Maximum Clean Cut Thickness	1-1/4 inch (32 mm)
Cooling Method	Fan-cooled
Torch Options	Hand