Hypertherm Powermax 30 - Maintenance Procedures

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