Hypertherm Powermax 65 Service Manual

powermax 65/85 Service Manual 5-1
Section 5
TROUBLESHOOTING AND SYSTEM TESTS
In this section:
Controls and indicators .........................................................................................................................................................................5-3
Theory of operation .................................................................................................................................................................................5-4
General ...........................................................................................................................................................................................5-4
200 – 600 V CSA 1- or 3-phase power supply functional description ..........................................................................5-4
380/400 V CE 3-phase power supply functional description ...........................................................................................5-5
Sequence of operation ................................................................................................................................................................5-6
Troubleshooting preparation ................................................................................................................................................................5-7
Test equipment .............................................................................................................................................................................5-7
Troubleshooting procedures and sequence ..........................................................................................................................5-7
External inspection .......................................................................................................................................................................5-9
Internal inspection ........................................................................................................................................................................5-9
Initial resistance check ...........................................................................................................................................................................5-9
Check the power switch ............................................................................................................................................................. 5-9
Hypertherm IGBT tester .......................................................................................................................................................... 5-12
Indicator LEDs and device tests ............................................................................................................................................ 5-12
IGBT test preparation ............................................................................................................................................................... 5-13
IGBT device test using the Hypertherm tester ................................................................................................................... 5-14
Troubleshoot the Hypertherm IGBT tester .......................................................................................................................... 5-14
Schematic for building an IGBT tester ................................................................................................................................. 5-15
IGBT device test using a non-Hypertherm tester .............................................................................................................. 5-16
200 – 600 V CSA power supply overview .................................................................................................................................... 5-17
380/400 V CE power supply overview .......................................................................................................................................... 5-18
200 – 600 V CSA power supply overview (power board removed) ....................................................................................... 5-19
380/400 V CE power supply overview (power board removed) .............................................................................................. 5-20

Hypertherm Powermax 65 Specifications

General

Open Circuit Voltage (OCV)	300 VDC
Gas Supply	Clean, dry, oil-free air or nitrogen
Maximum Cut Capacity (Mild Steel)	1" (25 mm)
Input Voltage	200-600 V, 1/3-PH, 50/60 Hz
Output Current	20 – 65 A
Duty Cycle	50% @ 65 A
Recommended Gas Inlet Flow Rate/Pressure	6.7 scfm @ 85 psi
Torch Lead Length	25 ft (7.6 m)
Maximum Cut Capacity (Aluminum)	5/8" (16 mm)
Severance Cut Capacity (Mild Steel)	1-1/4" (32 mm)
Maximum Severance Thickness	1-1/4 in (32 mm)
Gas Type	Air/Nitrogen
Torch Options	Hand Torch, Mechanized Torch