Hypertherm Powermax 65 Service Manual

TroubleshooTing and sysTem TesTs
powermax 65/85 Service Manual 5-25
Fault
code
Description
(System test number)
Power
LED
Fault
LED
Fault
icon
Solutions
0-30-0 Torch stuck open (Test 6)
The nozzle and electrode are
not touching after a start is
received.
On On
• If incorrect consumables are installed or
the consumables became loose or were
removed while the power supply is ON, turn
OFF the power supply, correct the problem
and then turn ON the power supply to clear
this fault.
• Inspect the torch for signs of wet or oily air.
• Inspect the torch for any signs of damage or
pitting on the electrode contact surface.
• If the consumables appear to be installed
correctly, the torch may be damaged. Test
with a known working torch.
• For a 0-30-1 fault code, place the unit in gas
test mode (refer to page 5-21 Displaying
the service screen). Enter “manual mode”,
move to “G” (gas), and use the adjustment
knob to toggle to “1” (gas test mode).
Ensure that only the dump valve light is on
during the gas test. Toggle back to “0” and
exit “manual mode.” Replace the regulator if
necessary.
• If the problem persists, contact your
Hypertherm distributor or authorized repair
facility.
0-30-1 Torch stuck closed (Test 6)
• The nozzle and electrode
will not separate after a
start is received.
• The regulator may not be
functioning properly.
0-40-0 PFC/Boost IGBT module
under temperature (Test 4)
On On
For an over-temperature fault, leave the
machine powered ON and confirm that the fan
is operating (Test 11). Ensure adequate air
flow around the unit.
Ensure the cover is placed with the air fins on
the fan side of the power supply.
If the duty cycle has been exceeded, let the
unit cool and work within the duty cycle limits
listed in the Operation section.
For an under-temperature (<-22°F or -30°C)
fault, move the unit to a warmer location.
The inverter temperature sensor is a thermistor
mounted on the heat sink beside the inverter
IGBT module. Its room temperature resistance
is about 10kΩ.
0-40-1 PFC/Boost IGBT module
over temperature (Test 4)
0-40-2 Inverter IGBT module under
temperature (Test 4)
0-40-3 Inverter IGBT module over
temperature (Test 4)

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