Hypertherm Powermax 65 Service Manual

TroubleshooTing and sysTem TesTs
5-34 powermax 65/85 Service Manual
Problem Meaning Causes Solution
When pressing the torch
trigger or start switch,
gas flows from the torch,
but the torch does not
fire or fires for only a
short duration.
Worn or damaged
consumables.
• Overused or
improperly
installed
consumables.
• Replace consumables.
Damaged torch or
lead assembly.
• Electrode is not
moving properly
in the torch or
the torch lead is
damaged.
• Perform Test 6.
Insufficient or
excessive gas flow.
• Gas pressure is
too high or too
low, or the gas
supply is leaking
or restricted.
• Ensure the inlet pressure is 85 to 135
PSI (5.9 to 9.3 bar).
• Repair air leaks or restrictions.
• Manually adjust the gas pressure on the
power supply.
Poor air quality.
• Air filter element
is dirty.
• Moisture or
contaminants in
the gas supply
line.
• Replace the air filter element.
• Add appropriate filtration and purge the
lines with nitrogen to flush out oil and
moisture.
Insufficient input
power.
Undersized
electrical supply
installation:
• Breaker or fuse.
• Supply wire.
• Extension cord.
• Verify that the external electrical power
is installed according to Section 2,
Specifications.
Faulty inverter IGBT
• Faulty inverter
IGBT.
• Use an IGBT tester to check the inverter
IGBT.
Capacitor voltage
imbalance on the
power board.
• Faulty resistors
on the power
board (PCB3)
or faulty bulk
capacitor(s).
• Perform Tests 1, 2, or 3.
• If the voltage across the capacitors is
not balanced, replace the power board
(PCB3).

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