Hypertherm Powermax 65 Service Manual

TroubleshooTing and sysTem TesTs
powermax 65/85 Service Manual 5-49
Before continuing, turn OFF the power.
If the resistance value is always less than 100 Ω, remove the torch and recheck the resistance. If the value is still less
than 100 Ω:
• Use an IGBT tester to check for a shorted pilot arc IGBT.
• Replace the pilot arc IGBT if it is shorted.
If the resistance is always greater than 100 Ω:
• Replace all consumables and recheck.
• If the resistance is correct (<100 Ω) the old consumables are bad.
• If the resistance is still greater than 100 Ω, measure the resistance in the torch between the pilot arc wires (Pin
1 or 2) and negative arc power (the center connection).
• If the resistance is still too high, replace the torch and lead.
Note: The retaining cap should be snug but not over-tightened.
All values are ±15%
Check the function of the pilot arc IGBT:
• Turn the machine off and disconnect power.
• Install a jumper wire from the work lead (J26 for CSA, J27 for CE) to the pilot arc IGBT (dual black wires).
• Reconnect power and turn on the machine.
• Attempt to fire the torch.
• If the torch fires, replace the pilot arc IGBT.
WORK
LEAD
J26
J28
Install a test
jumper here

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