MAINTENANCE
3-28
Service Manual
CONTROL BOARD
Control Board LEDs
There are 4 control board LEDs visible from the Powermax800 front panel. There are 6 more LEDs
that are visible only when the cover is removed. See Figure 3-6 for location of LEDs.
• D8 POWER ON: Illuminates when power is applied.
• D15 LINE VOLTAGE: Illuminates when the input voltage is out of limits. This LED will remain
on if the line voltage is too low, and go on briefly before the power supply shuts down if the line
voltage is too high.
Note: LINE VOLTAGE LED always remains on for about 5 seconds after the power supply is
turned on and before a "soft start" signal is sent from the control board to the power board.
The upper and lower range for line voltages are as follows:
Lower Limit Line Voltage Upper Limit
170VAC 200VAC 235VAC
178VAC 208VAC 239VAC
195VAC 230VAC 270VAC
204VAC 240VAC 276VAC
340VAC 400VAC 470VAC
408VAC 480VAC 552VAC
510VAC 600VAC 690VAC
• D24 OVERCURRENT: Illuminates when CS1 or CS2 senses current above 70 amps.
• D25 PILOT ARC RELAY: Illuminates when pilot arc relay CR2 is energized.
• D26 GAS SOLENOID: Illuminates when gas solenoid is energized (when GAS TEST switch is
pressed or when plasma start is pressed).
• D27 MAIN CONTACTOR: Illuminates when contactor CR1 is energized (following "soft start").
• D29 TEMP LED: Remains off when temperature is within operating limits. It Illuminates when
the thermostat in the power transformer opens (over 110° C (230° F)) or if the heatsink
becomes too hot (over 85°C (185° F)). Overheating can be caused by exceeding the duty
cycle rate.
• D35 GAS PRESSURE: Illuminates when incoming gas pressure sensed by PS1 is within
operating limits (over 39 psi (2.7 bar)).
• D38 ARC TRANSFER: Illuminates when arc transfers to the workpiece.
• D42 PLASMA START: Illuminates when the torch start button is pushed or when start button is
activated from the machine interface.
The control board also controls the sequence required to generate plasma:
• Turns on the inverter when the torch switch button is pressed
• After a short delay, turns on the gas solenoid valve V1 to blow back the electrode
• Monitors the pilot arc for arc transfer
• Ramps the current control command from the pilot arc level (20 amps) to the cut current
selected by the operator
• Turns the inverter off if the arc transfer does not occur within 5 seconds
• Turns the power supply off when the retaining cap is loose or when line voltage is too high
Note: To avoid performance
deterioration of the
Powermax800, input voltage
should be within 10% of the
specified system line voltage
setting.
9-96
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