Hypertherm Powermax 85

TABLE OF CONTENTS
x powermax 65/85 Service Manual
Fault codes ............................................................................................................................................................................................ 5-21
Displaying the service screen ................................................................................................................................................. 5-21
Important fault icons ................................................................................................................................................................. 5-22
Performing a cold restart ......................................................................................................................................................... 5-22
Fault codes and solutions ........................................................................................................................................................ 5-23
Troubleshooting guide ........................................................................................................................................................................ 5-32
System tests.......................................................................................................................................................................................... 5-38
Test 1 – Voltage input .............................................................................................................................................................. 5-39
Test 2 – DC Power Buss ........................................................................................................................................................ 5-40
Test 3 – Output diodes............................................................................................................................................................ 5-42
Test 4 – Inverter and PFC temperature sensor .................................................................................................................. 5-43
Test 5 – Flyback circuit (DC minor voltages) ..................................................................................................................... 5-46
Test 6 – Torch stuck open (TSO) ......................................................................................................................................... 5-48
Test 7 – Start signal ................................................................................................................................................................. 5-50
Test 8 – Torch cap switch ...................................................................................................................................................... 5-51
Test 9 – Electronic regulator .................................................................................................................................................. 5-52
Test 10 – Pressure sensor ...................................................................................................................................................... 5-53
Test 11 – Fan ............................................................................................................................................................................. 5-54
Test 12 – AUX switch .............................................................................................................................................................. 5-55
Section 6
Component Replacement
Remove and replace the power supply cover and Mylar® barrier ..............................................................................................6-2
Remove the power supply cover and Mylar barrier ..............................................................................................................6-2
Replace the Mylar barrier ............................................................................................................................................................6-3
Replace the power supply cover ..............................................................................................................................................6-4
Replace the power cord ........................................................................................................................................................................6-5
Replace the power cord (200 - 600 V 3-phase CSA, 400 V 3-phase CE) ..................................................................6-5
Replace the power cord (200 - 480 V 1-phase CSA) .................................................................................................... 6-10
Replace the work lead ........................................................................................................................................................................ 6-11
Replace the fan .................................................................................................................................................................................... 6-12
Replace the air filter element ............................................................................................................................................................. 6-14
Replace the air filter subassembly ................................................................................................................................................... 6-15
Replace the power board .................................................................................................................................................................. 6-17
Remove the DSP board ........................................................................................................................................................... 6-17
Replace the power board (380/400V CE) ......................................................................................................................... 6-19
Replace the power board (200-600V CSA) ...................................................................................................................... 6-22
Install the DSP board ............................................................................................................................................................... 6-25
Replace the Mylar barrier and power supply cover. .......................................................................................................... 6-26
Replace the control board ................................................................................................................................................................. 6-27
Replace the heat sink components ................................................................................................................................................. 6-29
65A CSA ..................................................................................................................................................................................... 6-30
65A CE ........................................................................................................................................................................................ 6-31
85A CSA ..................................................................................................................................................................................... 6-32
85A CE ........................................................................................................................................................................................ 6-33