TroubleshooTing and sysTem TesTs
5-38 powermax
65/85
Service Manual
System tests
Test # Description Associated fault codes
1 Voltage input 0-60-ALL
2 DC power buss 3-43-0
3 Output diode bridge General
4 Temperature out of range 0-40-ALL, 2-10-ALL, 3-11-ALL
5 Flyback (DC to DC) circuit 3-00-0, 3-42-ALL, 3-43-ALL
6 Torch stuck open 0-30-ALL
7 Start signal General, 0-51-0
8 Torch cap-sensor switch 0-50-0
9 Electronic regulator 0-21-0, 3-20-ALL
10 Pressure sensor 0-12-0, 0-20-0, 2-11-ALL
11 Fan 3-10-ALL
12 Power switch auxiliary Unreported interlock at START
Before performing any tests do the Internal inspection and the Resistance check in Test 2 below. These tests should
only be performed by a qualified service technician. Wear the proper personal protective equipment and use approved
tools and measurement equipment.
Before purchasing a major replacement component, verify the problem with Hypertherm Technical Service (1-800-643-
9878) or the nearest Hypertherm repair facility.
Several connectors require you to remove a white cap to access the test points. The figure below shows examples
of connectors located at the top of the power board. You can pry off most covers with your thumbnail. However, you
may need to use a small blade screwdriver to carefully pry off some of the covers. Be careful not to bend or break the
connectors.
Pressure sensor
J5 (CSA), J7 (CE)
Fan
J3 (CSA), J5 (CE)
Electronic regulator
J4 (CSA), J6 (CE)
Inverter temperature sensor
J2 (CSA), J4 (CE)
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