Hypertherm powermax45

powermax 45 Service Manual 5-1
Section 5
TROUBLESHOOTING AND SYSTEM TESTS
In this section:
Theory of operation ....................................................................................................................................................................................5-2
General ..............................................................................................................................................................................................5-2
200–240V CSA and 230V CE 1-phase power supply functional description .............................................................5-2
400V CE 3-phase power supply functional description .......................................................................................................5-2
480V CSA 3-phase power supply functional description ...................................................................................................5-3
Sequence of operation ...................................................................................................................................................................5-4
Troubleshooting preparation ....................................................................................................................................................................5-5
Test equipment .................................................................................................................................................................................5-5
Troubleshooting procedures and sequence..............................................................................................................................5-5
External inspection ..........................................................................................................................................................................5-6
Internal inspection ...........................................................................................................................................................................5-6
Initial resistance check .............................................................................................................................................................................. 5-7
200–240V CSA and 230V CE power supply overview ................................................................................................................5-8
400V CE power supply overview .........................................................................................................................................................5-9
480V CSA power supply overview ................................................................................................................................................... 5-10
Troubleshooting guide ...........................................................................................................................................................................5-11
Control Board LEDs...............................................................................................................................................................................5-16
Use the control board Error and Reset LEDs to troubleshoot .......................................................................................... 5-17
System tests.............................................................................................................................................................................................5-18
Test 1 – voltage input ..................................................................................................................................................................5-18
Test 2 – power board voltage checks .....................................................................................................................................5-19
Test 3 – VBUS and voltage balance .......................................................................................................................................5-20
Test 4 – solenoid valve ................................................................................................................................................................5-24
Test 5 – torch stuck open (TSO) or torch stuck closed (TSC) .........................................................................................5-25
Test 6 – plasma start ................................................................................................................................................................... 5-26
Test 7 – torch cap sensor ...........................................................................................................................................................5-27
Test 8 – fan .................................................................................................................................................................................... 5-27
Test 9 – pressure transducer .....................................................................................................................................................5-28
Test 10 – power switch trip coil ................................................................................................................................................5-28