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Powermax65 SYNC
Hypertherm Powermax65 SYNC Troubleshooting Guide
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SYN
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roubleshooting Guide
81
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Table of Contents
Table of Contents
5
Before You Begin
11
Prepare to Troubleshoot Internal Components
13
Troubleshooting Procedures and Sequence
15
Get the Necessary Test Equipment
16
Troubleshooting Checklist
17
Do an Internal Inspection
21
Frequently Used Troubleshooting Procedures
22
Do a Cold Restart or Quick Restart
22
Do a Cold Restart
22
Do a Quick Restart
22
Examine the Gas Pressure
23
Examine the Gas Quality
24
Do a Check for Continuity
25
Do a Gas Test
26
Start and Stop a Gas Test in Automatic Gas Pressure Mode
26
Do a Gas Test in Manual Gas Pressure Mode
27
Do an Initial Resistance Check
28
Examine the Power Switch
28
Hypertherm IGBT Tester
32
Indicator Leds and Device Tests
33
IGBT Test Preparation
33
IGBT Device Test for the Hypertherm Tester
35
Troubleshooting Steps for the Hypertherm IGBT Tester
35
IGBT Device Test for a Non-Hypertherm Tester
36
Schematic to Build an IGBT Tester
38
Troubleshooting for Fault Codes
39
Fault Codes and Solutions
39
Identify Fault Icons
41
Remove Fault Code Conditions
42
Operational Faults (0-Nn-N)
42
Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)
57
Generator Considerations
62
Troubleshooting for Common Problems
63
Problems with System Performance
64
Common Cutting and Gouging Problems
72
Hand Cutting Problems
72
Hand Gouging Problems
74
Do System Tests to Identify Defective Components
75
Important Information before You Do These System Tests
75
System Tests in this Section
76
How to Attach to Ground
76
How to Get Voltage Measurements for Internal Components
77
Test 1 - Voltage Input
78
Examine the Incoming Power
78
Examine the Power Switch and the Plasma Power Supply
80
Test 2 - DC Power Bus
83
Measure the Voltage
83
Measure the Resistance
87
Test 3 - Output Diodes
90
Test 4 - Inverter Thermal Sensor and PFC Temperature Sensor
91
Identify the Fault Code
91
Procedure for Fault Codes 0-40-0, 0-40-1, 3-11-0, or 3-11-1
91
Procedure for Fault Codes 0-40-2, 0-40-3, 2-10-0, or 2-10-1
92
Test 5 - Flyback Circuit (DC Minor Voltages)
94
Test 6 - Torch Stuck Open (TSO) or Torch Stuck Closed (TSC)
98
Examine the Torch
98
Examine the Plasma Power Supply
99
Measure the Resistance at Idle and with Gas Flowing
99
Measure the Resistance with the Power off
100
Do a Check of the Pilot Arc IGBT
101
Test 7 - Start Signal
102
Test 7 - Procedure for a Hand Torch
102
Test 7 - Procedure for a Machine Torch
105
Examine the CNC and the Machine Interface Cable
105
Examine the Plasma Power Supply
106
Test 8 - Torch Cap Switch
108
Examine the Torch and Torch Lead
108
Examine the Plasma Power Supply
110
Test 9 - Solenoid Valve Electronic Regulator
112
Do a Test of the Solenoid Valve with the Gas Supply Disconnected
112
Do a Test of the Solenoid Valve after Disconnecting from the Power PCB
114
Test 10 - Solenoid Valve Pressure Sensor
115
Do a Check for Electrical Interference and Pinched Wires
115
Examine the Power Input and Solenoid Valve Coils
115
Examine the Solenoid Valve Sensor and Power PCB Sensor Input
118
Test 11 - Fan
120
Test 12 - Auxiliary (AUX) Switch
123
Test 13 - Pilot Arc IGBT
125
Test 14 - Radio Frequency (RF) Communication Errors
126
0-98-1 Fault: Cartridge or Torch
126
0-98-2 Fault: Torch or Plasma Power Supply
127
Do a Test of the Plasma Power Supply
127
Do a Test of the Torch
128
Access Service Information and Settings
133
View Current System Status
133
Go to the Main Menu Screen
135
View System Performance, Operation, and Fault Data
136
Cartridge Performance and Fault Data
136
Plasma Power Supply Performance and Operation Data
138
Cumulative Cartridge Data for the Plasma Power Supply
140
View Printed Circuit Board (PCB) and Firmware Information
142
Lcd/Control PCB Information
142
DSP PCB and Power PCB Information
143
Torch PCB Information
144
View Internal Component Faults and Radio Frequency Logs
145
Internal Component Faults
145
Radio Frequency (RF) Settings and Operation Logs
146
Cut Counter Data for Backups
147
View or Change System Settings
148
LCD Display Brightness and Contrast
148
Show Cartridge Data on the Status Screen
149
Serial Communications Parameters
150
Default Feature Configuration
153
Smart Mode Versus Basic Mode
155
Smart Mode
155
Basic Mode
155
Set System Settings to Factory Default
156
How the Plasma Power Supply Operates
157
Sequence of Operation
158
Powermax65/85 SYNC Plasma Power Supply Overviews
159
Powermax105 SYNC Plasma Power Supply Overviews
163
Theory of Operation
169
Powermax65/85 SYNC
169
200 V - 600 V CSA 1-Phase or 3-Phase Functional Description
169
380 V CCC / 400 V CE 3-Phase Functional Description
169
Powermax105 SYNC
170
200 V - 600 V CSA 3-Phase Functional Description
170
230 V - 400 V CE 3-Phase Functional Description
170
380 V CCC / 400 V CE 3-Phase Functional Description
171
System Diagrams
173
Powermax65/85 SYNC Schematic - CSA Models
175
Powermax65/85 SYNC Schematic - CE/CCC Models
176
Powermax105 SYNC Schematic - CSA Models and 230 V - 400 V CE Models
177
Powermax105 SYNC Schematic - 380 V CCC Models and 400 V CE Models
178
Timing Chart for Torch Start
179
Other manuals for Hypertherm Powermax65 SYNC
Manual
136 pages
Reference Guide
79 pages
4
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Hypertherm Powermax65 SYNC Specifications
General
Brand
Hypertherm
Model
Powermax65 SYNC
Category
Welding System
Language
English
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