Name: Hypertherm Powermax65 SYNC
Brand: Hypertherm
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Do System Tests to Identify Defective Components

Powermax65/85/105 SYNC Troubleshooting Guide 810430 111

Figure 27 – Machine interface pins on power PCB

J20 / J17

BLU

ORG

YEL

RED

J21

ORG

J20

J12

J4 J2 J1J3

J6 J5 J2 J1

J22

RED

J18

ORG

J17

J11

Powermax65/85 SYNC

Powermax105 SYNC

Table of Contents5
Before You Begin11
Prepare to Troubleshoot Internal Components13
Troubleshooting Procedures and Sequence15
Get the Necessary Test Equipment16
Troubleshooting Checklist17
Do an Internal Inspection21
Frequently Used Troubleshooting Procedures22
Do a Cold Restart or Quick Restart22
Do a Cold Restart22
Do a Quick Restart22
Examine the Gas Pressure23
Examine the Gas Quality24
Do a Check for Continuity25
Do a Gas Test26
Start and Stop a Gas Test in Automatic Gas Pressure Mode26
Do a Gas Test in Manual Gas Pressure Mode27
Do an Initial Resistance Check28
Examine the Power Switch28
Hypertherm IGBT Tester32
Indicator Leds and Device Tests33
IGBT Test Preparation33
IGBT Device Test for the Hypertherm Tester35
Troubleshooting Steps for the Hypertherm IGBT Tester35
IGBT Device Test for a Non-Hypertherm Tester36
Schematic to Build an IGBT Tester38
Troubleshooting for Fault Codes39
Fault Codes and Solutions39
Identify Fault Icons41
Remove Fault Code Conditions42
Operational Faults (0-Nn-N)42
Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)57
Generator Considerations62
Troubleshooting for Common Problems63
Problems with System Performance64
Common Cutting and Gouging Problems72
Hand Cutting Problems72
Hand Gouging Problems74
Do System Tests to Identify Defective Components75
Important Information before You Do These System Tests75
System Tests in this Section76
How to Attach to Ground76
How to Get Voltage Measurements for Internal Components77
Test 1 - Voltage Input78
Examine the Incoming Power78
Examine the Power Switch and the Plasma Power Supply80
Test 2 - DC Power Bus83
Measure the Voltage83
Measure the Resistance87
Test 3 - Output Diodes90
Test 4 - Inverter Thermal Sensor and PFC Temperature Sensor91
Identify the Fault Code91
Procedure for Fault Codes 0-40-0, 0-40-1, 3-11-0, or 3-11-191
Procedure for Fault Codes 0-40-2, 0-40-3, 2-10-0, or 2-10-192
Test 5 - Flyback Circuit (DC Minor Voltages)94
Test 6 - Torch Stuck Open (TSO) or Torch Stuck Closed (TSC)98
Examine the Torch98
Examine the Plasma Power Supply99
Measure the Resistance at Idle and with Gas Flowing99
Measure the Resistance with the Power off100
Do a Check of the Pilot Arc IGBT101
Test 7 - Start Signal102
Test 7 - Procedure for a Hand Torch102
Test 7 - Procedure for a Machine Torch105
Examine the CNC and the Machine Interface Cable105
Examine the Plasma Power Supply106
Test 8 - Torch Cap Switch108
Examine the Torch and Torch Lead108
Examine the Plasma Power Supply110
Test 9 - Solenoid Valve Electronic Regulator112
Do a Test of the Solenoid Valve with the Gas Supply Disconnected112
Do a Test of the Solenoid Valve after Disconnecting from the Power PCB114
Test 10 - Solenoid Valve Pressure Sensor115
Do a Check for Electrical Interference and Pinched Wires115
Examine the Power Input and Solenoid Valve Coils115
Examine the Solenoid Valve Sensor and Power PCB Sensor Input118
Test 11 - Fan120
Test 12 - Auxiliary (AUX) Switch123
Test 13 - Pilot Arc IGBT125
Test 14 - Radio Frequency (RF) Communication Errors126
0-98-1 Fault: Cartridge or Torch126
0-98-2 Fault: Torch or Plasma Power Supply127
Do a Test of the Plasma Power Supply127
Do a Test of the Torch128
Access Service Information and Settings133
View Current System Status133
Go to the Main Menu Screen135
View System Performance, Operation, and Fault Data136
Cartridge Performance and Fault Data136
Plasma Power Supply Performance and Operation Data138
Cumulative Cartridge Data for the Plasma Power Supply140
View Printed Circuit Board (PCB) and Firmware Information142
Lcd/Control PCB Information142
DSP PCB and Power PCB Information143
Torch PCB Information144
View Internal Component Faults and Radio Frequency Logs145
Internal Component Faults145
Radio Frequency (RF) Settings and Operation Logs146
Cut Counter Data for Backups147
View or Change System Settings148
LCD Display Brightness and Contrast148
Show Cartridge Data on the Status Screen149
Serial Communications Parameters150
Default Feature Configuration153
Smart Mode Versus Basic Mode155
Smart Mode155
Basic Mode155
Set System Settings to Factory Default156
How the Plasma Power Supply Operates157
Sequence of Operation158
Powermax65/85 SYNC Plasma Power Supply Overviews159
Powermax105 SYNC Plasma Power Supply Overviews163
Theory of Operation169
Powermax65/85 SYNC169
200 V - 600 V CSA 1-Phase or 3-Phase Functional Description169
380 V CCC / 400 V CE 3-Phase Functional Description169
Powermax105 SYNC170
200 V - 600 V CSA 3-Phase Functional Description170
230 V - 400 V CE 3-Phase Functional Description170
380 V CCC / 400 V CE 3-Phase Functional Description171
System Diagrams173
Powermax65/85 SYNC Schematic - CSA Models175
Powermax65/85 SYNC Schematic - CE/CCC Models176
Powermax105 SYNC Schematic - CSA Models and 230 V - 400 V CE Models177
Powermax105 SYNC Schematic - 380 V CCC Models and 400 V CE Models178
Timing Chart for Torch Start179

Hypertherm Powermax65 SYNC Troubleshooting Guide

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Brand	Hypertherm
Model	Powermax65 SYNC
Category	Welding System
Language	English