Contents
6 810430 Troubleshooting Guide Powermax65/85/105 SYNC
IGBT device test for a non-Hypertherm tester................................................................................. 36
Schematic to build an IGBT tester ......................................................................................... 38
3 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
4 Troubleshooting for Common Problems................................................................................ 63
Problems with system performance................................................................................................................ 64
Common cutting and gouging problems....................................................................................................... 72
Hand cutting problems .......................................................................................................................... 72
Hand gouging problems........................................................................................................................ 74
5 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
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