Hypertherm Powermax65 SYNC Troubleshooting Manual
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Hypertherm Powermax65 SYNC Troubleshooting Manual

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Powermax65/85/105 SYNC
Troubleshooting Guide
810430 – REVISION 0
ENGLISH

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  • Page 1 ™ Powermax65/85/105 SYNC Troubleshooting Guide 810430 – REVISION 0 ENGLISH...
  • Page 2 _______________________________________________________________________________________ _______________________________________________________________________________________ Powermax, SYNC, SmartSYNC, FastConnect, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment...
  • Page 3 Powermax65/85/105 SYNC Troubleshooting Guide 810430 REVISION 0 ENGLISH Original instructions January 2022 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) technicalservice.emeia@hypertherm.com (Technical Service) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.

  • Page 5: Table Of Contents

    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 Powermax65/85/105 SYNC Troubleshooting Guide...
  • Page 6 Contents 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) .......................
  • Page 7 Contents 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 –...
  • Page 8 Contents 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 7 How the Plasma Power Supply Operates ................157 Sequence of operation ...........................
  • Page 9 Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs. DE (DEUTSCH/GERMAN) WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die IT (ITALIANO/ITALIAN) Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla...
  • Page 10 OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu คํ า เตื อ น! ก อ นการใช ง านอุ ป กรณ ข อง Hypertherm ทั ้ ง หมด โปรดอ า นคํ า แนะนํ า ด า นความ firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi ปลอดภั...

  • Page 11: Before You Begin

    2. Contact your Hypertherm distributor or authorized repair facility. 3. Contact the nearest Hypertherm office shown in the front of this manual. For related information, refer to the following documents: Powermax65/85 SYNC Service Parts and Procedures Guide (810440) ...
  • Page 12 Before You Begin 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 13: Prepare To Troubleshoot Internal Components

    157. In addition to being technically qualified, technicians must do all testing with safety in mind. If questions or problems occur during servicing, contact the correct Hypertherm Technical Service office shown in the front of this manual. WARNING...
  • Page 14 Prepare to Troubleshoot Internal Components WARNING Always put on correct personal protective equipment (PPE) before you do tests on equipment that is connected to power. CAUTION HOT PARTS CAN CAUSE SEVERE BURNS Let the plasma power supply become cool before doing maintenance. Wait for approximately 1 hour to make sure that the temperature of the plasma power supply is approximately at room temperature.

  • Page 15: Troubleshooting Procedures And Sequence

    Powermax105 SYNC Service Parts and Repair Procedures (810450)  SmartSYNC Torches Service Parts and Repair Procedures (810460)  The most recent revisions of technical documentation are available at www.hypertherm.com/docs. Power OFF (O) and disconnect Troubleshooting checklist Do an internal inspection...

  • Page 16: Get The Necessary Test Equipment

    – The power PCB contains test points with a diameter of 2.25 mm (0.09 inch) that accept miniature banana plugs (for example, Pamona 2945 plugs). ® Hypertherm IGBT tester (128883) – Refer to  Hypertherm IGBT tester on page 32. Assorted jumpers and jumper wires. ...

  • Page 17: Troubleshooting Checklist

    If you are using torch height control (THC), is an ohmic contact ring (428895) installed on the Hypertherm cartridge? Is the ohmic contact ring connected correctly to the THC? If you are using torch height control (THC) and are connecting to raw arc voltage directly, is the wiring correct? •...
  • Page 18 (at right) but not the icon? Does the plasma power supply operate as expected? For example, does the plasma power supply not change to the correct operating mode for the Hypertherm cartridge that you installed when you are using a SmartSYNC torch and Hypertherm...
  • Page 19 Is the torch-lock switch operating correctly? The mini machine torch does not have a torch-lock switch. Examine the Hypertherm cartridge Is the Hypertherm cartridge worn or damaged? A higher rate of 0-30-0 faults is typical as a cartridge gets near end-of-life. Is the Hypertherm cartridge installed correctly?
  • Page 20 Prepare to Troubleshoot Internal Components Examine the gas supply Is the gas supply hose connected correctly to the fitting on the rear panel of the plasma power supply? Is the gas supply hose connected correctly to the air compressor, gas cylinder, or other gas source? Examine each fitting and connection point in the gas supply line.

  • Page 21: Do An Internal Inspection

    Prepare to Troubleshoot Internal Components Do an internal inspection WARNING SHOCK HAZARD You can get a serious electric shock if you touch exposed plasma power supply components. Electric shock can seriously injure or kill you. You must install the component barrier and the plasma power supply cover. Never operate the plasma power supply unless the component barrier and the plasma power supply cover are in position.

  • Page 22: Frequently Used Troubleshooting Procedures

    Prepare to Troubleshoot Internal Components Frequently used troubleshooting procedures The following procedures are used frequently to help with troubleshooting: Do a cold restart or quick restart on page 22  Examine the gas pressure on page 23  Examine the gas quality on page 24 ...

  • Page 23: Examine The Gas Pressure

    Prepare to Troubleshoot Internal Components Examine the gas pressure Inlet gas supply: Incorrect gas pressure can cause errors that prevent cutting or problems  with cut quality. Refer to the Powermax65/85/105 SYNC Operator Manual (810470) for information on the inlet gas supply requirements. For optimum system performance, make sure that the inlet gas pressure stays between 7.6 bar –...

  • Page 24: Examine The Gas Quality

    Prepare to Troubleshoot Internal Components Examine the gas quality It is extremely important to keep a clean, dry gas line to prevent oil, water, dirt, and other contaminants from causing damage to internal components. A clean gas line also helps you to get optimal cut quality and consumable life.

  • Page 25: Do A Check For Continuity

    Prepare to Troubleshoot Internal Components Do a check for continuity For some torch-related faults, you can do a check for continuity between the following test points to identify if the problem is with the plasma power supply. If there is no continuity between any of these points, replace the quick-disconnect receptacle.

  • Page 26: Do A Gas Test

    Prepare to Troubleshoot Internal Components Do a gas test Do a gas test to make sure that sufficient gas pressure is getting to the torch. WARNING CHANCE OF BURNS AND CUTS Point the torch away from you before doing a gas test. Always keep hands, clothes, and objects away from the torch tip.

  • Page 27: Do A Gas Test In Manual Gas Pressure Mode

    Prepare to Troubleshoot Internal Components 5. Use the gas test screen to compare the plasma power supply’s actual output gas pressure the gas pressure that the system sets to align with the type of cartridge and torch installed. For the system to operate optimally, the output gas pressure must not be lower than the system’s target gas pressure by more than the following quantities:...

  • Page 28: Do An Initial Resistance Check

    Prepare to Troubleshoot Internal Components Do an initial resistance check Make sure that you get all resistance values with the power cord disconnected and all internal plasma power supply wires correctly attached. Before you do an initial resistance check, do the steps in Do an internal inspection on page 21.
  • Page 29 Prepare to Troubleshoot Internal Components 6. Measure the resistance from the input leads to ground to make sure that they read as open. Look for the symbol on the heatsink . For all models, the resistance from input to ground must read as greater than 20 megaohms (MΩ).
  • Page 30 Prepare to Troubleshoot Internal Components 7. Measure the output resistance for the values shown in the following tables and figures: Powermax65/85 SYNC: Refer to Table 3 Figure 2 on page 30.  Powermax105 SYNC: Refer to Table 4 Figure 3 on page 31.
  • Page 31 Refer to Theory of operation on page 169. Before you purchase a major replacement component, make sure that you correctly identify  the problem and solution with Hypertherm Technical Service or the nearest Hypertherm repair facility. Powermax65/85/105 SYNC Troubleshooting Guide 810430...

  • Page 32: Hypertherm Igbt Tester

    Prepare to Troubleshoot Internal Components Hypertherm IGBT tester Use the Hypertherm IGBT (insulated gate bipolar transistor) tester (128883) as described in the following sections. Or you can assemble your own IGBT tester from the schematic diagram shown page 38 and use it to do IGBT tests.

  • Page 33: Indicator Leds And Device Tests

    Prepare to Troubleshoot Internal Components Indicator LEDs and device tests A minimum of 8 V is necessary to provide the correct power to the circuitry of the Hypertherm IGBT tester. Green “pass” LED When illuminated, this LED indicates that the IGBT passed the test for an open circuit in the IGBT when the switch is pressed to the right or for a short-circuited IGBT when the switch is pressed to the left.
  • Page 34 Prepare to Troubleshoot Internal Components Figure 4 – Common IGBT configurations IGBT module, Inverter test 1 IGBT module, Inverter test 2 1 Yellow lead Gate 2 (G2) 4 Red lead Collector 1 (C1) 2 Black lead Emitter 2 (E2) 5 Black lead Emitter 1 (E1) 6 Yellow lead Gate 1 (G1) 3 Red lead Collector 2 (C2) IGBT module, PFC...

  • Page 35: Igbt Device Test For The Hypertherm Tester

    Prepare to Troubleshoot Internal Components IGBT device test for the Hypertherm tester Using the Hypertherm IGBT tester, push and hold the switch in the necessary position to do each test shown in the following table. Switch Meaning Corrective action Position...

  • Page 36: Igbt Device Test For A Non-Hypertherm Tester

    Prepare to Troubleshoot Internal Components IGBT device test for a non-Hypertherm tester The device tester shown on page 38 has one LED and one push-button switch that are used in combination to do 2 tests. Do the following before you do a test of an IGBT: Electrically isolate the IGBT from all other circuits.
  • Page 37 Prepare to Troubleshoot Internal Components Figure 5 – Common IGBT configurations IGBT module, Inverter test 1 IGBT module, Inverter test 2 1 Yellow lead Gate 2 (G2) 4 Red lead Collector 1 (C1) 2 Black lead Emitter 2 (E2) 5 Black lead Emitter 1 (E1) 3 Red lead Collector 2 (C2) 6 Yellow lead Gate 1 (G1) IGBT module, PFC...

  • Page 38: Schematic To Build An Igbt Tester

    Prepare to Troubleshoot Internal Components Schematic to build an IGBT tester Figure 6 – IGBT tester schematic 1 Collector 1 (C1) 9 D1 Red LED lamp 2 Emitter 2 (E2) 10 R3 2.0K 3 Collector 2, Emitter 1(C2, E1) 11 R4 2.0K 4 Gate 1 (G1) 12 9 VDC battery 5 Emitter 1 (E1)

  • Page 39: Troubleshooting For Fault Codes

    Troubleshooting for Fault Codes Fault codes and solutions When a fault occurs with the plasma power supply or the torch, a fault code and related fault icon show on the status screen. The yellow fault LED also comes on.  The yellow fault LED does not come on for the 0-11-n, 0-12-n, 0-14-1, 0-98-1, or 0-98-2 fault codes.
  • Page 40 Troubleshooting for Fault Codes The status LED on the SmartSYNC hand torch also shows the fault status. Green = prepared Yellow = a 0-nn-n Red = a 0-32-0, to cut fault code, or the 1-nn-n, 2-nn-n, or torch is locked 3-nn-n fault code When the status LED on the hand torch is yellow, the LED can be flashing or solid, as follows: The yellow status LED flashes quickly (multiple flashes per second) for fault codes that are...

  • Page 41: Identify Fault Icons

    Torch Cap Sensor – This icon identifies when the SmartSYNC torch is in the yellow lock (X) position. It also identifies fault conditions in which the Hypertherm cartridge is loose, incorrectly installed, or missing. Temperature – This icon identifies fault conditions in which the plasma power supply is outside the range of permitted operating temperatures.

  • Page 42: Remove Fault Code Conditions

    Supply Log screen. An operational fault code can be for a notification or for a condition that stops the cutting process. Hypertherm recommends that you do the steps in the following table for all fault codes that occur. 810430 Troubleshooting Guide...
  • Page 43 0-11-0 The remote control operating These fault codes do not stop the system from mode is incorrect or not operating. Hypertherm recommends that you do permitted for the installed the following. cartridge. There is a problem with the remote control or The permitted operating the software interface to the system.
  • Page 44 Solutions 0-12-1 The gas pressure output is These fault codes do not stop the system from low. operating. Hypertherm recommends that you do the following. 0-12-2 The gas pressure output is • For 0-12-1 faults, increase the inlet gas high.
  • Page 45 (A) and the operating mode manually. Also, the system cannot collect data about the Hypertherm cartridge. • Lightly blow air into the cartridge to remove all dust or other contamination. Install the cartridge again.
  • Page 46 Troubleshooting for Fault Codes Fault Fault Fault code icon LEDs Description Solutions 0-19-9 The input power stopped. Or, This fault code stops the system from operating. power PCB hardware Do the following. protection occurred for Yellow • This fault can be the result of electrical components in the plasma noise.
  • Page 47 Yellow • Examine all the connections for the input operating mode, torch, lead gas supply. Make sure that there are no length, and Hypertherm leaks or loose connections. cartridge type. • Make sure that the incoming gas supply The gas pressure is hose has an internal diameter of 10 mm inconsistent at your work site.
  • Page 48 • Make sure that the torch lead is not leaking. Also make sure that it is not kinked or twisted. • Install a new Hypertherm cartridge. • For mechanized applications, lock out the torch height control. • Make sure that gas flows through the solenoid valve electronic regulator in gas test mode.
  • Page 49 Start signal is the following: received. • If the Hypertherm cartridge became loose or was removed while the plasma power 0-30-1 There is a torch stuck closed supply was ON and the torch-lock switch (TSC) condition.
  • Page 50 Yellow (PFC IGBT) is too cold. no longer too hot or too cold. Hypertherm recommends that you operate the system only in This is applicable to CSA and external temperatures between -10°C to 40°C to Powermax105 SYNC (14°F to 104°F).
  • Page 51 ON (I). Do a quick restart. • If the Hypertherm cartridge is in good condition and is installed correctly, the torch has possible damage. If possible, do a test with a different torch that is known to operate correctly.
  • Page 52 Troubleshooting for Fault Codes Fault Fault Fault code icon LEDs Description Solutions 0-50-1 The torch-lock switch is set to This fault code stops the system from operating. the yellow lock (X) position. Do the following. A restart is not necessary. Yellow •...
  • Page 53 Troubleshooting for Fault Codes Fault Fault Fault code icon LEDs Description Solutions 0-51-0 The plasma power supply This fault code stops the system from operating. was receiving a signal to start Do the following. A quick restart is necessary. cutting at the same time that Yellow •...
  • Page 54 Troubleshooting for Fault Codes Fault Fault Fault code icon LEDs Description Solutions 0-60-1 An AC input voltage is too This fault code stops the system from operating. low. Do the following. A cold restart is necessary. Yellow • The input line voltage is too low (more than 15% below the rated voltage).
  • Page 55 This fault code does not stop the system from failure occurred between the operating. The system can continue to cut, but LCD/control PCB and the Hypertherm recommends that you find the Yellow DSP PCB. cause of the problem first because the controls on the front panel are not available.
  • Page 56 You can continue to cut or gouge, but you must set the output current (A) and the operating mode manually. Cartridge: • Make sure that the Hypertherm cartridge is installed correctly. • Make sure that the green ring inside the cartridge is not broken.

  • Page 57: Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)

    Troubleshooting for Fault Codes Internal component faults (1- - , 2- - , 3- - ) Fault codes in the 1-nn-n, 2-nn-n, and 3-nn-n formats identify possible damage to components inside the plasma power supply. These faults show on the Power Supply Log screen. - fault codes Fault Fault...
  • Page 58 Troubleshooting for Fault Codes Fault Fault Fault code icon LEDs Description Solutions 2-11-0 The pressure sensor is open. • Examine the related wiring. • Do Test 10 – Solenoid valve pressure 2-11-1 The pressure sensor Yellow sensor on page 115. short-circuited.
  • Page 59 Troubleshooting for Fault Codes - fault codes Fault Fault Fault code icon LEDs Description Solutions 3-00-0 The DC bus voltage (VBUS) • Examine the circuitry for the PFC IGBT is out of range. (CSA and Powermax105 SYNC CE/CCC 230 V – 400 V models only). Yellow •...
  • Page 60 Do Test 2 – DC power bus on page 83. • Do a test of the inverter IGBT. Refer to Hypertherm IGBT tester on page 32. • Replace the bulk capacitors. 3-44-1 The PFC IGBT current is too The current in the PFC IGBT is too high.
  • Page 61 The inverter in phase instead of 180° out of phase. current is too high. Yellow • Do a test of the 2 inverter IGBTs. Refer to Hypertherm IGBT tester on page 32. 3-52-0 A short circuit caused high-current distortion in the •...

  • Page 62: Generator Considerations

    If you consistently see these fault codes, you can temporarily set the GEN setting to on. This setting is on the Feature Configuration screen (FEATURE CONFIG). Hypertherm recommends that only experienced operators change this setting. This setting decreases the system’s sensitivity to changes in current and voltage from incoming power.

  • Page 63: Troubleshooting For Common Problems

    Troubleshooting for Common Problems This section is for common troubleshooting problems that do not include fault codes. WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you.

  • Page 64: Problems With System Performance

    Causes Solutions The cut quality is The cartridge is • The cartridge is worn. • Examine the Hypertherm cartridge. unsatisfactory, or worn, the work lead Replace it if it is worn or has the cut does not connection is not damage.
  • Page 65 Troubleshooting for Common Problems Problem Meaning Causes Solutions The ON / OFF Voltage to the • Voltage to the system is • Make sure that the power cord is power switch is control circuits is not missing. connected correctly to the power set to ON (I), but sufficient, or a power outlet or line-disconnect switch box.
  • Page 66 Troubleshooting for Common Problems Problem Meaning Causes Solutions The power ON A power component • The fan is defective. • Do Test 11 – Fan on page 120. LED ( ) flashes has a short circuit. • The DSP PCB is •...
  • Page 67 Troubleshooting for Common Problems Problem Meaning Causes Solutions Gas flows when The cartridge is worn • The cartridge is not • Make sure that the cartridge is not you fire the torch, or has damage. installed correctly. too loose or too tight. but there is no •...
  • Page 68 Troubleshooting for Common Problems Problem Meaning Causes Solutions The plasma arc The plasma arc • The work lead is • If possible, move the work clamp goes out while cannot keep contact defective. Or the work closer to the area of the workpiece you are cutting, or with the workpiece.
  • Page 69 Troubleshooting for Common Problems Problem Meaning Causes Solutions The plasma arc There is a problem • The filter element in the • Replace the air filter element. makes sputtering with the air filter air filter is dirty. and hissing element, or it is •...
  • Page 70 • You set the output current below feature is on. 40 A for any type of Hypertherm cartridge. • You set the output current (A) below 55 A and the field not to smart mode (SMART). Refer to page 153.
  • Page 71 Troubleshooting for Common Problems Problem Meaning Causes Solutions The system The manual gas The following conditions • Go back to manual gas pressure changes the gas pressure mode gets cause the system to override mode, and set the gas pressure pressure after you overridden in some a manual gas pressure...

  • Page 72: Common Cutting And Gouging Problems

    • Make sure that the Hypertherm cartridge is installed correctly. hisses, or you lose the • Examine the Hypertherm cartridge. Replace it if it is worn or damaged. A plasma arc. higher rate of 0-30-0 faults is typical as a cartridge gets near end-of-life.
  • Page 73 • Examine the Hypertherm cartridge. Replace it if it is worn or damaged. A higher rate of 0-30-0 faults is typical as a cartridge gets near end-of-life. • Make sure that the incoming gas supply hose has an internal diameter of 9.5 mm (3/8 inch) or greater.

  • Page 74: Hand Gouging Problems

    When you install a Hypertherm gouging cartridge, the plasma power supply  automatically sets the operating mode to Gouge mode. There is a condition in which the operating mode does not automatically set to Gouge mode even if a Hypertherm gouging cartridge is used. Problem...

  • Page 75: Do System Tests To Identify Defective Components

    Before you purchase a major replacement component, make sure that you have correctly identified the problem with help from Hypertherm Technical Service or the nearest Hypertherm repair facility. Powermax65/85/105 SYNC Troubleshooting Guide...

  • Page 76: System Tests In This Section

    Do System Tests to Identify Defective Components System tests in this section System test Associated fault codes Test 1 – Voltage input on page 78 0-60-n Test 2 – DC power bus on page 83 3-43-0 Test 3 – Output diodes on page 90 3-51-1, 3-52-0 Test 4 –...

  • Page 77: How To Get Voltage Measurements For Internal Components

    Do System Tests to Identify Defective Components How to get voltage measurements for internal components For some tests it is necessary to get access to pins on the power PCB in order to measure voltage. The pins for the following components are behind the DSP PCB. Use extended thin meter points to measure voltage on these pins.

  • Page 78: Test 1 - Voltage Input

    Do System Tests to Identify Defective Components Figure 9 – J1, J2, J5, and J6 pins in Powermax105 SYNC J1 = Fan J2 = Inverter temperature sensor J5 = Auxiliary switch J6 = Solenoid valve electronic regulator Test 1 – Voltage input WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or...
  • Page 79 Do System Tests to Identify Defective Components 4. Measure the voltage on the input leads as follows: a. Measure the voltage from each input lead to ground. The leads have the labels L1, L2, and L3 on the power switch. Look for the symbol on the heatsink to identify the ground...

  • Page 80: Examine The Power Switch And The Plasma Power Supply

    Do System Tests to Identify Defective Components Examine the power switch and the plasma power supply 1. Make sure that the power switch on the plasma power supply is ON (I). 2. Measure the input voltage to the input diode bridge. The AC voltage between each pair of input wires must be equal to the line voltage.
  • Page 81 Do System Tests to Identify Defective Components Figure 11 – Powermax105 SYNC LV = incoming line voltage 3-phase Black (CSA) Brown (CE/CCC) LV/1.732 White (CSA) Black (CE/CCC) LV/1.732 LV/1.732 Red (CSA) Gray (CE/CCC) Green (CSA) Green/yellow (CE/CCC) Ground (GRD) LV X 1.414 Black wire 5.
  • Page 82 Do System Tests to Identify Defective Components 6. If the value in the VL field correct, but you continue to get a 0-60-n fault code, do the following: a. Do a check for a short-circuited fan. Disconnect the fan from the power PCB, as follows: J3 in Powermax65/85 SYNC ...

  • Page 83: Test 2 - Dc Power Bus

    Do System Tests to Identify Defective Components Test 2 – DC power bus If you get the 3-43-0 fault code, use this test to do a check of the internal capacitors. Do not use a multimeter with test leads for this test. This can cause a short circuit between the bus and the heatsink.
  • Page 84 Do System Tests to Identify Defective Components 5. Measure the voltage of the inverter IGBT . For the correct voltages for your system, refer to Figure 12 on page 85 and Figure 13 on page 86.  All values are ±15%. 6.
  • Page 85 Do System Tests to Identify Defective Components Figure 12 – Powermax65/85 SYNC voltages for inverter IGBT and bulk capacitors 750 VDC 200 VAC – 480 VAC input 375 VDC (CSA) 375 VDC TP10 TP11 850 VDC 600 VAC input 425 VDC (CSA) TP12 425 VDC...
  • Page 86 Do System Tests to Identify Defective Components Figure 13 – Powermax105 SYNC voltages for inverter IGBT and bulk capacitors CSA / CE 750 VDC 200 VAC – 480 VAC input (CSA) 375 VDC 230 VAC – 400 VAC input 375 VDC (CE) 850 VDC 600 VAC input...

  • Page 87: Measure The Resistance

    Do System Tests to Identify Defective Components Measure the resistance WARNING ELECTRIC SHOCK CAN KILL Wait for internal voltages to be fully released before you touch the bulk capacitors. The bulk capacitors can be charged for up to 10 minutes after the plasma power supply is set to OFF (O).
  • Page 88 Do System Tests to Identify Defective Components 5. Put the 2 bulk capacitors back into the plasma power supply. Position each capacitor so that the gray polarity dot on the capacitor aligns with the viewing hole on the power PCB. 6.
  • Page 89 Do System Tests to Identify Defective Components Figure 14 – Powermax65/85 SYNC test points Test points Resistance TP10 TP10 and TP12 25 kΩ TP11 TP11 and TP12 25 kΩ TP12 CE / CCC Test points Resistance TP11 TP11 and TP13 18 kΩ...

  • Page 90: Test 3 - Output Diodes

    Do System Tests to Identify Defective Components Test 3 – Output diodes Do this test if you get the 3-51-1 or 3-52-0 fault code. 1. Set the power switch on the plasma power supply to OFF (O), and disconnect the power cord. 2.

  • Page 91: Test 4 - Inverter Thermal Sensor And Pfc Temperature Sensor

    5 kiloohms (kΩ)? If yes, continue with the next step.  If no, replace the PFC IGBT and its gate drive cable. A replacement PFC IGBT from  Hypertherm comes with a new gate drive cable. Powermax65/85/105 SYNC Troubleshooting Guide 810430...

  • Page 92: Procedure For Fault Codes 0-40-2, 0-40-3, 2-10-0, Or 2-10-1

    Do System Tests to Identify Defective Components 3. Measure the resistance between pin 1 and pin 2 on the power PCB. Is the resistance approximately 4.7 kiloohms (kΩ)? If yes, replace the DSP PCB.  If no, replace the power PCB. ...
  • Page 93 Do System Tests to Identify Defective Components Figure 18 – Inverter thermal sensor pins on power PCB Powermax65/85 SYNC Powermax65/85 SYNC CE/CCC TP10 TP11 WORK LEAD TP12 Powermax105 SYNC Powermax65/85/105 SYNC Troubleshooting Guide 810430...

  • Page 94: Test 5 - Flyback Circuit (Dc Minor Voltages)

    Do System Tests to Identify Defective Components Test 5 – Flyback circuit (DC minor voltages) Use this test if you get a 3-00-0, 3-42- , or 3-43- fault code. Minor voltages are missing. The flyback circuit is the source of minor DC voltages for the internal fan, solenoid valve electronic regulator, and power PCB.
  • Page 95 Do System Tests to Identify Defective Components Table 7 System Component Pin number to ground Correct voltage (±15%) Pin 1 on J3 +48 VDC Pin 7 on J4 +48 VDC Solenoid valve Powermax65/85 SYNC CSA Pin 5 on J4 +24 VDC electronic regulator Pin 4 on J4 +5 VDC...
  • Page 96 Do System Tests to Identify Defective Components 8. Install the DSP PCB, but disconnect the ribbon cable from J6 on the DSP PCB. Measure the voltage again from pin 4 to ground. Is the voltage correct now? If yes, replace the control PCB. ...
  • Page 97 Do System Tests to Identify Defective Components Figure 19 – Component pins on power PCB Powermax65/85 SYNC (J11) Powermax65/85 SYNC CE/CCC TP10 TP11 (J14) WORK LEAD TP12 Powermax105 SYNC (J15) Powermax65/85/105 SYNC Troubleshooting Guide 810430...

  • Page 98: Test 6 - Torch Stuck Open (Tso) Or Torch Stuck Closed (Tsc)

    Do System Tests to Identify Defective Components Test 6 – Torch stuck open (TSO) or torch stuck closed (TSC) Use this test when you get 0-30- faults during postflow and the Hypertherm cartridge is in good condition and is installed correctly.

  • Page 99: Examine The Plasma Power Supply

    Do System Tests to Identify Defective Components Examine the plasma power supply WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you. Use extreme caution if you do service or maintenance work on a plasma power supply when it is connected to an electric power source and the outer cover or panels are removed.

  • Page 100: Measure The Resistance With The Power Off

    Do System Tests to Identify Defective Components Figure 20 – Powermax65/85 SYNC System at idle Gas is flowing < 5 Ω > 10 kΩ J28 (J29) J28 (J29) J26 (J27) J26 (J27) WORK WORK LEAD LEAD Figure 21 – Powermax105 SYNC System at idle Gas is flowing >...

  • Page 101: Do A Check Of The Pilot Arc Igbt

    Do System Tests to Identify Defective Components 4. Measure the resistance again between the pilot arc IGBT and J28 (or J29). Is the resistance still less than 100 ohms (Ω)? If yes, use an IGBT tester to do a check for a short-circuited pilot arc IGBT. Replace the ...

  • Page 102: Test 7 - Start Signal

    Do System Tests to Identify Defective Components Test 7 – Start signal Use this test if you fire the torch but there is no plasma arc. Test 7 – Procedure for a hand torch 1. Make sure that the torch is set to the green “ready to fire” ( ) position.
  • Page 103 Do System Tests to Identify Defective Components 7. If the torch continues to not fire a plasma arc, and gas does not flow from the torch, do a check for continuity between the torch and the plasma power supply, as follows: a.
  • Page 104 Do System Tests to Identify Defective Components Figure 23 – Pins for continuity check between torch and plasma power supply Pin 4 and pin 5 on torch PCB Pin 2 and pin 3 on power PCB J20 / J17 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 105: Test 7 - Procedure For A Machine Torch

    Do System Tests to Identify Defective Components Test 7 – Procedure for a machine torch 1. Make sure that the torch is set to the green “ready to fire” ( ) position. 2. Look at the main screen as you set the power switch on the plasma power supply to ON (I).

  • Page 106: Examine The Plasma Power Supply

    Do System Tests to Identify Defective Components Figure 24 – Pins for plasma start on machine interface cable Machine interface connector Examine the plasma power supply 1. Set the power switch on the plasma power supply to OFF (O), and disconnect the power cord. 2.
  • Page 107 Do System Tests to Identify Defective Components 4. At J21or J18 on the power PCB, do a check for continuity on pin 1 (red) and pin 2 (black). Refer Figure 25. Is there continuity on both pins? If yes, there is possibly a problem with the wiring harness for the machine interface ...

  • Page 108: Test 8 - Torch Cap Switch

    Do System Tests to Identify Defective Components Test 8 – Torch cap switch If a new Hypertherm cartridge does not cause the 0-50-0 fault to go away, there can be a problem with the torch or with the plasma power supply.
  • Page 109 Do System Tests to Identify Defective Components 7. Do a check for continuity on the torch wires, as follows: a. Remove the left side of the torch shell. b. Do a check for continuity between the blue wire and pin 5 (BLU) in the torch connector. c.

  • Page 110: Examine The Plasma Power Supply

    Do System Tests to Identify Defective Components Examine the plasma power supply WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you. Use extreme caution if you do service or maintenance work on a plasma power supply when it is connected to an electric power source and the outer cover or panels are removed.
  • Page 111 Do System Tests to Identify Defective Components Figure 27 – Machine interface pins on power PCB Powermax65/85 SYNC J20 / J17 Powermax105 SYNC Powermax65/85/105 SYNC Troubleshooting Guide 810430...

  • Page 112: Test 9 - Solenoid Valve Electronic Regulator

    Do System Tests to Identify Defective Components Test 9 – Solenoid valve electronic regulator If you get a 3-20-n fault code, do this test to identify if the solenoid valve electronic regulator or power PCB is possibly defective. WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill you.
  • Page 113 Do System Tests to Identify Defective Components Figure 29 – Solenoid valve pins on the power PCB J4 / J6 TP10 TP11 WORK LEAD TP12 6. Measure the voltage between pin 1 and pin 7 at J4 or J6 on the power PCB. Refer to Figure Is the voltage approximately 48 VDC? If yes, replace the solenoid valve.

  • Page 114: Do A Test Of The Solenoid Valve After Disconnecting From The Power Pcb

    Do System Tests to Identify Defective Components Do a test of the solenoid valve after disconnecting from the power PCB 1. Disconnect the solenoid valve from J4 or J6 on the power PCB. 2. Measure the voltage again between pin 1 and pin 7 at J4 or J6 on the power PCB. Is the voltage approximately 48 VDC? If yes, continue with the next step.

  • Page 115: Test 10 - Solenoid Valve Pressure Sensor

    Do System Tests to Identify Defective Components Test 10 – Solenoid valve pressure sensor If you get a 2-11-n fault code, do this test to identify if the solenoid valve, DSP PCB, or power PCB is possibly defective. The 2-11-n fault codes identify an electrical problem that is most likely not related to the gas supply.
  • Page 116 Do System Tests to Identify Defective Components 3. Measure the voltage between pin 1 and pin 4 at J4 or J6 on the power PCB. Refer to Figure Is the voltage approximately 5 VDC? If yes, continue with the next step. ...
  • Page 117 Do System Tests to Identify Defective Components 4. Measure the resistance on the solenoid valve J4 or J6 connector as follows: The correct resistance between pin 5 and pin 6 is approximately 22 ohms (Ω) (±3 Ω).  The correct resistance between pin 7 and pin 8 is approximately 44 ohms (Ω) (±5 Ω). ...

  • Page 118: Examine The Solenoid Valve Sensor And Power Pcb Sensor Input

    Do System Tests to Identify Defective Components Examine the solenoid valve sensor and power PCB sensor input 1. Set the power switch to OFF (O). 2. Disconnect the solenoid valve from J4 or J6 on the power PCB. J4 / J6 3.
  • Page 119 Do System Tests to Identify Defective Components 10. Disconnect the DSP PCB from the power PCB by removing the 2 mounting screws. 11. Measure the resistance between pin 2 on J4 or J6 on the power PCB and pin 32 on J8. Refer to Figure 33.

  • Page 120: Test 11 - Fan

    Do System Tests to Identify Defective Components Test 11 – Fan Use this test if you have one of these conditions: The system shows a 3-10-n fault code, which is related to the fan.  Nothing shows on the LCD screen after the plasma power supply is set to ON (I). This can ...
  • Page 121 Do System Tests to Identify Defective Components 7. Measure the DC voltage between pin 1 and pin 4 at the fan connector. Use extended thin meter points to get the voltage reading on the external side of the power PCB. Refer to Figure 34 page 122.
  • Page 122 Do System Tests to Identify Defective Components Figure 34 – Fan pins on power PCB Powermax65/85 SYNC Powermax65/85 SYNC CE/CCC TP10 TP11 WORK LEAD TP12 Powermax105 SYNC 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 123: Test 12 - Auxiliary (Aux) Switch

    Do System Tests to Identify Defective Components Test 12 – Auxiliary (AUX) switch Use this test if you see one of these conditions: The main screen is blank after you set the plasma power supply to ON.  The 2-01-1 fault code shows. ...
  • Page 124 Do System Tests to Identify Defective Components Figure 35 – Auxiliary switch pins on power PCB Powermax65/85 SYNC TP10 TP11 WORK LEAD TP12 Powermax105 SYNC 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 125: Test 13 - Pilot Arc Igbt

    Do System Tests to Identify Defective Components Test 13 – Pilot arc IGBT Do this test to identify if the pilot arc IGBT is operating correctly. 1. Set the power switch on the plasma power supply to OFF (O), and disconnect the power cord. 2.

  • Page 126: Test 14 - Radio Frequency (Rf) Communication Errors

    0-98-1 fault: cartridge or torch If a new Hypertherm cartridge does not cause the 0-98-1 fault to go away, there can be a problem with the antenna on the torch PCB or the wires that connect to the antenna. Do the following: 1.

  • Page 127: 0-98-2 Fault: Torch Or Plasma Power Supply

    Do System Tests to Identify Defective Components 0-98-2 fault: torch or plasma power supply If you see an 0-98-2 fault, do the following to identify if the cause of the fault is with the torch or with the plasma power supply. Do a test of the plasma power supply 1.

  • Page 128: Do A Test Of The Torch

    Do System Tests to Identify Defective Components Do a test of the torch 1. Connect the SmartSYNC torch to the plasma power supply. 2. Remove the left side of the torch shell. 3. Make sure that all wires are correctly and securely connected to the torch PCB. 4.
  • Page 129 Do System Tests to Identify Defective Components 8. Disconnect the torch lead connector from the torch PCB. 9. Measure the voltage again between pin 3 (black wire) and pin 5 (orange wire). This time, put the multimeter leads directly in the sockets for pin 3 and pin 5. Is the voltage approximately 18 VDC? If yes, replace the power PCB.
  • Page 130 Do System Tests to Identify Defective Components Figure 38 – Pins for resistance check between torch and plasma power supply Pin 1 and pin 2 on torch PCB Pin 7 and pin 8 on power PCB J20 / J17 810430 Troubleshooting Guide Powermax65/85/105 SYNC...
  • Page 131 Do System Tests to Identify Defective Components Figure 39 – Torch lead connector pins RFID Powermax65/85/105 SYNC Troubleshooting Guide 810430...
  • Page 132 Do System Tests to Identify Defective Components 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 133: Access Service Information And Settings

    System process – This icon shows the maximum output current (A) of the Hypertherm cartridge. If there are no cartridge communications with the plasma power supply, this icon does not show on the status screen.
  • Page 134 Cartridge data – These fields show the total number of pilot arc starts (STA) and the cumulative plasma arc transfer time (XT) for the life of the Hypertherm cartridge that is installed on the torch. These fields do not show by default. Refer to page 149.

  • Page 135: Go To The Main Menu Screen

    Cartridge and plasma power supply data – Select this icon to go to use data and other information about the Hypertherm cartridge and the plasma power supply. System information – Select this icon to go to service-related information about printed circuit boards (PCBs) in the plasma power supply and in the SmartSYNC torch.

  • Page 136: View System Performance, Operation, And Fault Data

    3. Turn the adjustment knob to scroll down and see the CARTRIDGE DATA 2 screen. P/N – This field shows the part number (nnnnnn) and the version (X) of the Hypertherm cartridge. NAM – This field shows the Hypertherm cartridge type.
  • Page 137 (@nn). UID – This field shows the unique identification number of the Hypertherm cartridge. STA – This field shows the total number of pilot arc starts that the Hypertherm cartridge has done in its life. XFR – This field shows the total number of arc transfers that the Hypertherm cartridge has done in its life.

  • Page 138: Plasma Power Supply Performance And Operation Data

    Access Service Information and Settings Plasma power supply performance and operation data Go to the Power Supply Data screen (POWER SUPPLY DATA) to see information about plasma power supply performance and use. 1. Select on the main menu screen. 2. Select to go to the POWER SUPPLY DATA screen.
  • Page 139 Access Service Information and Settings TP – This field shows the boost PFC IGBT temperature in Celsius. This field shows on the screen for CSA and for Powermax105 SYNC 230 V – 400 V CE models only. TI – This field shows the inverter IGBT temperature in Celsius. STA –...

  • Page 140: Cumulative Cartridge Data For The Plasma Power Supply

    – This field shows the total number of pilot arc starts for all cartridge types that the plasma power supply has done in its life. – This field shows the total number of Hypertherm cutting cartridge starts that the plasma power supply has done in its life while in Expanded Metal mode.
  • Page 141 Access Service Information and Settings – This field shows the total number of pilot arc starts that the plasma power supply has done while there was no communication between the plasma power supply and the torch or cartridge. For example, the value in this field includes pilot arc starts when the system is in an 0-98-n fault condition or when the system is set to basic mode.

  • Page 142: View Printed Circuit Board (Pcb) And Firmware Information

    LCD/control PCB. FDC – This field shows the code for the firmware’s build day (nnnnnn_xx) and the bootloader version (.n) of the firmware.  The other fields on this screen are for internal Hypertherm use only. 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 143: Dsp Pcb And Power Pcb Information

    (.n) of the firmware. PWR – This field shows the model of power PCB that is installed in the plasma power supply.  The other fields on this screen are for internal Hypertherm use only. Powermax65/85/105 SYNC Troubleshooting Guide...

  • Page 144: Torch Pcb Information

    BH = Hand torch, and the plasma power supply is in basic mode. Refer to  page 155. BM = Machine torch, and the plasma power supply is in basic mode. Refer to  page 155.  The other fields on this screen are for internal Hypertherm use only. 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 145: View Internal Component Faults And Radio Frequency Logs

    Access Service Information and Settings View internal component faults and radio frequency logs Internal component faults Go to the Power Supply Log screen (POWER SUPPLY LOG) to see the 10 most recent internal component faults that have occurred on the plasma power supply. This is a service screen that helps to identify possible damage to components inside the plasma power supply.

  • Page 146: Radio Frequency (Rf) Settings And Operation Logs

    Access Service Information and Settings XT – This field shows when each fault occurred. The value is a timestamp in hours (HH), minutes (MM), and seconds (SS): HH:MM:SS. This value is related to the XT field on the Power Supply Data screen (POWER SUPPLY DATA). Refer to page 138.

  • Page 147: Cut Counter Data For Backups

    Access Service Information and Settings AM RSSI L – This field shows the received signal strength indicator (RSSI) of the most recently used amplitude modulation (AM) channel. RSSI is a measurement of how strong the radio signal is between the transmitter and the receiver. W/R COUNT –...

  • Page 148: View Or Change System Settings

    Access Service Information and Settings View or change system settings LCD display brightness and contrast Do the following to adjust the brightness and contrast of the liquid-crystal display (LCD) screen: 1. Push and hold for 2 seconds to go to the main menu screen. 2.

  • Page 149: Show Cartridge Data On The Status Screen

    Access Service Information and Settings Show cartridge data on the status screen You can show the cartridge data for pilot arc starts (STA) and arc transfer time (XT) on the status screen. When you set the STA/XT field to on, these values stay on the status screen until you set the STA/XT field to off.

  • Page 150: Serial Communications Parameters

    Access Service Information and Settings 7. Push to go back to the status screen. The STA and XT fields now show on the screen. Serial communications parameters Use the CNC Interface Settings screen (CNC INTERFACE) to set parameters for serial communication.
  • Page 151 Access Service Information and Settings 6. Push to select the new value. Stop bits Baud rate (can be changed) (cannot be changed) Parity (can be changed) Data bits (cannot be changed) Powermax65/85/105 SYNC Troubleshooting Guide 810430...
  • Page 152 Access Service Information and Settings – Set the parity-check configuration and stop-bit configuration for this Powermax. Make sure that the values in this field are the same as the values at the CNC. Select one of the following values for parity checking: Even (default) No parity checking Select one of the following values for stop bit:...

  • Page 153: Default Feature Configuration

    Access Service Information and Settings Default feature configuration Go to the Feature Configuration screen (FEATURE CONFIG) to change system settings. Changing these fields from their default settings is recommended only for experienced operators. Changing one of these fields from the default setting causes the non-default configuration icon (at right) to show on the status screen.
  • Page 154 0-20-0 fault code. This field is on by default. Hypertherm recommends that you keep this field on. But you can set it to off if the inlet gas pressure at your work site is not stable or if it stays low enough that you get frequent 0-20-0 faults.

  • Page 155: Smart Mode Versus Basic Mode

    155. Smart mode versus basic mode By default the system is in smart mode. Hypertherm recommends that you keep the system in smart mode. But very experienced operators can use basic mode to help with troubleshooting if necessary. To go into basic mode, set the field to BASIC.

  • Page 156: Set System Settings To Factory Default

    The non-default configuration icon (at right) no longer shows on the status  screen. If you have a Hypertherm cartridge on a SmartSYNC torch, the system  process icon (at right) shows on the status screen. The system goes back to the factory default settings for the cartridge ...

  • Page 157: How The Plasma Power Supply Operates

    How the Plasma Power Supply Operates This section contains reference information that explains how the plasma power supply operates and that identifies internal components, as follows: Sequence of operation on page 158  Powermax65/85 SYNC plasma power supply overviews on page 159 ...

  • Page 158: Sequence Of Operation

    How the Plasma Power Supply Operates Sequence of operation • Power OFF (O) • Connect the gas supply to the gas fitting on the plasma power supply. • Connect the work lead to the plasma power supply and workpiece. • Connect the torch to the plasma power supply. •...

  • Page 159: Powermax65/85 Sync Plasma Power Supply Overviews

    How the Plasma Power Supply Operates plasma power supply overviews Powermax65/85 SYNC Figure 40 – 200 V – 600 V CSA plasma power supply TP10 TP11 WORK LEAD TP12 1 J12 connector 12 Ground 2 J20 connector 13 AC input wires (3) 3 J21 connector 14 Power switch 4 Nozzle wire...
  • Page 160 How the Plasma Power Supply Operates Figure 41 – 380 V CCC / 400 V CE plasma power supply TP11 TP12 WORK TP13 LEAD 1 J12 connector 12 Ground 2 J20 connector 13 MOV assembly 3 J21 connector 14 AC input wires (3) 15 Power switch 4 Nozzle wire 5 Electrode wire...
  • Page 161 How the Plasma Power Supply Operates Figure 42 – 200 V – 600 V CSA plasma power supply (power PCB removed) 1 Output bridge diode 8 Snubber resistor 2 Pilot arc IGBT 9 Power switch (S1) 3 Inverter snubber resistor 10 PFC IGBT 4 Inverter IGBT module 11 PFC snubber resistor...
  • Page 162 How the Plasma Power Supply Operates Figure 43 – 380 V CCC / 400 V CE plasma power supply (power PCB removed) 1 Output bridge diode 6 Input diode bridge 2 Pilot arc IGBT 7 Ground 3 Inverter snubber resistor 8 Power switch (S1) 4 Inverter IGBT module 9 Output snubber resistor...

  • Page 163: Powermax105 Sync Plasma Power Supply Overviews

    How the Plasma Power Supply Operates plasma power supply overviews Powermax105 SYNC Figure 44 – 200 V – 600 V CSA plasma power supply C152 C151 WORK LEAD 1 J11 connector 12 PFC inductor wires 2 J17 connector 13 Damper resistor wires 3 J18 connector 14 Ground 15 AC input wires (3)
  • Page 164 How the Plasma Power Supply Operates Figure 45 – 230 V – 400 V CE plasma power supply C152 C151 WORK LEAD 1 J11 connector 12 PFC inductor wires 2 J17 connector 13 Damper resistor wires 3 J18 connector 14 Ground 4 Output inductor wires 15 AC input wires (3) 5 Nozzle wires...
  • Page 165 How the Plasma Power Supply Operates Figure 46 – 380 V CCC / 400 V CE plasma power supply C151 C152 WORK LEAD 1 J11 connector 11 PFC inductor wires 2 J17 connector 12 3uF Capacitors 3 J18 connector 13 Ground 4 Output inductor wires 14 AC input wires (3) 5 Nozzle wires...
  • Page 166 How the Plasma Power Supply Operates Figure 47 – 200 V – 600 V CSA plasma power supply (power PCB removed) 1 Output snubber resistor 8 PFC IGBT module 2 Output diode bridge 9 Damper resistor 10 Ground 3 Pilot arc IGBT 4 Inverter snubber resistor 11 Input diode bridge 5 Inverter IGBT module...
  • Page 167 How the Plasma Power Supply Operates Figure 48 – 230 V – 400 V CE plasma power supply (power PCB removed) 1 Output snubber resistor 8 PFC IGBT module 2 Output diode bridge 9 Damper resistor 3 Pilot arc IGBT 10 Ground 4 Inverter snubber resistor 11 Input diode bridge...
  • Page 168 How the Plasma Power Supply Operates Figure 49 – 380 V CCC / 400 V CE plasma power supply (power PCB removed) 1 Output snubber resistor 6 Bulk capacitors 2 Output bridge diode 7 Ground 3 Pilot arc IGBT 8 Input diode bridge 4 Inverter snubber resistor 9 Power switch (S1) 5 Inverter IGBT module...

  • Page 169: Theory Of Operation

    The amperage adjustment knob on the control PCB (PCB1) is used to set the output current: 20 A – 65 A for the Powermax65 SYNC or 25 A – 85 A for the Powermax85 SYNC. The system compares the setpoint to the output current by monitoring the current sensors and adjusting the output of the inverter IGBTs (Q12).

  • Page 170: Powermax105 Sync

    The amperage adjustment knob on the control PCB (PCB1) is used to set the output current: 20 A – 65 A for the Powermax65 SYNC or 25 A – 85 A for the Powermax85 SYNC. The system compares the setpoint to the output current by monitoring the current sensors and adjusting the output of the inverter IGBTs (Q9).

  • Page 171: 380 V Ccc / 400 V Ce 3-Phase Functional Description

    How the Plasma Power Supply Operates The digital signal processor (PCB2) monitors and controls the system’s operation and safety circuits. The amperage adjustment knob on the control PCB (PCB1) is used to set the output current: 30 A – 105 A. The system compares the setpoint to the output current by monitoring the current sensors and adjusting the output of the inverter IGBT module.
  • Page 172 How the Plasma Power Supply Operates 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 173: System Diagrams

    System Diagrams This section contains the following system diagrams: Powermax65/85 SYNC schematic – CSA models on page 175  Powermax65/85 SYNC schematic – CE/CCC models on page 176  Powermax105 SYNC schematic – CSA models and 230 V – 400 V CE models ...
  • Page 174 System Diagrams 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

  • Page 175: Powermax65/85 Sync Schematic - Csa Models

    EXTERIOR VIEW SEE TORCH BELOW 5 6 7 8 9 10 1 2 3 1 2 3 4 5 4 3 2 1 MICRO SD CARD READER (HYPERTHERM USE ONLY) HEATSINK PWR SW TEMP FILL PRESSURE FAN PWM ACTIVATE SPEED...

  • Page 176: Powermax65/85 Sync Schematic - Ce/Ccc Models

    (BLU) FRONT PANEL EXTERIOR VIEW SEE TORCH BELOW 5 6 7 8 9 10 1 2 3 5 4 3 2 1 MICRO SD CARD READER (HYPERTHERM USE ONLY) FILL PRESSURE FAN PWM ACTIVATE DRVD SPEED DSP BOARD DUMP VALVE...

  • Page 177: Powermax105 Sync Schematic - Csa Models And 230 V - 400 V Ce Models

    SEE TORCH EXTERIOR VIEW BELOW 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 4 3 2 1 MICRO SD CARD READER (HYPERTHERM USE ONLY) SWITCH HEATSINK FILL PRESSURE STATE TEMP SPEED FAN ACTIVATE...

  • Page 178: Powermax105 Sync Schematic - 380 V Ccc Models And 400 V Ce Models

    SEE TORCH EXTERIOR VIEW BELOW 5 6 7 8 9 10 1 2 3 4 1 2 3 4 5 4 3 2 1 MICRO SD CARD READER (HYPERTHERM USE ONLY) SWITCH HEATSINK FILL STATE TEMP SPEED PRESSURE ACTIVATE DUMP...

  • Page 179: Timing Chart For Torch Start

    System Diagrams Timing chart for torch start Transfer Inverter on and (when work lead Cutting Start signal OFF/ Idle solenoid opens pilot arc established current ≥ 1.6 A) (steady state) Torch trigger released Idle Start signal/torch trigger ON/OFF icon ON/OFF on status screen Pilot arc IGBT ON/OFF Postflow Gas solenoid ON/OFF...
  • Page 180 System Diagrams 810430 Troubleshooting Guide Powermax65/85/105 SYNC...

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