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Hypertherm Powermax105 Troubleshooting Manual Download Page 171

How the Plasma Power Supply Operates

7

Powermax65/85/105 SYNC

Troubleshooting Guide

810430

171

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. (Q12).

380 V CCC / 400 V CE 3-phase functional description

AC power goes into the system through the power switch (S1) to the input diode bridge (D38). The 
voltage from the bridge supplies a nominal 530 VDC to 560 VDC bus voltage. The bus supplies 
voltage and current to the inverter and the flyback circuit (DC to DC converter) on the power PCB 
(PCB3). The power PCB provides noise suppression and spike protection. The power PCB 
resistors (RT4, RT5) and relay (K2) do a “soft start.”

The inverter has a dual IGBT package (Q12), the power transformer, a current sensor, and the 
control circuit. The inverter operates as a pulse-width modulated half-bridge circuit driving an 
isolation transformer. The output bridge (D36 and D37) corrects the output of the isolation 
transformer.

The output circuitry has 2 current sensors located on the power PCB, the pilot arc IGBT (Q13), and 
the output choke.

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. (Q12).

Summary of Contents for Powermax105

Page 1: ...Powermax65 85 105 SYNC Troubleshooting Guide 810430 REVISION 0 ENGLISH ...

Page 2: ...f you experience any problems with the product registration process please contact registration hypertherm com For your records Serial number __________________________________________________________________________ Purchase date __________________________________________________________________________ Distributor _____________________________________________________________________________ ____...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com Powermax65 85 105 SYNC Troubleshooting Guide 810430 REVISION 0 ENGLISH Original instructions January 2022 ...

Page 4: ... 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 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 Hypertherm Shanghai Trading Co Ltd B301 495 ShangZhong Road Shanghai 200231 PR China 86 21 80231122 Tel 86 21 80231120 Fax 86 21 80231128 Tel Technical Service techsupport...

Page 5: ... 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...

Page 6: ...ystem 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 ...

Page 7: ...X 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 6 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 1...

Page 8: ...ory 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 8 System Diagrams 173 Powermax65 85 SYNC schematic CSA models 17...

Page 9: ...urvallisuuden ja vaatimustenmukaisuuden käsikirja 80943C ja radiotaajuusvaroitusten käsikirja 80945C Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa Sähköiset kopiot ovat myös verkkosivustollamme Monet käyttöoppaat ovat myös saatavissa useilla kielillä www hypertherm com docs FR FRANÇAIS FRENCH AVERTISSEMENT Avant d utiliser tout équipement Hypertherm lire le...

Page 10: ...bo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka v Priročniku za varnost in skladnost 80669C v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom 80943C in v Priročniku Opozorilo o radijskih frekvencah 80945C Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki Elektronski izvodi so na voljo tudi na našem spletnem...

Page 11: ...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 Powermax105 SYNC Service Parts and Procedures Guide 810450 SmartSYNC Torches Service Parts and Procedures Guide 810460 Powermax65 85 105 SYNC Operator Manual 810470 Powermax65 85 105 SYNC Mech...

Page 12: ...Before You Begin 1 12 810430 Troubleshooting Guide Powermax65 85 105 SYNC ...

Page 13: ...e cover from the plasma power supply If the plasma power supply is connected directly to a line disconnect box switch the line disconnect to OFF O In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts Do not touch the tip of the nozzle when the system...

Page 14: ...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 CAUTION MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts NOTICE Static electricity can cause damage to printed circuit boards PCBs Use correct precautions when you touch PCBs Keep PCBs in ant...

Page 15: ... Parts and Repair Procedures 810440 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 After you repair the problem do a test of the plasma power supply for correct operation Refer to Sequence of operation on page 158 Power OFF O and di...

Page 16: ... Extended thin meter points Use extended thin meter points to get a voltage or resistance reading on certain parts of the power PCB Miniature banana plugs 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: ...n on best practices to decrease noise refer to the Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 For example keep the torch lead and work lead together by using cable ties or intertwining them like a twisted pair Also keep the routing of the torch lead and work lead separate from the shielded cables and from all other components of the mechanized cutting system Does other industrial equip...

Page 18: ...roximately 2 seconds Refer to Set system settings to factory default on page 156 Examine the power cord Is the power cord plugged in Or is it connected correctly to a line disconnect switch or other power source Is there any visible damage to the power cord Are any wires exposed or frayed Examine the power cord wires in the power plug or line disconnect box Are any of the wires short circuited Is ...

Page 19: ...nected to the cutting table Does the work clamp have good metal to metal contact If not remove any rust paint or other debris to give a clean surface for a better connection Examine the torch and torch lead Is the torch lead connected correctly to the plasma power supply The torch lead connector makes a click when it is fully connected Examine the torch lead Are any wires exposed or frayed Is the ...

Page 20: ...e there other devices that use gas from the same source Is sufficient gas pressure getting to the plasma power supply Refer to page 23 Are you able to keep gas pressure constant while you are cutting Refer to page 23 Examine the gas quality Examine the whole gas supply line Are there any signs of contamination such as from oil water or dirt It is extremely important to keep a clean dry gas line Re...

Page 21: ...ower supply 4 Inspect the inside of the plasma power supply especially on the side with the power PCB Look for broken or loose wiring connections burn and char marks and damage to components Repair or replace internal components as necessary 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 ...

Page 22: ...st on page 26 Do a cold restart or quick restart Do a cold restart 1 Set the power switch on the plasma power supply to OFF O 2 Wait approximately 1 minute If you are using a SmartSYNC hand torch wait until all the amperage LEDs on the hand torch go off 3 Set the power switch on the plasma power supply to ON I Do a quick restart 1 Set the power switch on the plasma power supply to OFF O 2 Immediat...

Page 23: ...eet use an internal diameter of 13 mm 1 2 inch or greater Pressure setting The plasma power supply adjusts gas pressure automatically but you can adjust the gas pressure manually if necessary If you manually adjust the gas pressure and then start to see problems with cut quality or cut performance set the gas pressure back to the default setting Gas test You can do a gas test to see if the plasma ...

Page 24: ...tremely warm and humid or if work site conditions let oil vapor or other contaminants into the gas line install an external filtration system that cleans the gas supply before it gets into the plasma power supply To keep a clean gas line 1 Examine the air filter element in the plasma power supply s built in air filter Replace it if it is contaminated Refer to the Powermax65 85 105 SYNC Operator Ma...

Page 25: ...these points replace the quick disconnect receptacle Table 1 Continuity test points in the plasma power supply Table 2 Continuity test points in the plasma power supply Quick disconnect receptacle J20 or J17 on the power PCB Wire color 5 1 Blue 6 3 Violet 7 2 Orange 8 9 Black 9 7 Brown 10 8 Gray 11 4 Yellow 12 5 White 13 6 Red J20 on Powermax65 85 SYNC J17 on Powermax105 SYNC 8 7 6 5 4 3 2 1 J20 J...

Page 26: ...e warning puffs of air 3 Make sure that the correct operating mode is selected for the process that you want to examine Cut mode Gouge mode or Expanded Metal mode 4 Push and hold the operating mode button for 2 seconds until the gas test screen shows Gas flows continuously from the torch when the plasma power supply is in gas test mode WARNING CHANCE OF BURNS AND CUTS Point the torch away from you...

Page 27: ...stop the gas test and go back to the status screen Gas stops flowing from the torch 7 If the output gas pressure was too low in step 5 examine the inlet pressure from the gas supply source It is possible that the solenoid valve electronic regulator must be replaced Do Test 9 Solenoid valve electronic regulator on page 112 Do a gas test in manual gas pressure mode If the plasma power supply is in m...

Page 28: ...ou find the problem After you repair the problem refer to Sequence of operation on page 158 to do a test of the plasma power supply for correct operation Examine the power switch 1 Set the power switch on the plasma power supply to OFF O and disconnect the power cord 2 Disconnect the torch from the plasma power supply 3 Remove the plasma power supply cover and the component barrier 4 Set the power...

Page 29: ...he heatsink For all models the resistance from input to ground must read as greater than 20 megaohms MΩ With the power disconnected and the power switch set to OFF O all circuits must read as open The electrical values shown are 25 Figure 1 Power switch in the plasma power supply 1 L1 L2 L3 20 MΩ L1 L2 L3 CSA and 230 V 400 V CE models CCC and 400 V CE models 650 kΩ 650 kΩ 500 kΩ 20 MΩ 400 kΩ 400 k...

Page 30: ...3 on page 31 Table 3 Powermax65 85 SYNC power switch resistance values Figure 2 Powermax65 85 SYNC Measure resistance from CSA power PCB location CE CCC power PCB location Approximate values with torch disconnected Work lead to nozzle J26 to black wire J27 to black wire 230 kΩ Work lead to electrode J26 to J28 red wire J27 to J29 red wire 15 kΩ Electrode to nozzle J28 red wire to black wire J29 re...

Page 31: ...nditions Refer to the system wiring diagrams on page 173 Make sure that you understand the theory of operation before you do troubleshooting procedures 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 Measure resistance...

Page 32: ...ibed in the following sections Or you can assemble your own IGBT tester from the schematic diagram shown on page 38 and use it to do IGBT tests Table 5 Hypertherm IGBT tester 128884 7 8 9 1 2 3 4 5 6 10 1 Test for short circuited IGBT 2 Fail LED red 3 Pass LED green 4 Circuit diagram 5 Low battery LED red 6 Test for open circuit in the IGBT 7 Rocker switch 8 Collector red 9 Gate yellow 10 Emitter ...

Page 33: ...ch connection on the IGBT has a label with an abbreviation These label abbreviations can be C E G or 1 2 3 with a schematic that shows numbers and pin functions 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 Red fail LED When...

Page 34: ...Inverter test 2 1 2 3 4 5 6 1 Yellow lead Gate 2 G2 2 Black lead Emitter 2 E2 3 Red lead Collector 2 C2 4 Red lead Collector 1 C1 5 Black lead Emitter 1 E1 6 Yellow lead Gate 1 G1 IGBT module PFC IGBT Pilot arc 1 2 3 4 1 2 3 1 Yellow lead Gate G 2 Black lead Emitter E 3 Red lead Collector C 4 This pin is for the IGBT internal temperature sensor Do not use the IGBT tester here ...

Page 35: ...st of the IGBT tester as shown in the following table If the results do not agree with the values in the table replace the lead connections Switch Position LED Meaning Corrective action Fail Pass Battery Left X IGBT is short circuited Replace IGBT Left X IGBT passed the short circuit test None Left X Battery below 8 V Replace battery Left Dead battery Replace battery Right X IGBT has an open circu...

Page 36: ...ine the IGBT for cracks or black marks Replace the IGBT if it has damage 2 Make sure that the battery voltage is higher than 8 V 3 Connect the test leads as shown in Figure 5 on page 37 4 Make sure that the test leads are connected and the push button switch is not engaged Is the LED illuminated If yes the IGBT is short circuited Replace the IGBT If no continue with the next step 5 Make sure that ...

Page 37: ...nverter test 2 1 2 3 4 5 6 1 Yellow lead Gate 2 G2 2 Black lead Emitter 2 E2 3 Red lead Collector 2 C2 4 Red lead Collector 1 C1 5 Black lead Emitter 1 E1 6 Yellow lead Gate 1 G1 IGBT module PFC IGBT Pilot arc 1 2 3 4 1 2 3 1 Yellow lead Gate G 2 Black lead Emitter E 3 Red lead Collector C 4 These pins are for the IGBT internal temperature sensor Do not use the IGBT tester here ...

Page 38: ...ematic 7 8 9 1 2 3 4 5 6 11 13 14 15 16 12 10 1 Collector 1 C1 2 Emitter 2 E2 3 Collector 2 Emitter 1 C2 E1 4 Gate 1 G1 5 Emitter 1 E1 6 Emitter 2 E2 7 Gate 2 G2 8 Red minigrabber test clip 9 D1 Red LED lamp 10 R3 2 0K 11 R4 2 0K 12 9 VDC battery 13 Normally open N O push button switch 14 R1 3 01M 15 Black minigrabber test clip 16 Yellow minigrabber test clip ...

Page 39: ...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 Fault codes are in the format N nn n The fault code value identifies the importance of the fault the higher the number the higher the importance If more than one fault occurs at the same time the fault code with the highest importance shows The Power Supply Log screen shows the 10 most recent f...

Page 40: ... fault icons on page 41 The yellow status LED also flashes quickly for the 0 32 1 fault code to remind you that it is necessary to install a new cartridge The 0 32 1 fault code shows the fault icon The yellow status LED flashes slowly one flash every 1 2 seconds for the 0 98 2 torch communication fault code The yellow status LED also flashes slowly when the system is in basic mode Refer to page 15...

Page 41: ... identifies fault conditions in which the plasma power supply is outside the range of permitted operating temperatures Gas This icon identifies fault conditions in which the gas supply is disconnected from the plasma power supply or there is a problem with the gas supply Cartridge Not Recognized This icon shows when a cartridge cannot communicate with the plasma power supply When a cartridge canno...

Page 42: ...ear your work area for reference Operational faults 0 nn n Fault codes in the 0 nn n format identify operational faults These faults do not show on the Power 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 Torch Communications Thi...

Page 43: ...llowing There is a problem with the remote control or the software interface to the system The system cannot interpret the operating mode output current or gas pressure information coming from the controller Examine the programming code for incorrect process variables Repair the controller 0 11 1 The remote control output current A is incorrect or not permitted for the installed cartridge The perm...

Page 44: ... if the plasma power supply s actual output gas pressure is lower than the set pressure by more than an acceptable quantity Refer to Do a gas test on page 26 The gas subsystem is not operating correctly Examine the solenoid valve Do Test 10 Solenoid valve pressure sensor on page 115 0 12 2 The gas pressure output is high 0 12 3 The gas pressure output is not stable 0 13 0 Yellow Flashes green Flas...

Page 45: ...ets the operating mode to Cut mode It sets the output gas pressure to cut pressure The system adjusts the pressure even if the system is in manual gas pressure mode when the fault occurs If necessary you can manually change these settings to cut without a data connection To prevent the system from adjusting these settings when communication with the cartridge is broken put the system in basic mode...

Page 46: ...of electrical noise Wait for the fault to go away and continue to cut If you use serial communications this fault can occur temporarily on the CNC when you set the plasma power supply to OFF O Wait for 1 minute for the fault to go away on its own If this fault continues to occur a 3 nn n fault code can show on the status screen to identify a hardware fault with an internal component Go to Internal...

Page 47: ...er Make sure that there is sufficient inlet gas pressure from the gas supply source Manually adjust the gas pressure on the plasma power supply Do a gas test to see if the plasma power supply s actual output gas pressure is lower than the set pressure by more than an acceptable quantity Refer to page 26 If there is no apparent problem with the inlet gas supply examine the air filter bowl and air f...

Page 48: ...all 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 Replace the solenoid valve assembly if necessary The DSP PCB or the power PCB are possibly defective Do Test 9 Solenoid valve electronic regulator on page 112 0 22 0 Yellow Yellow There is no gas supply input This fau...

Page 49: ...ound the tip of the cartridge Remove the cartridge and carefully shake it to remove unwanted material that has collected inside the cartridge This material can cause 0 30 0 faults to occur A higher rate of 0 30 0 faults is typical as a cartridge gets near end of life Install a new Hypertherm cartridge If the fault occurred during postflow or during a cut do the following Examine the gas line Refer...

Page 50: ...too cold Hypertherm recommends that you operate the system only in external temperatures between 10 C to 40 C 14 F to 104 F The system is possibly overheated Keep the plasma power supply ON to let the fan decrease the temperature of the internal components Make sure that there is sufficient air flow around the plasma power supply Make sure that the plasma power supply cover is installed with the l...

Page 51: ...emove the Hypertherm cartridge and install it correctly Machine torch This fault code shows when you remove the cartridge without first setting the power switch to OFF O or moving the torch lock switch to the yellow lock X position Lock and unlock the torch or do a quick restart Mini machine torch This fault code can show if you change the cartridge while the power switch on the plasma power suppl...

Page 52: ... the torch 1 time to get the warning puffs of air The 0 50 2 fault code goes off and the LED on the hand torch changes from yellow to green The torch is now prepared to fire a plasma arc Machine torch The 0 50 2 fault code shows for approximately 1 second and then goes off Fire the torch to get a plasma arc There are no warning puffs of air If the 0 50 2 fault code does not go off send a STOP sign...

Page 53: ...ode stops the system from operating Do the following A quick restart is necessary Make sure that the torch lead is correctly connected to the FastConnect receptacle on the front of the plasma power supply Do a quick restart Do a check for continuity at the FastConnect receptacle Refer to page 25 If you disconnect the torch while the plasma power supply is set to ON I you get the 0 52 0 fault code ...

Page 54: ...ted voltage Have an electrical technician examine the line and decrease the voltage If applicable disconnect the system from generator power or set the generator mode feature to on Refer to Generator considerations on page 62 Do Test 1 Voltage input on page 78 This fault code is not applicable for Powermax65 85 SYNC CSA models 0 61 0 Yellow Yellow An AC input is not stable Shut down the system Thi...

Page 55: ...on cable Refer to Powermax65 85 SYNC Service Parts and Procedures Guide 810440 or Powermax105 SYNC Service Parts and Procedures Guide 810450 If the system is in basic mode when the fault occurs the system automatically adjusts the following settings to prevent damage to the cartridge It sets the output current to 45 A It sets the operating mode to Cut mode It sets the output gas pressure to cut pr...

Page 56: ...tridge Install a new Hypertherm cartridge Torch The RF component on the PCB in the SmartSYNC torch has damage Make sure that the wires in the torch are in the correct slots in the torch PCB and are connected correctly Do Test 14 Radio Frequency RF communication errors on page 126 0 98 2 Flashes yellow A communication failure occurred between the torch and the plasma power supply This fault code do...

Page 57: ...it is possible that the DSP PCB or the power PCB must be replaced 1 20 0 An input output I O fault occurred 1 30 0 A flash memory fault occurred Fault code Fault icon Fault LEDs Description Solutions 2 00 0 Yellow Red The analog to digital converter ADC value is out of range Do a cold restart If restarting the plasma power supply does not remove the fault condition it is possible that the DSP PCB ...

Page 58: ...cuited 2 20 0 Yellow Red The DSP PCB does not recognize the torch Make sure that the torch lead is correctly connected to the FastConnect receptacle on the front of the plasma power supply Do a quick restart Examine the FastConnect receptacle to make sure that the pin out is correct Refer to Do a check for continuity on page 25 Also refer to the wiring diagram for your system starting on page 173 ...

Page 59: ...t DC minor voltages on page 94 3 10 0 Yellow Red The fan speed is less than the minimum speed Clean the fan assembly Do Test 11 Fan on page 120 3 10 1 A fan fault occurred Examine the related wiring Do Test 11 Fan on page 120 If necessary replace the fan 3 11 0 Yellow Red The PFC IGBT temperature sensor is open This is applicable to CSA and Powermax105 SYNC CE CCC 230 V 400 V models only Examine t...

Page 60: ...red in the Start Transfer relay or the soft start inrush current relay on the power PCB 3 42 0 The 5 VDC or 24 VDC supply is out of range The 5 VDC or 24 VDC supply from the flyback circuit is out of range Do Test 5 Flyback circuit DC minor voltages on page 94 3 42 1 The 18 VDC supply is out of range The 18 VDC supply from the flyback circuit is out of range Replace the power PCB Examine the inver...

Page 61: ...replace the power PCB 3 52 0 A short circuit caused high current distortion in the inverter IGBT This is sometimes referred to as a shoot through 3 60 0 Yellow Red The DSP PCB does not recognize the power PCB Make sure that the correct power PCB is installed for the plasma power supply 3 70 0 Yellow Red There is an internal serial communications fault between the DSP PCB and power PCB There is a f...

Page 62: ...ome generators 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 Make sure that you set the GEN field to off when you a...

Page 63: ...ires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 80669C for more safety information WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY BURNS Ignition of the plasma arc occurs immediately when you pull the torch trigger Before changing the cartridge one of the following steps is necessary Whenever poss...

Page 64: ...rkpiece or cutting table Remove any rust paint or other residue Make sure that there is good metal to metal contact Examine the work clamp for damage Repair or replace it if necessary Make sure that the cutting table is correctly grounded and has good contact with the workpiece The output current A is set too low Increase the output current A as necessary The operating mode setting on the plasma p...

Page 65: ...on page 78 to do a check of the incoming voltage and the power switch Do Test 12 Auxiliary AUX switch on page 123 This test is not applicable for Powermax65 85 SYNC CE CCC models The fan is defective The solenoid valve is defective The power PCB is defective Do Test 5 Flyback circuit DC minor voltages on page 94 An IGBT is defective The power PCB is defective Do Test 1 Voltage input on page 78 Do ...

Page 66: ...he workpiece or cutting table Remove any rust paint or other residue Make sure that there is good metal to metal contact Examine the work clamp for damage Repair or replace it if necessary Make sure that the cutting table is correctly grounded and has good contact with the workpiece Decrease the cut height Gas flows from the torch when you set the plasma power supply to ON I but you did not fire t...

Page 67: ...e gas quality is unsatisfactory The filter element in the air filter is dirty Oil moisture or other contaminants are in the gas supply line Replace the air filter element Add additional external filtration that is applicable for the work environment Refer to the Powermax65 85 105 SYNC Operator Manual 810470 Flush the gas supply line with nitrogen to remove oil and moisture The input power is not s...

Page 68: ...yback circuit DC minor voltages on page 94 The system is in Expanded Metal mode but the torch does not keep the plasma arc when you move the torch off of the metal The Expanded Metal mode feature is not operating correctly The operating mode setting on the plasma power supply is not correct Make sure that the operating mode is correctly set to Expanded Metal mode The DSP PCB is defective The power...

Page 69: ...oes not time out after 5 seconds The system is not connected to ground sufficiently The work lead connection is not satisfactory If possible move the work clamp closer to the area of the workpiece you are cutting Clean the area where the work clamp comes into contact with the workpiece or cutting table Remove any rust paint or other residue Make sure that there is good metal to metal contact The w...

Page 70: ...he fan If the LED screen does not come on do Test 11 Fan on page 120 The LCD screen on the front panel is too bright or too dark The ambient temperature of the work site is having an effect on the LCD screen Very hot environments can make the LCD screen darker Very cold environments can make the LCD screen brighter Adjust the brightness and contrast settings as necessary on the LCD Display screen ...

Page 71: ...not keep changes to the output current A or operating mode while the torch lock switch is in the yellow lock X position or while there is an 0 50 n cartridge off fault condition Set the torch lock switch to the ready to fire position before you adjust the amperage or operating mode When you set the torch lock switch to the ready to fire position the system automatically sets the amperage and opera...

Page 72: ...ine 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 Examine the gas filtration system for signs of moisture Refer to page 24 Cartridge life is shorter than expected Examine the gas pressure and the gas supply hose Refer to page 23 Examine the gas filtration system for signs of moisture Refer to page 24 Rest...

Page 73: ...tridge If it does not look at the LCD screen Do you see the non default configuration icon at right If yes put the plasma power supply in smart mode if it is in basic mode Refer to page 155 If no there is possibly a problem with the Hypertherm cartridge torch or plasma power supply Make sure that the torch is being used correctly Increase the output current A on the plasma power supply If the outp...

Page 74: ... Smart mode versus basic mode on page 155 Problem Solution Problem Solution The arc goes out during gouging Decrease the arc stretch standoff Put the torch in a more upright position The torch tip hits the molten metal slag Increase the arc stretch standoff Keep the torch tip pointed in the direction of the gouge that you want to make The gouge has too much depth Tilt the torch down so that it is ...

Page 75: ...hase 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 WARNING Use extreme caution when working near live electrical circuits Dangerous voltages are inside the plasma power supply that can cause serious injury or death Live voltages can continue to be present on the DC bus for...

Page 76: ...on page 91 0 40 n 2 10 n 3 11 n Test 5 Flyback circuit DC minor voltages on page 94 3 00 0 3 42 n 3 43 n Test 6 Torch stuck open TSO or torch stuck closed TSC on page 98 0 30 n Test 7 Start signal on page 102 0 51 0 general Test 8 Torch cap switch on page 108 0 50 0 Test 9 Solenoid valve electronic regulator on page 112 0 21 0 3 20 n Test 10 Solenoid valve pressure sensor on page 115 0 12 0 0 20 0...

Page 77: ...ing components are behind the DSP PCB Use extended thin meter points to measure voltage on these pins Refer to Get the necessary test equipment on page 16 Figure 7 J1 J2 J3 and J4 pins in Powermax65 85 SYNC CSA Figure 8 J4 J5 and J6 pins in Powermax65 85 SYNC CE CCC J12 B R J4 J2 J1 J3 2 J3 J1 Auxiliary switch J2 Inverter temperature sensor J3 Fan J4 Solenoid valve electronic regulator J12 B R J6 ...

Page 78: ...emove the plasma power supply cover and the component barrier 3 Connect the power cord to the power source but keep the plasma power supply set to OFF O J6 J5 J2 J1 J11 B R J6 J1 Fan J2 Inverter temperature sensor J5 Auxiliary switch J6 Solenoid valve electronic regulator WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contains dangerous electric voltages that can seriously injure or kill ...

Page 79: ...y If yes an additional check is necessary to identify if the problem is with the power switch or with a different component Continue with Examine the power switch and the plasma power supply If no continue with the next step 6 If the voltage across the input leads is not correct have a qualified service technician examine the following electrical components Power cord Receptacle where the power co...

Page 80: ...tage 3 Is the voltage to the power switch correct but the voltage to the input diode bridge is low If yes replace the power switch If no continue with the next step 4 Measure the output voltage of the input diode bridge Refer to Figure 10 or Figure 11 Output VDC Line Voltage x 1 414 VDC All values are 15 Figure 10 Powermax65 85 SYNC BLK BLK J13 1 phase L Black CSA N White CSA PE Green CSA 3 phase ...

Page 81: ...but you continue to get an 0 60 n fault code do the following a Go to the POWER SUPPLY DATA screen b Make sure that the value in the VL field is 15 of the AC line voltage 3 phase L1 Black CSA Brown CE CCC L2 White CSA Black CE CCC L3 Red CSA Gray CE CCC PE Green CSA Green yellow CE CCC LV 1 732 Black wire Ground GRD LV LV LV LV X 1 414 LV 1 732 LV 1 732 LV incoming line voltage ...

Page 82: ...screen after the plasma power supply is set to ON I b With the fan disconnected does the problem go away If yes replace the fan If no perform the steps in Test 5 Flyback circuit DC minor voltages on page 94 that are related to the fan If the problem continues examine the DSP PCB c Disconnect the DSP PCB from the power PCB Carefully remove the conformal coating from the pins if necessary Too much o...

Page 83: ...upply to ON I NOTICE Do not use a multimeter with test leads for this test This can cause a short circuit between the bus and the heatsink Use miniature banana plugs instead and attach them to the test point TP openings in the power PCB 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 se...

Page 84: ...he torch 8 The voltage between the bulk capacitors must be approximately the same before and during torch operation The voltage must also be approximately half of the bus voltage as shown in Table 6 Table 6 9 If the voltage measurements are out of range replace the power PCB 1 2 Powermax system and input power Correct voltage approximate Powermax65 85 105 SYNC CSA on 200 VAC 480 VAC input power 37...

Page 85: ...ure 12 Powermax65 85 SYNC voltages for inverter IGBT and bulk capacitors J19 TP13 TP11 TP12 W R B J18 J23 J24 J30 J16 J17 J18 J19 J29 TP12 TP10 TP11 W R B 1 2 1 2 750 VDC 375 VDC 375 VDC 850 VDC 425 VDC 425 VDC 560 VDC 280 VDC 280 VDC CSA CE CCC 200 VAC 480 VAC input CSA 600 VAC input CSA 400 VAC input CE CCC ...

Page 86: ... IGBT and bulk capacitors J26 C152 C151 J25 _ _ TP7 TP9 TP8 W R B J22 J21 D38 J22 J21 J20 J19 J26 J25 _ _ C152 C151 TP7 TP9 TP8 W R B 1 2 1 2 750 VDC 375 VDC 375 VDC 850 VDC 425 VDC 425 VDC 560 VDC 280 VDC 280 VDC 530 VDC 265 VDC 265 VDC CSA CE CE CCC 200 VAC 480 VAC input CSA 230 VAC 400 VAC input CE 600 VAC input CSA 400 VAC input CE 380 VAC input CCC ...

Page 87: ...unting screws b From the fan side remove the 2 bulk capacitors by pulling them straight out of the plasma power supply Remove the fan shroud from the fan if necessary 4 Measure the resistance between the test points TPn on the power PCB as shown in Figure 14 on page 89 and Figure 15 on page 89 Use miniature banana plugs for example Pamona 2945 plugs to connect to the test points If miniature banan...

Page 88: ...tion each capacitor so that the gray polarity dot on the capacitor aligns with the viewing hole on the power PCB 6 From the power PCB side attach the bulk capacitors to the power PCB with the 4 mounting screws Install the screws by hand first For Powermax65 85 SYNC tighten the screws to 2 3 N m 20 lbf in For Powermax105 SYNC tighten the screws to 4 0 N m 35 lbf in 1 2 1 2 ...

Page 89: ... TP12 W R B J23 J24 J30 J29 TP12 TP10 TP11 W R B CSA Test points Resistance TP10 and TP12 25 kΩ TP11 and TP12 25 kΩ CE CCC Test points Resistance TP11 and TP13 18 kΩ TP12 and TP13 18 kΩ J27 WORK LEAD J26 _ C152 TP7 TP9 TP8 W R B 200 V 600 V CSA 230 V 400 V CE Test points Resistance TP7 and TP9 25 kΩ TP8 and TP9 25 kΩ 380 V CCC 400 V CE Test points Resistance TP7 and TP9 18 kΩ TP8 and TP9 18 kΩ ...

Page 90: ...e put the black common lead on 3 Refer to Figure 16 A diode that is operating correctly gives the following values The value is open very high resistance with the meter leads in one direction The value is within the range of 0 1 V 1 0 V with the meter leads in the opposite direction 4 If a diode has one of the following conditions replace both output diode bridges Always replace output diodes as a...

Page 91: ... 5 Do the procedure for the fault code you saw in step 1 as follows Procedure for fault codes 0 40 0 0 40 1 3 11 0 or 3 11 1 on page 91 Procedure for fault codes 0 40 2 0 40 3 2 10 0 or 2 10 1 on page 92 Procedure for fault codes 0 40 0 0 40 1 3 11 0 or 3 11 1 This procedure is only for the following systems All Powermax65 85 105 SYNC CSA models Powermax105 SYNC 230 V 400 V CE models 1 Disconnect ...

Page 92: ...llows J2 in Powermax65 85 SYNC CSA models J4 in Powermax65 85 SYNC CE CCC models J2 in all Powermax105 SYNC models 2 Measure the resistance between pin 1 and pin 3 on the connector Is the resistance approximately 10 kiloohms kΩ 1 5 kΩ If yes continue with the next step If no replace the thermal sensor 3 Remove the DSP PCB 4 Keep the thermal sensor disconnected and measure the resistance between pi...

Page 93: ... 810430 93 Figure 18 Inverter thermal sensor pins on power PCB RED J32 RED J21 ORG J20 J12 B R WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 J29 TP12 J28 TP10 TP11 W R B J4 J2 J1 J3 2 J3 J4 J2 J1 J3 1 3 J6 J2 J1 J5 1 3 J6 J4 J3 J5 1 3 Powermax65 85 SYNC CE CCC Powermax65 85 SYNC CSA Powermax105 SYNC ...

Page 94: ...lasma power supply to OFF O and disconnect the power cord 2 Remove the plasma power supply cover and the component barrier 3 Connect the power cord to the power source and set the power switch on the plasma power supply to ON I 4 Measure the voltages for the internal components shown in Table 7 on page 95 Refer to Figure 19 on page 97 WARNING ELECTRIC SHOCK CAN KILL The plasma power supply contain...

Page 95: ...place the solenoid valve assembly If no continue with the next step 7 Is the 3 3 VDC measurement on the power PCB correct If yes continue with the next step If no remove the DSP PCB from the system Measure the voltage again from pin 4 to ground Is the voltage correct now If yes continue with the next step If no replace the power PCB System Component Pin number to ground Correct voltage 15 Powermax...

Page 96: ...ll 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 If no replace the DSP PCB 9 If all of the voltage measurements are correct but you continue to see the same fault code replace the power PCB ...

Page 97: ...pins on power PCB ORG J20 J12 B R J4 J2 J1 J3 5 7 1 4 J11 4 ORG J20 J15 B R J6 J4 J3 J5 5 7 1 4 J14 4 J6 J5 J2 J1 ORG 7 J11 B R 5 7 1 4 J15 4 RED J32 RED J21 ORG J20 J12 B R WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 J29 TP12 J28 TP10 TP11 W R B J4 J2 J1 J3 2 J3 Powermax65 85 SYNC CE CCC Powermax65 85 SYNC CSA Powermax105 SYNC ...

Page 98: ... that can cause gas pressure leaks 3 Connect a different torch to the plasma power supply that is known to operate correctly Does the 0 30 n fault go away If yes continue with the next step If no continue with Examine the plasma power supply on page 99 4 Do a check for continuity on the original torch as follows a Make sure that a cartridge is installed on the torch and that the torch is not conne...

Page 99: ...nnect to the pilot arc IGBT and the red wire that connects to J28 on the power PCB or J29 on Powermax65 85 SYNC CE CCC models Refer to Figure 20 on page 100 and Figure 21 on page 100 7 Start a gas test 8 With gas flowing from the torch measure the resistance again between the pilot arc IGBT and J28 or J29 Refer to Figure 20 on page 100 and Figure 21 on page 100 Is the resistance greater than 10 ki...

Page 100: ... and disconnect the power cord 2 Measure the resistance again between the pilot arc IGBT and J28 or J29 Is the resistance less than 100 ohms Ω If yes continue with the next step If no continue with step 5 3 Disconnect the torch from the plasma power supply WORK LEAD J26 J27 J28 J29 WORK LEAD J26 J27 J28 J29 System at idle Gas is flowing 5 Ω 10 kΩ 1 1 2 2 RED J27 WORK LEAD J26 J32 J28 RED J27 WORK ...

Page 101: ...the next step Do a check of the pilot arc IGBT 1 Make sure that the plasma power supply is still OFF and is disconnected from power 2 Install a jumper wire from the pilot arc IGBT to the work lead connector on the power PCB as follows Refer to Figure 22 Use a wire that is 8 AWG at a minimum Connect to the work lead at J26 on Powermax65 85 SYNC CSA models Connect to the work lead at J27 on Powermax...

Page 102: ...cuits in the torch lead Replace the torch lead if the wires in it are short circuited Also do a check for short circuits in the trigger switch assembly Replace the trigger switch if it is short circuited If no reconnect the torch to the plasma power supply and continue with the next step 5 Does the torch started icon show as you fire the torch If yes continue with step 8 If no disconnect the torch...

Page 103: ...k for continuity between pin 5 on the torch PCB orange wire and pin 2 at J20 Powermax65 85 SYNC or J17 Powermax105 SYNC on the power PCB Refer to Figure 23 on page 104 d If you do not have continuity between the pins examine the DSP PCB Continue with the next step 8 Set the power switch on the plasma power supply to OFF O and disconnect the power cord 9 Remove the plasma power supply cover and the...

Page 104: ...e 23 Pins for continuity check between torch and plasma power supply 6 5 4 3 2 1 18V BLU ORG RED BLK GRY BRN BLK BLK 1 2 3 4 5 BLU 6 VIO 7 ORG 8 BLK 9 BRN 10 GRY 11 YEL 12 WHT 13 RED 14 15 16 17 8 7 6 5 4 3 2 1 J20 J17 BLU ORG VIO YEL WHT RED BRN GRY 9 BLK Pin 4 and pin 5 on torch PCB Pin 2 and pin 3 on power PCB ...

Page 105: ...ower supply and do a quick restart again If you continue to see the 0 51 0 fault code disconnect the machine interface cable from the plasma power supply again 4 Do a check for continuity on pin 3 and on pin 4 in the machine interface cable connector Refer to Figure 24 on page 106 Is there continuity on both pins If yes there can be a problem with the CNC or with the cable Continue with the next s...

Page 106: ...the plasma power supply 1 Set the power switch on the plasma power supply to OFF O and disconnect the power cord 2 Remove the plasma power supply cover and the component barrier 3 Disconnect the 4 pin machine interface connector from the side of the power PCB as follows J21 in Powermax65 85 SYNC models J18 in Powermax105 SYNC models 3 4 5 6 12 14 Machine interface connector ...

Page 107: ...045 for Powermax105 SYNC If no there is possibly a problem with the power PCB Replace the power PCB The problem will more often be with the power PCB In unusual situations there can be a problem with the DSP PCB If possible install a different DSP PCB that is known to operate correctly before you replace the power PCB to see if the problem goes away Figure 25 Machine interface pins for plasma star...

Page 108: ...tridge must not be too loose or too tight 3 Make sure that the torch is set to the green ready to fire position 4 Measure the resistance between pin 5 and pin 7 in the torch connector Refer to Figure 26 on page 109 Is the resistance very low If yes continue with the next step If no the cap sensor switch in the torch is open Continue with step 7 5 Set the torch to the yellow lock X position 6 Measu...

Page 109: ...or continuity between the blue wire and pin 5 BLU in the torch connector c Do a check for continuity between the orange wire and pin 7 ORG in the torch connector 8 Do both torch wires have continuity If yes replace the cap sensor switch If no replace the torch lead Figure 26 Torch connector pins BLK BLK 1 2 3 4 5 B L U 6 V I O 7 O R G 8 BLK 9 B R N 10 G R Y 11 YEL 12 WHT 13 RED 14 15 16 17 Cap Sta...

Page 110: ...re 27 on page 111 Is there continuity If yes continue with the next step If no do a check for continuity at the quick disconnect receptacle Refer to Do a check for continuity on page 25 7 Make sure that the power is OFF O and put a jumper wire between pin 1 and pin 2 on J20 or J17 8 Connect the power cord to the power source and set the power switch on the plasma power supply to ON I 9 Does the 0 ...

Page 111: ... 105 SYNC Troubleshooting Guide 810430 111 Figure 27 Machine interface pins on power PCB 8 7 6 5 4 3 2 1 J20 J17 BLU ORG VIO YEL WHT RED BRN GRY 9 BLK RED J21 ORG J20 J12 B R J4 J2 J1 J3 2 J J6 J5 J2 J1 J22 RED J18 ORG J17 J11 B R Powermax65 85 SYNC Powermax105 SYNC ...

Page 112: ... supply 5 Set the power switch to ON I Does the solenoid valve make an audible clicking sound If yes examine the gas hoses that connect to the solenoid valve assembly Refer to Figure 28 If the hoses are twisted kinked or have other damage replace them Reconnect the gas supply Set the power switch to ON I and fire the torch If no continue with the next step Figure 28 Gas hoses connected to the sole...

Page 113: ...tween pin 1 and pin 7 at J4 or J6 on the power PCB Refer to Figure 29 Is the voltage approximately 48 VDC If yes replace the solenoid valve If no continue with Do a test of the solenoid valve after disconnecting from the power PCB on page 114 ORG B R J4 J6 1 7 RED J32 RED J21 ORG J20 J12 B R WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 J29 TP12 J28 TP10 TP11 W R B J4 J2 J1 J3 2 J3 ...

Page 114: ... 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 If no replace the power PCB 3 Do a resistance check to make sure that the solenoid valve is defective Measure the resistance between pin 7 and pin 8 on the solenoid valve connector Refer to Figure 30 If the resistance is less than 44 ohms Ω approximately replace the so...

Page 115: ...to OFF O and disconnect the power cord from the power source 3 Remove the plasma power supply cover 4 Remove the component barrier 5 Examine the connection to the torch lead at the quick disconnect receptacle Is the connection secure Are the wires in the torch lead pinched twisted or damaged Replace the torch lead if necessary Examine the power input and solenoid valve coils 1 Disconnect the solen...

Page 116: ...1 and pin 4 at J4 or J6 on the power PCB Refer to Figure 31 Is the voltage approximately 5 VDC If yes continue with the next step If no replace the power PCB Figure 31 Solenoid valve pins on the power PCB ORG B R J4 J6 1 4 RED J32 RED J21 ORG J20 J12 B R WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 J29 TP12 J28 TP10 TP11 W R B J4 J2 J1 J3 2 J3 ...

Page 117: ...id 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 Are the resistance values correct If yes continue with the next step If no replace the solenoid valve Figure 32 Pins of solenoid valve connector 5 8 7 6 ...

Page 118: ...on the power PCB 6 Reconnect J1 to the solenoid valve PCB 7 Disconnect the gas supply 8 Set the power switch set to ON I 9 Do a check of the output signal from the solenoid valve pressure sensor If the sensor is operating correctly the output signal is approximately 0 2 VDC at 0 bar 0 psi Measure the voltage between pin 1 and pin 2 on J4 or J6 Is the voltage 0 18 VDC 0 22 VDC but you continue to g...

Page 119: ...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 Is the voltage approximately 100 ohms Ω If yes replace the DSP PCB If no replace the power PCB Figure 33 Pin 32 on J8 on power PCB ...

Page 120: ...wermax65 85 SYNC CE CCC models J2 in all Powermax105 SYNC models 4 Put a jumper between pin 1 and pin 3 in the receptacle for the inverter thermal sensor 5 Connect the power cord to the power source and set the power switch on the plasma power supply to ON I With the inverter thermal sensor disconnected the fan operates as soon as the system is on 6 Make sure that the fan stays connected to the po...

Page 121: ...ing on the external side of the power PCB Refer to Figure 34 on page 122 Is the voltage approximately 48 VDC 2 4 VDC If yes replace the fan If no continue with the next step 8 Disconnect the fan from the power PCB 9 Measure the voltage again between pin 1 and pin 4 at the fan receptacle on the power PCB Is the voltage approximately 48 VDC 2 4 VDC If yes replace the fan If no do Test 5 Flyback circ...

Page 122: ...igure 34 Fan pins on power PCB J6 J5 J2 J1 ORG 7 J11 B R 1 4 ORG J20 J15 B R J6 J4 J3 J5 1 4 ORG J20 J12 B R J4 J2 J1 J3 1 4 RED J32 RED J21 ORG J20 J12 B R WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 J29 TP12 J28 TP10 TP11 W R B J4 J2 J1 J3 2 J3 Powermax65 85 SYNC CE CCC Powermax65 85 SYNC CSA Powermax105 SYNC ...

Page 123: ...nd disconnect the power cord 2 Remove the plasma power supply cover and the component barrier 3 Powermax65 85 SYNC CSA Disconnect the auxiliary switch cable from J1 on the power PCB Powermax105 SYNC Disconnect the auxiliary switch cable from J5 on the power PCB 4 With the power switch on the plasma power supply set to OFF O measure the resistance between pin 4 and pin 5 on the auxiliary cable s co...

Page 124: ...wermax65 85 105 SYNC Figure 35 Auxiliary switch pins on power PCB ORG J20 J12 B R J4 J2 J1 J3 5 4 J6 J5 J2 J1 ORG 7 J11 B R 5 4 RED J32 RED J21 ORG J20 J12 B R WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 J29 TP12 J28 TP10 TP11 W R B J4 J2 J1 J3 2 J3 Powermax65 85 SYNC CSA Powermax105 SYNC ...

Page 125: ...the cartridge from the torch but make sure that the torch is connected to the plasma power supply 4 Measure the resistance between the center contact on the torch head and the work clamp If the resistance is less than 5 kiloohms kΩ continue with the next step 5 Measure the resistance between the 2 pilot arc screws on the power PCB Refer to Figure 36 If the resistance is less than 5 kiloohms kΩ rep...

Page 126: ...urely connected to the torch PCB If yes continue with the next step If no adjust the antenna wires as necessary until they connect fully and securely in the connector on the torch PCB 4 Disconnect the 2 antenna wires from the torch PCB as follows a Lightly push down the tabs on the antenna connector on the torch PCB with your thumb or fingers You can also use a tool to push down the tabs if the po...

Page 127: ...on the front of the plasma power supply measure the voltage between pin 5 blue wire and pin 7 orange wire Refer to Figure 37 Is the voltage approximately 18 VDC If yes the problem is possibly with the torch Continue with Do a test of the torch on page 128 If no continue with the next step 5 At the J20 connector for Powermax65 85 SYNC or the J17 connector for Powermax105 SYNC on the power PCB measu...

Page 128: ...re and pin 7 at J20 Powermax65 85 SYNC or J17 Powermax105 SYNC on the power PCB Refer to Figure 38 on page 130 b Do a check for continuity between pin 2 on the torch PCB gray wire and pin 8 at J20 Powermax65 85 SYNC or J17 Powermax105 SYNC on the power PCB Refer to Figure 38 on page 130 c If there is continuity between the pins continue with step 10 d If there is not continuity between the pins co...

Page 129: ...a possible problem with the original torch Continue with the next step 11 Connect the original SmartSYNC torch to the plasma power supply Is the torch a hand torch or a mechanized torch Hand torch Are any LEDs on the torch PCB illuminated or flashing If yes replace the torch PCB If no replace the torch lead Mechanized torch Replace the torch PCB If the 0 98 2 fault does not go away replace the tor...

Page 130: ...e 38 Pins for resistance check between torch and plasma power supply 6 5 4 3 2 1 18V BLU ORG RED BLK GRY BRN BLK BLK 1 2 3 4 5 BLU 6 VIO 7 ORG 8 BLK 9 BRN 10 GRY 11 YEL 12 WHT 13 RED 14 15 16 17 8 7 6 5 4 3 2 1 J20 J17 BLU ORG VIO YEL WHT RED BRN GRY 9 BLK Pin 1 and pin 2 on torch PCB Pin 7 and pin 8 on power PCB ...

Page 131: ...131 Figure 39 Torch lead connector pins 6 5 4 3 2 1 18V 1 2 BLU ORG VIO BLK GRY BRN BLK BLK 1 2 3 4 5 BLU 6 VIO 7 ORG 8 BLK 9 BRN 10 GRY 11 YEL 12 WHT 13 RED 14 15 16 17 MCU RFID 6 5 4 3 2 1 18V BLU ORG RED BLK GRY BRN BLK BLK 1 2 3 4 5 BLU 6 VIO 7 ORG 8 BLK 9 BRN 10 GRY 11 YEL 12 WHT 13 RED 14 15 16 17 ...

Page 132: ...Do System Tests to Identify Defective Components 5 132 810430 Troubleshooting Guide Powermax65 85 105 SYNC ...

Page 133: ...con shows that the torch has received a start signal and has started a pilot arc Torch is transferring This icon shows that the plasma arc transferred to the workpiece and the torch is cutting or gouging 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 ...

Page 134: ...ges the current setting Non default configuration This icon shows that at least one default system setting has been changed Remote control This icon shows that a CNC or other controller is controlling the plasma power supply The front panel controls are disabled during remote mode operation But fault codes and fault icons still show as they would otherwise and you can go to the menu screens to see...

Page 135: ...ridge 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 Service Select this icon to go to service related information about fault codes radio frequency RF settings and logs and cut counter transfers Settings Select this icon to go to system settings that you ca...

Page 136: ...ect to go to the CARTRIDGE DATA 1 screen 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 C HAND Standard cutting cartridge for hand torch C HFNC FineCut cartridge for hand torch C MECH Standard cutting cartridge for machine torch...

Page 137: ...c 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 PT This field shows the cumulative pilot arc time in hours minutes and seconds HH MM SS that the Hypertherm cartridge has had in its life XT This field shows the cumulative arc transfer time in hours minutes and seconds HH MM SS that ...

Page 138: ...this field to adjust the set current if necessary for troubleshooting P This field shows the inlet set pressure followed by the actual output gas pressure in psi When the system in manual mode you can use the first part of this field to adjust the set pressure if necessary for troubleshooting The system cannot go into manual mode from this screen F This field shows the active fault code if any VL ...

Page 139: ...erature in Celsius STA This field shows the total number of torch starts the plasma power supply has done in its life XFR This field shows the total number of arc transfers the plasma power supply has done in its life PT This field shows the cumulative pilot arc time in hours minutes and seconds HH MM SS that the plasma power supply has had in its life XT This field shows the cumulative arc transf...

Page 140: ...tarts 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 This field shows the total number of Hypertherm cutting cartridge starts that the plasma power supply has done in its life while in Cut mode This field shows the total ...

Page 141: ...y 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 This field shows the total number of pilot arc starts that the plasma power supply has done while an unrecognized type of cartridge was used In basic mode the system continues to record data for field 1 and 6 For all othe...

Page 142: ...ervice related information about the firmware on the plasma power supply s LCD control PCB 1 Select on the main menu screen 2 Select to go to the LCD CTRL BD INFO screen F W This field shows the part number nnnnnn and the version x of the firmware on the 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 field...

Page 143: ...mware on the digital signal processing DSP PCB 1 Select on the main menu screen 2 Select to go to the DSP PWR BD INFO screen F W This field shows the part number nnnnnn and the version x of the firmware on the DSP PCB FDC This field shows the code for the firmware s build day nnnnnn_xx and the bootloader version n of the firmware PWR This field shows the model of power PCB that is installed in the...

Page 144: ...o go to the TORCH BD INFO screen F W This field shows the part number nnnnnn and the version x of the firmware on the torch PCB FDC This field shows the code for the firmware s build day nnnnnn_xx and the bootloader version x of the firmware TYP This field shows the torch type followed by the length of the torch lead in feet SH SmartSYNC hand torch SM SmartSYNC machine torch BH Hand torch and the ...

Page 145: ...nent 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 The plasma power supply does not show operational fault codes 0 nn n on this screen 1 Select on the main menu screen 2 Select to go to the POWER SUPPLY LOG screen 3 Turn the adjustment knob to move through the list This field shows t...

Page 146: ... is N nn n Refer to page 39 Radio Frequency RF settings and operation logs Go to the Radio Frequency Data screen RF DATA to see service related information about radio frequency RF settings and logs To see values on this screen make sure that there is a cartridge installed on the torch and that the torch is set to the green ready to fire position 1 Select on the main menu screen 2 Select to go to ...

Page 147: ...T This field shows how many write read occurrences have been done to the test cell ERROR RF This field shows how many RF operation errors have occurred ERROR COM This field shows how many torch communication errors have occurred Cut counter data for backups Go to the Cut Counters Transfer screen CUT COUNTERS to do a transfer of the plasma power supply s cut counter data before installing a new DSP...

Page 148: ... 2 Turn the adjustment knob to go to Push to select it 3 Turn the adjustment knob to go to and push to select it The LCD Display screen LCD DISPLAY shows 4 Turn the adjustment knob to adjust the value in the field to increase or decrease the brightness of the LCD screen Push to enter the value 0 Darkest setting 9 Brightest setting 5 Adjust the value in the field to increase or decrease the contras...

Page 149: ...XT field to on these values stay on the status screen until you set the STA XT field to off 1 Push and hold for 2 seconds to go to the main menu screen 2 Turn the adjustment knob to go to Push to select it 3 Turn the adjustment knob to go to and push to select it The LCD Display screen LCD DISPLAY shows 4 Turn the adjustment knob to go to the STA XT field and push to select it 5 Turn the adjustmen...

Page 150: ...on the screen Serial communications parameters Use the CNC Interface Settings screen CNC INTERFACE to set parameters for serial communication 1 Select on the main menu screen 2 Select to go to the CNC INTERFACE screen 3 Turn the adjustment knob to go to the field you want to change 4 Push to select the field 5 Turn the adjustment knob to change the value in the field ...

Page 151: ...Information and Settings 6 Powermax65 85 105 SYNC Troubleshooting Guide 810430 151 6 Push to select the new value Baud rate cannot be changed Data bits cannot be changed Parity can be changed Stop bits can be changed ...

Page 152: ...e of zero 0 lets the CNC set the node address for the Powermax automatically The node address is set by the first valid Modbus request message that the Powermax receives from the CNC after the Powermax power switch is set to the ON I position This field continues to show a value of zero 0 during Modbus communication to indicate that the node address is being controlled by the CNC For cutting syste...

Page 153: ...reen By default this screen is locked To change any of the settings on this screen you must first unlock the screen using the icon 1 Push and hold for 2 seconds to go to the main menu screen 2 Select on the main menu screen 3 Select to go to the FEATURE CONFIG screen 4 Turn the adjustment knob to go to the field 5 Push to select the field 6 Turn the adjustment knob to set the field to the unlock p...

Page 154: ...set this field to off the system no longer shows the 0 32 0 or 0 32 1 fault codes when the cartridge gets to end of life This field is on by default But the system temporarily sets the feature to off when any one of the following conditions occurs You install a FineCut hand cutting cartridge You set the output current below 40 A for any Hypertherm cartridge The output current is set below 55 A and...

Page 155: ...artridge communication with the plasma power supply or when torch communication with the plasma power supply is broken the system operates as if it is in basic mode regardless of the setting in the field Smart mode When the system is in smart mode and you use a Hypertherm cartridge with a SmartSYNC torch the system does many things for you automatically including the following It sets the operatin...

Page 156: ...t right shows on the status screen instead of the system process icon Set system settings to factory default To set the plasma power supply to factory default settings do the following You can do these steps on all screens 1 Push and hold and at the same time for approximately 2 seconds until the FACTORY RESET message shows 2 Turn the adjustment knob to go to and push to select it The system goes ...

Page 157: ...y 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 Theory of operation on page 169 ...

Page 158: ...w fault LED does not show on the front panel Refer to page 39 The operating mode and the output current A automatically adjust to align with the cartridge installed on the torch The gas pressure automatically adjusts for optimal cutting to align with the system settings and the torch and cartridge that are connected to the plasma power supply Position the torch over the workpiece Pull the plasma s...

Page 159: ...2 J1 J3 2 J3 7 8 9 1 2 3 4 5 6 11 13 14 15 16 17 18 19 12 10 21 20 19 22 1 J12 connector 2 J20 connector 3 J21 connector 4 Nozzle wire 5 Electrode wire 6 J32 connector 7 Output inductor wire 8 Work lead 9 Transformer wires 10 Test points 11 PFC inductor wires 12 Ground 13 AC input wires 3 14 Power switch 15 Damper resistor wires 16 Power PCB 17 PFC temperature sensor 18 Flyback circuit 19 Gate dri...

Page 160: ...J24 J30 7 8 9 1 2 3 4 5 6 11 13 14 15 16 17 18 19 12 10 21 20 1 J12 connector 2 J20 connector 3 J21 connector 4 Nozzle wire 5 Electrode wire 6 J33 connector 7 Output inductor wire 8 Work lead 9 Transformer wires 10 Test points 11 PFC inductor wires 12 Ground 13 MOV assembly 14 AC input wires 3 15 Power switch 16 Power PCB 17 Flyback circuit 18 3uF capacitors 19 Gate drive connectors 20 Digital sig...

Page 161: ...sma power supply power PCB removed 7 8 9 1 2 3 4 5 6 10 11 13 12 1 Output bridge diode 2 Pilot arc IGBT 3 Inverter snubber resistor 4 Inverter IGBT module 5 Bulk capacitors 6 Ground 7 Input diode bridge 8 Snubber resistor 9 Power switch S1 10 PFC IGBT 11 PFC snubber resistor 12 Output snubber resistor 13 Optional serial PCB ...

Page 162: ...C Figure 43 380 V CCC 400 V CE plasma power supply power PCB removed 7 8 9 1 2 3 4 5 6 10 1 Output bridge diode 2 Pilot arc IGBT 3 Inverter snubber resistor 4 Inverter IGBT module 5 Bulk capacitors 6 Input diode bridge 7 Ground 8 Power switch S1 9 Output snubber resistor 10 Optional serial PCB ...

Page 163: ... TP8 W R B J6 7 8 9 1 2 3 4 5 6 11 13 14 15 16 17 18 19 12 10 21 20 13 22 1 J11 connector 2 J17 connector 3 J18 connector 4 Output inductor wires 5 Nozzle wires 6 Electrode wire 7 J32 connector 8 Work lead 9 Transformer wires 10 Test points 11 3uF capacitors 12 PFC inductor wires 13 Damper resistor wires 14 Ground 15 AC input wires 3 16 Power switch 17 Power PCB 18 PFC temperature sensor 19 Flybac...

Page 164: ...4 5 6 11 13 14 15 16 17 18 19 12 10 13 21 20 22 1 J11 connector 2 J17 connector 3 J18 connector 4 Output inductor wires 5 Nozzle wires 6 Electrode wire 7 J32 connector 8 Work lead 9 Transformer wires 10 Test points 11 3uF Capacitors 12 PFC inductor wires 13 Damper resistor wires 14 Ground 15 AC input wires 3 16 Power switch 17 Power PCB 18 PFC temperature sensor 19 Flyback circuit 20 Gate drive co...

Page 165: ...2 J1 J22 J21 6 5 7 8 9 1 2 3 4 5 6 12 13 14 15 16 17 18 19 11 10 20 1 J11 connector 2 J17 connector 3 J18 connector 4 Output inductor wires 5 Nozzle wires 6 Electrode wire 7 J32 connector 8 Work lead 9 Transformer wires 10 Test points 11 PFC inductor wires 12 3uF Capacitors 13 Ground 14 AC input wires 3 15 Power switch 16 Power PCB 17 Flyback circuit 18 Gate drive connectors 19 Digital signal proc...

Page 166: ...a power supply power PCB removed 7 8 9 1 2 3 4 5 6 11 13 12 10 1 Output snubber resistor 2 Output diode bridge 3 Pilot arc IGBT 4 Inverter snubber resistor 5 Inverter IGBT module 6 Bulk capacitor 7 PFC snubber resistor 8 PFC IGBT module 9 Damper resistor 10 Ground 11 Input diode bridge 12 Power switch S1 13 Optional serial PCB ...

Page 167: ... power supply power PCB removed 7 8 9 1 2 3 4 5 6 11 13 12 10 1 Output snubber resistor 2 Output diode bridge 3 Pilot arc IGBT 4 Inverter snubber resistor 5 Inverter IGBT module 6 Bulk capacitors 7 PFC snubber resistor 8 PFC IGBT module 9 Damper resistor 10 Ground 11 Input diode bridge 12 Power switch S1 13 Optional serial PCB ...

Page 168: ...C Figure 49 380 V CCC 400 V CE plasma power supply power PCB removed 7 8 9 1 2 3 4 5 6 10 1 Output snubber resistor 2 Output bridge diode 3 Pilot arc IGBT 4 Inverter snubber resistor 5 Inverter IGBT module 6 Bulk capacitors 7 Ground 8 Input diode bridge 9 Power switch S1 10 Optional serial PCB ...

Page 169: ...transformer The output circuitry has 2 current sensors located on the power PCB the pilot arc IGBT Q13 and the output choke 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 20 A 65 A for the Powermax65 SYNC or 25 A 85 A for the Powermax85 SYNC The system compares...

Page 170: ... a pulse width modulated half bridge circuit driving an isolation transformer The output bridge D36 and D37 corrects the output of the isolation transformer The output circuitry has 2 current sensors located on the power PCB the pilot arc IGBT Q13 and the output choke The digital signal processor PCB2 monitors and controls the system s operation and safety circuits The amperage adjustment knob on ...

Page 171: ...lyback circuit DC to DC converter on the power PCB PCB3 The power PCB provides noise suppression and spike protection The power PCB resistors RT4 RT5 and relay K2 do a soft start The inverter has a dual IGBT package Q12 the power transformer a current sensor and the control circuit The inverter operates as a pulse width modulated half bridge circuit driving an isolation transformer The output brid...

Page 172: ...How the Plasma Power Supply Operates 7 172 810430 Troubleshooting Guide Powermax65 85 105 SYNC ...

Page 173: ...tem 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 on page 177 Powermax105 SYNC schematic 380 V CCC models and 400 V CE models on page 178 Timing chart for torch start on page 179 ...

Page 174: ...System Diagrams 8 174 810430 Troubleshooting Guide Powermax65 85 105 SYNC ...

Page 175: ...OLTAGE DIVIDER BOARD PCB4 RED TO J32 GRN YEL FACTORY SET 50 1 NOZZLE ELECTRODE WORK CLAMP 1 2 TORCH SOCKET TORCH SOCKET CENTER PIN QUICK DISCONNECT RED WHITE RED J19 3 3 J17 J16 R198 15 OHM TO OUTPUT DIODES PRIMARY PWR XFR PFC INDUCTOR AC J18 D50 3 3 1 2 BLK RED TO PCB4 20 1 J32 PE PE GROUND TO HEATSINK L1 L2 L3 T1 T2 T3 AUX SW S1 TO J1 3 L1 BLK L2 WHT L3 RED GRN CONTROL GND TO HEATSINK MTG8 TP11 ...

Page 176: ...H SOCKET CENTER PIN QUICK DISCONNECT RED WHITE RED J19 R171 15 OHM TO OUTPUT DIODES PRIMARY PWR XFR PFC INDUCTOR AC D45 3 3 1 2 BLK RED TO PCB4 20 1 J33 1 2 3 5 J3 8 5 J5 J1 J2 EMI FILTER CONNECT WIRES TO J1 J2 J13 J13 J18 SOFT START J24 J23 L1 L2 L3 T1 T2 T3 L1 BRN L2 BLK L3 GRY TP12 W TP11 R TP13 B OUTPUT INDUCTOR PILOT ARC COMMON PE PE GROUND TO HEATSINK GRN YEL 8 5 SEE TORCH BELOW TORCH SOCKET...

Page 177: ...FC INDUCTOR J25 SOFT START TO D38 S1 TO J5 AUX SW J12 J16 J14 J13 D38 TO J12 3 OHM TO 3 OHM PE PE GROUND TO HEATSINK AC FERRITE CORES 230 V 400 V CE MODELS ONLY PFC TEMP SENSOR PFC IGBT Q11 WORK CLAMP 1 2 24 MM GRN YEL 230 V 400 V CE MODELS CONNECT WIRES TO J13 J14 J16 CSA MODELS CONNECT WIRES TO D38 EMI FILTER 230 V 400 V CE MODELS ONLY J31 J30 24 V 0 1 A MAX GRN YEL 0 20 1 TORCH SOCKET TORCH SOC...

Page 178: ...C IGBT Q13 J27 J28 1 2 BLK RED TO PCB4 RED NOZZLE ELECTRODE OUTPUT INDUCTOR TO OUTPUT DIODES PRIMARY PWR XFR R201 15 OHM 3 J22 J21 INVERTER IGBT Q12 J26 C152 C151 PFC INDUCTOR J25 SOFT START S1 TO J5 AUX SW J16 J14 J13 D38 PE PE GROUND TO HEATSINK AC FERRITE CORES WORK CLAMP 1 2 24 MM GRN YEL J31 J30 24 V 0 1 A MAX GRN YEL 20 1 TORCH SOCKET TORCH SOCKET CENTER PIN FACTORY SET 50 1 J32 48 QUICK DIS...

Page 179: ...d pilot arc established Transfer when work lead current 1 6 A Cutting steady state Start signal OFF Torch trigger released Idle Start signal torch trigger ON OFF icon ON OFF on status screen Pilot arc IGBT ON OFF Gas solenoid ON OFF Inverter output Transfer relay ON OFF icon ON OFF on status screen Postflow User set current Pilot arc current ...

Page 180: ...System Diagrams 8 180 810430 Troubleshooting Guide Powermax65 85 105 SYNC ...

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