powermax1000
Service Manual
3-1
1
Section 3
MAINTENANCE
In this section
Controls and indicators .............................................................................................................................................3-3
Indicator LEDs..................................................................................................................................................3-3
Theory of operation...................................................................................................................................................3-4
General ............................................................................................................................................................3-4
Functional description ......................................................................................................................................3-4
Sequence of operation .....................................................................................................................................3-5
Troubleshooting preparation .....................................................................................................................................3-6
Test equipment.................................................................................................................................................3-6
Troubleshooting procedures and sequence .....................................................................................................3-6
External inspection...........................................................................................................................................3-6
Internal inspection ............................................................................................................................................3-7
Initial resistance check..............................................................................................................................................3-7
Check power switch .........................................................................................................................................3-8
Hypertherm IGBT tester ...................................................................................................................................3-9
Indicator LEDS and device tests ......................................................................................................................3-9
IGBT test preparation .....................................................................................................................................3-10
IGBT device test using the Hypertherm tester ...............................................................................................3-10
Troubleshoot the Hypertherm IGBT tester .....................................................................................................3-11
Schematic for building an IGBT tester............................................................................................................3-11
IGBT device test using non-Hypertherm tester ..............................................................................................3-12
Troubleshooting guide ............................................................................................................................................3-14
Control board LEDs........................................................................................................................................3-18
Test 1 – voltage input .....................................................................................................................................3-19
Test 2 – voltage balance ................................................................................................................................3-20
Test 3 – output diodes ....................................................................................................................................3-21
Test 4 – pilot arc IGBT (Q8) ...........................................................................................................................3-22
Test 5 – inverter IGBT (Q6) and PFC IGBT (Q7) ...........................................................................................3-23
Test 6 – flyback circuit ....................................................................................................................................3-24
Test 7 – torch stuck open (TSO) ....................................................................................................................3-25
Test 8 – plasma start ......................................................................................................................................3-26
Test 9 – torch cap sensor ...............................................................................................................................3-26
Test 10 – gas solenoid ...................................................................................................................................3-27
Test 11 – incoming line voltage (VACR) .........................................................................................................3-27
Test 12 – pressure switch...............................................................................................................................3-27
Test 13 – fan...................................................................................................................................................3-27
