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TroubleshooTing and sysTem TesTs

5-8 powermax

Service Manual

TP 19

TP 18

TP 17

192 VDC

Power switch (S1)Power board (PCB2)

Control board (PCB1)

Flyback circuit

PE (ground)

Newer power board

Input diode bridge

(D48)

Output diode and pilot arc

IGBT module (D38)

PFC IGBT (Q2)

Inverter IGBT

(Q3)

Work lead connection (J21)

Test points

200–240V CSA and 230V CE power supply overview

TP 19

TP 18

TP 17

192 VDC

Older power board

Input diode bridges

(D29, D39)

Default Chapter5
- Safety Information5
- Table of Contents7
Electromagnetic Compatibility (Emc)11
- Mains Supply11
- Assessment of Area11
- Maintenance of Cutting Equipment12
Warranty13
- Patent Indemnity14
Section 115
Specifications15
- System Description16
- Where to Find Information16
- Power Supply Dimensions and Weights17
  - Dimensions17
  - Weights17
- Power Supply Ratings18
- T45V Torch Dimensions19
- T45M Torch Dimensions19
- T45V and T45M Torch Specifications20
- Symbols and Marks21
- IEC Symbols22
Section 223
Power Supply Setup23
- Unpack the Powermax4524
  - Claims24
  - Contents24
- Position the Power Supply25
- Prepare the Electrical Power25
Table of Contents26
- Power Cord Considerations26
  - Extension Cord Recommendations27
  - Generator Recommendations28
- Prepare the Gas Supply28
  - Connect the Gas Supply29
  - Additional Gas Filtration29
Section 332
Torch Setup Introduction32
- Consumable Life32
- Hand Torch Setup32
- Machine Torch Setup36
- Connect the Torch Lead60
Operation62
Section 462
- Controls and Indicators62
  - Front Controls and Leds62
  - Rear Controls63
- Operate the Powermax4563
- Understand Duty-Cycle Limitations66
- How to Use the Hand Torch67
- How to Use the Machine Torch72
Section 577
Troubleshooting and System Tests77
- Theory of Operation78
- Troubleshooting Preparation81
- Initial Resistance Check83
- 200-240 V CSA and 230 V Ce Power Supply Overview84
- 400 V Ce Power Supply Overview85
- 480 V CSA Power Supply Overview86
- Troubleshooting Guide87
- Control Board Leds92
  - Use the Control Board Error and Reset Leds to Troubleshoot93
- System Tests94
Section 6105
Component Replacement105
- Remove and Replace the Cover and Mylar ® Barrier106
- Replace the Work Lead (CSA and CE)107
- Replace the Power Cord (200-240 V CSA)109
- Replace the Power Cord (230 V CE)110
- Replace the Power Cord (400 V CE)112
- Replace the Power Cord (480 V CSA)114
- Replace the Fan116
- Replace the Gas Filter Element117
- Replace the Air Filter and Regulator119
- Replace the Control Board120
- Replace the Power Board (200-240 V CSA and 230 V CE)121
- Replace the Power Board (400 V CE and 480 V CSA)125
Section 7129
Parts129
- Power Supply Parts130
- T45V Hand Torch Parts135
  - T45V Hand Torch Consumables136
  - T30V (Powermax30) 30 a Consumables136
- T45M Machine Torch Parts137
  - T45M Machine Torch Consumables138
- Accessory Parts138
- Safety-Critical Parts139
- Recommended Spare Parts140
- Powermax45 Labels141
Section 8143
Wiring Diagrams143
- Control Board Diagram: 200-240 V CSA and 230 V CE144
- Control Board Diagram: 400 V CE and 480 V CSA145
- Power Board Wiring Diagram: 400 V CE148
- Power Board Wiring Diagram: 480 V CSA149

Brand	Hypertherm
Model	powermax45
Category	Welding System
Language	English

Hypertherm powermax45 Service Manual

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