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Table of ConTenTs

powermax

Service Manual

iii

Pierce a workpiece ..........................................................................................................................................................................4-9

Gouge a workpiece .....................................................................................................................................................................4-10

Common hand-cutting faults .....................................................................................................................................................4-12

How to use the machine torch .............................................................................................................................................................4-12

Ensure the torch and table are set up correctly .................................................................................................................... 4-12

Understand and optimize cut quality ........................................................................................................................................4-13

To pierce a workpiece using the machine torch ...................................................................................................................4-14

Common machine-cutting faults ...............................................................................................................................................4-15

SECTION 5

TROUBLESHOOTING AND SYSTEM TESTS

Theory of operation ....................................................................................................................................................................................5-2

General ..............................................................................................................................................................................................5-2

200–240V CSA and 230V CE 1-phase power supply functional description..............................................................5-2

400V CE 3-phase power supply functional description .......................................................................................................5-2

480V CSA 3-phase power supply functional description ....................................................................................................5-3

Sequence of operation ...................................................................................................................................................................5-4

Troubleshooting preparation ...................................................................................................................................................................5-5

Test equipment ................................................................................................................................................................................5-5

Troubleshooting procedures and sequence .............................................................................................................................5-5

External inspection ..........................................................................................................................................................................5-6

Internal inspection ...........................................................................................................................................................................5-6

Initial resistance check ..............................................................................................................................................................................5-7

200–240V CSA and 230V CE power supply overview ................................................................................................................5-8

400V CE power supply overview .........................................................................................................................................................5-9

480V CSA power supply overview ...................................................................................................................................................5-10

Troubleshooting guide ........................................................................................................................................................................... 5-11

Control Board LEDs ...............................................................................................................................................................................5-16

Use the control board Error and Reset LEDs to troubleshoot ...........................................................................................5-17

System tests.............................................................................................................................................................................................5-18

Test 1 – voltage input ..................................................................................................................................................................5-18

Test 2 – power board voltage checks .....................................................................................................................................5-19

Test 3 – VBUS and voltage balance .......................................................................................................................................5-20

Test 4 – solenoid valve ...............................................................................................................................................................5-24

Test 5 – torch stuck open (TSO) or torch stuck closed (TSC) ........................................................................................5-25

Test 6 – plasma start ...................................................................................................................................................................5-26

Test 7 – torch cap sensor .......................................................................................................................................................... 5-27

Test 8 – fan ....................................................................................................................................................................................5-27

Test 9 – pressure transducer ....................................................................................................................................................5-28

Test 10 – power switch trip coil ...............................................................................................................................................5-28