Hypertherm MAX200 Service Manual - Manual (Page 43)

3-2 MAX200 Service Manual
1-99
MAINTENANCE
WARNING
SHOCK HAZARD: The large electrolytic capacitor(s) (blue-cased cylinder(s)) store large amounts of
energy in the form of electric voltage. Even if the power is off, dangerous voltages exist at the capacitor
terminals, on the chopper, and the diode heatsinks. Never discharge the capacitor(s) with a screwdriver
or other implement…explosion, property damage and/or personal injury will result. Wait at least five
minutes after turning the power supply off before touching the chopper or the capacitor(s).
Introduction
The MAX200, and all Hypertherm plasma systems, undergo rigorous testing prior to shipment and should require
little maintenance if proper setup and operation procedures as outlined in instruction manuals #800870 (MAX200
Hand Torch) and #800980 (MAX200 Machine Torch) are followed.
If a problem does arise, this section will familiarize qualified service personnel with the proper operation of the
MAX200 system, and will provide guides to troubleshoot problems that may occur during operation. Isolation of a
problem at a modular level is the intent of this section. PC board component-level troubleshooting is not addressed
unless the component is easily isolated and easily replaced.
After a routine maintenance section, a general theory of operation for the chopper power supply and high
frequency circuits followed by a detailed sequence of events flowchart are presented so that service personnel can
gain knowledge of proper MAX200 operation. An initial checks procedure is then given, followed by a
troubleshooting guide and test procedures to aid in servicing the MAX200 system. Finally, procedures to remove,
and replace the torch and torch leads are given.
It is assumed that the service personnel performing the troubleshooting testing are high-level electronic
service technicians that have worked with high voltage electro-mechanical systems. Knowledge of final
isolation troubleshooting techniques is also assumed.
In addition to being technically qualified, maintenance personnel must perform all testing with safety in
mind. Refer to the Safety section for operating precautions and warning formats.
If you need additional assistance or need to order parts, call our Customer Service or Technical Service Group at
the phone numbers listed in the front of this manual.