Powermax1000, Maintenance 3-16, Service manual – Hypertherm Powermax1000 Service Manual User Manual

Page 49

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MAINTENANCE

3-16

powermax1000

Service Manual

1

P

ro

b

le

m

T

h

is

m

a

y

m

e

a

n

C

a

u

s

e

S

o

lu

ti

o

n

A

rc

lo

s

t

c

o

n

ta

c

t

w

it

h

th

e

w

o

rk

p

ie

c

e

.

F

a

u

lt

y

w

o

rk

le

a

d

,

w

o

rk

le

a

d

c

o

n

n

e

c

ti

o

n

,

o

r

c

o

n

n

e

c

ti

o

n

b

e

tw

e

e

n

th

e

w

o

rk

le

a

d

a

n

d

c

u

tt

in

g

ta

b

le

.

C

h

e

c

k

th

e

p

h

y

s

ic

a

l

c

o

n

d

it

io

n

o

f

th

e

w

o

rk

le

a

d

.

C

h

e

c

k

fo

r

lo

o

s

e

c

o

n

n

e

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ti

o

n

s

a

t

th

e

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la

m

p

a

n

d

p

o

w

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r

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u

p

p

ly

.

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e

p

o

s

it

io

n

w

o

rk

le

a

d

d

ir

e

c

tl

y

to

th

e

w

o

rk

p

ie

c

e

.

If

th

e

p

ro

b

le

m

g

o

e

s

a

w

a

y,

c

le

a

n

th

e

c

u

tt

in

g

ta

b

le

.

F

a

u

lt

y

fa

n

.

F

a

n

c

o

u

ld

b

e

lo

a

d

in

g

d

o

w

n

th

e

F

ly

b

a

c

k

c

ir

c

u

it

.

D

is

c

o

n

n

e

c

t

J

1

a

n

d

p

e

rf

o

rm

T

e

s

t

6

.

If

th

e

v

o

lt

a

g

e

v

a

lu

e

s

a

re

c

o

rr

e

c

t,

ru

n

w

it

h

th

e

fa

n

d

is

c

o

n

n

e

c

te

d

.

If

s

y

s

te

m

ru

n

s

fi

n

e

u

n

ti

l

th

e

s

y

s

te

m

re

a

c

h

e

s

o

v

e

r-

te

m

p

e

ra

tu

re

,

re

p

la

c

e

th

e

fa

n

.

W

o

rn

c

o

n

s

u

m

a

b

le

s

.

W

o

rn

-o

u

t

c

o

n

s

u

m

a

b

le

s

.

R

e

p

la

c

e

c

o

n

s

u

m

a

b

le

s

.

Im

p

ro

p

e

r

a

ir

p

re

s

s

u

re

s

e

tt

in

g

o

r

lo

w

fl

o

w

.

In

s

u

ffi

c

ie

n

t

s

u

p

p

ly

o

r

a

ir

le

a

k

o

n

s

u

p

p

ly

lin

e

.

T

u

rn

th

e

c

u

rr

e

n

t

a

d

ju

s

tm

e

n

t

k

n

o

b

to

te

s

t

fl

o

w

a

n

d

s

e

t

th

e

p

re

s

s

u

re

re

g

u

la

to

r

to

7

0

p

s

i

(4

.7

b

a

r)

fo

r

c

u

tt

in

g

o

r

5

0

p

s

i

(3

.4

b

a

r)

fo

r

g

o

u

g

in

g

.

If

u

n

a

b

le

to

a

d

ju

s

t

to

th

e

p

ro

p

e

r

s

e

tt

in

g

,

c

h

e

c

k

e

x

te

rn

a

l

a

ir

s

u

p

p

ly

.

P

o

o

r

q

u

a

lit

y

a

ir

.

M

o

is

tu

re

o

r

c

o

n

ta

m

in

a

te

s

in

a

ir

s

u

p

p

ly

.

A

d

d

a

p

p

ro

p

ri

a

te

fi

lt

ra

ti

o

n

a

n

d

p

u

rg

e

th

e

lin

e

s

w

it

h

n

it

ro

g

e

n

to

fl

u

s

h

o

u

t

o

il

a

n

d

m

o

is

tu

re

.

In

s

u

ffi

c

ie

n

t

in

p

u

t

p

o

w

e

r

(L

o

w

v

o

lt

a

g

e

a

n

d

fa

u

lt

L

E

D

s

m

a

y

n

o

t

ill

u

m

in

a

te

).

U

n

d

e

rs

iz

e

d

e

le

c

tr

ic

a

l

s

u

p

p

ly

in

s

ta

lla

ti

o

n

:

-

B

re

a

k

e

r

o

r

fu

s

e

-

S

u

p

p

ly

w

ir

e

-

E

x

te

n

s

io

n

c

o

rd

V

e

ri

fy

th

a

t

e

x

te

rn

a

l

e

le

c

tr

ic

a

l

p

o

w

e

r

is

in

s

ta

lle

d

a

c

c

o

rd

in

g

to

th

e

s

p

e

c

ifi

c

a

ti

o

n

s

in

S

e

c

ti

o

n

2

.

C

h

e

c

k

th

e

in

p

u

t

v

o

lt

a

g

e

w

h

ile

tr

y

in

g

to

fi

re

th

e

to

rc

h

.

A

v

o

lt

a

g

e

d

ro

p

in

d

ic

a

te

s

a

n

u

n

d

e

rs

iz

e

d

e

le

c

tr

ic

a

l

s

u

p

p

ly

in

s

ta

lla

ti

o

n

.

In

v

e

rt

e

r

fa

u

lt

o

r

in

te

rl

o

c

k

.

P

o

w

e

r

b

o

a

rd

(P

C

B

2

)

fa

ilu

re

.

C

h

e

c

k

th

e

fa

u

lt

L

E

D

s

o

n

th

e

b

a

c

k

o

f

th

e

c

o

n

tr

o

l

b

o

a

rd

(s

e

e

C

o

n

tr

o

l

B

o

a

rd

L

E

D

s

).

If

"I

F

"

is

ill

u

m

in

a

te

d

,

d

is

c

o

n

n

e

c

t

J

5

a

n

d

p

la

c

e

a

ju

m

p

e

r

b

e

tw

e

e

n

p

in

s

1

a

n

d

2

o

n

p

o

w

e

r

b

o

a

rd

(P

C

B

2

).

If

th

e

e

rr

o

r

c

le

a

rs

,

re

p

la

c

e

th

e

p

o

w

e

r

s

w

it

c

h

(S

1

).

If

n

o

t,

p

e

rf

o

rm

T

e

s

t

5

.

If

o

n

e

o

f

th

e

tw

o

te

s

ts

fa

ils

,

re

p

la

c

e

th

e

p

o

w

e

r

b

o

a

rd

a

n

d

in

v

e

rt

e

r

IG

B

T

(Q

6

).

C

a

p

a

c

it

o

r

v

o

lt

a

g

e

im

b

a

la

n

c

e

(C

9

4

/C

9

8

).

F

a

u

lt

y

re

s

is

to

rs

o

n

p

o

w

e

r

b

o

a

rd

(P

C

B

2

).

P

e

rf

o

rm

T

e

s

t

2

w

h

ile

tr

y

in

g

to

fi

re

th

e

to

rc

h

.

If

v

o

lt

a

g

e

a

c

ro

s

s

th

e

c

a

p

a

c

it

o

rs

is

n

o

t

b

a

la

n

c

e

d

,

th

e

n

re

p

la

c

e

th

e

p

o

w

e

r

b

o

a

rd

(P

C

B

2

).

P

o

o

r

w

o

rk

le

a

d

c

o

n

n

e

c

ti

o

n

.

V

e

ri

fy

th

a

t

th

e

w

o

rk

le

a

d

is

a

tt

a

c

h

e

d

to

w

o

rk

p

ie

c

e

a

n

d

th

e

w

o

rk

p

ie

c

e

is

fr

e

e

o

f

ru

s

t,

p

a

in

t,

o

r

o

th

e

r

c

o

a

ti

n

g

s

.

D

a

m

a

g

e

d

w

o

rk

le

a

d

.

C

h

e

c

k

th

e

re

s

is

ta

n

c

e

a

c

ro

s

s

th

e

w

o

rk

le

a

d

.

If

th

e

re

s

is

ta

n

c

e

is

g

re

a

te

r

th

a

n

3

o

h

m

s

,

re

p

la

c

e

o

r

re

p

a

ir

a

s

re

q

u

ir

e

d

.

D

e

fe

c

ti

v

e

p

ilo

t

a

rc

IG

B

T

(Q

8

).

T

u

rn

p

o

w

e

r

O

F

F

,

re

m

o

v

e

c

o

n

s

u

m

a

b

le

s

,

a

n

d

c

h

e

c

k

re

s

is

ta

n

c

e

b

e

tw

e

e

n

th

e

p

lu

n

g

e

r

a

n

d

th

e

w

o

rk

p

ie

c

e

.

If

th

e

re

s

is

ta

n

c

e

is

le

s

s

th

a

n

5

k

o

h

m

s

,

c

h

e

c

k

th

e

re

s

is

ta

n

c

e

a

c

ro

s

s

th

e

p

ilo

t

a

rc

IG

B

T

(t

w

o

s

c

re

w

s

o

n

Q

8

).

If

re

s

is

ta

n

c

e

is

le

s

s

th

a

n

5

k

o

h

m

s

,

re

p

la

c

e

th

e

p

ilo

t

a

rc

IG

B

T

.

D

e

fe

c

ti

v

e

c

o

n

tr

o

l

b

o

a

rd

(P

C

B

3

).

R

e

p

la

c

e

th

e

c

o

n

tr

o

l

b

o

a

rd

.

A

rc

g

o

e

s

o

u

t

w

h

il

e

c

u

tt

in

g

o

r

in

te

rm

it

te

n

tl

y

w

il

l

n

o

t

re

fi

re

.

In

a

d

e

q

u

a

te

g

ro

u

n

d

.

W

h

e

n

p

re

s

s

in

g

to

rc

h

tr

ig

g

e

r

o

r

s

ta

rt

s

w

it

c

h

,

p

il

o

t

a

rc

s

ta

rt

s

b

u

t

th

e

n

e

x

ti

n

g

u

is

h

e

s

b

e

fo

re

th

e

n

o

rm

a

l

5

-

s

e

c

o

n

d

ti

m

e

-o

u

t

p

e

ri

o

d

.

F

a

u

lt

L

E

D

s

m

a

y

il

lu

m

in

a

te

.

M

a

c

h

in

e

w

il

l

n

o

t

c

u

t

m

a

te

ri

a

l

w

e

ll

(d

o

e

s

n

o

t

a

p

p

e

a

r

to

b

e

o

p

e

ra

ti

n

g

a

t

fu

ll

c

u

tt

in

g

p

o

w

e

r)

,

a

n

d

th

e

a

rc

d

o

e

s

n

o

t

ti

m

e

o

u

t

a

ft

e

r

5

s

e

c

o

n

d

s

.

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