Hypertherm Powermax1000 Service Manual - Manual (Page 60)

MAINTENANCE
1
powermax1000
Service Manual 3-27
Test 11 – incoming line voltage (VACR)
• Check the voltage on output of the input diode, which
should equal 1.414 multiplied by the input voltage.
• If the value is low, check the input voltage or replace
the diode.
• If the value is correct, check the voltage between the
left side of R25 and ground (TP1). It should read
4.969 mV/V.
• If the value is correct, replace the control board
(PCB3). If not, replace the power board (PCB2) and
the PFC IGBT (Q7).
Test 12 – pressure switch
• Check the voltage from the right side of R50 to ground
(TP1). It should be approximately equal to 0.0463 VDC
multiplied by psi. For example, when the air regulator is
set to 80 psi, the voltage should be approximately 3.7
VDC.
• If the value is correct, replace the control board
(PCB3). If not, replace the pressure switch.
J4
J1
Q1 R7
R25
R50
TP1
Q7
J20
J2
Test 10 – gas solenoid
• If the air is continuously running, disconnect the gas solenoid connector (J20) from the power board
(PCB2). If the air does not shut off, replace the valve.
• If the air does shut off, disconnect the ribbon cable (J4) from the power board (PCB2) and reconnect J20. If
the air remains off, replace the control board (PCB3). If the air flow returns, replace the power board
(PCB2).
Test 13 – fan
• Force the fan into an over-temperature condition (place a jumper wire from J2 pin 1 to pin 2 to short it).
• Check the voltage across the fan on the power board (PCB2) J1 pins 1 and 2.
• The voltage should read 24 VDC, if not remove fan connector (J1) and check the voltage on the power
board (PCB2) J1 pins 1 and 2 again.
• If the voltage is 24 VDC, continue to the next step, if not perform Test 6 – flyback circuit.
• Place a jumper wire between the fan transistor (Q1) case to ground (TP1). If the fan turns on, continue to
the next step. If not, replace the fan.
• Check the voltage between the left side of R7 and ground (TP1). If the VDC is zero (0), replace the control
board (PCB3). If the value is 5 VDC, replace the power board (PCB2).