10
Powermax30 AIR Service Manual 808850
Contents
5
Troubleshooting and System Tests ....................................................................................... 55
Theory of operation ...................................................................................................................................................................... 55
Functional description ......................................................................................................................................................... 55
Sequence of operation ........................................................................................................................................................ 56
Troubleshooting preparation ...................................................................................................................................................... 57
Test equipment ...................................................................................................................................................................... 58
Troubleshooting procedures and sequence .................................................................................................................. 58
External inspection ............................................................................................................................................................... 59
Internal inspection ................................................................................................................................................................ 59
Initial resistance check ........................................................................................................................................................ 59
Check the power switch ............................................................................................................................................. 60
Power supply overview ................................................................................................................................................................ 62
Troubleshooting guide ................................................................................................................................................................. 63
Power LED faults .................................................................................................................................................................. 63
Temperature LED faults ....................................................................................................................................................... 65
Internal compressor LED faults ......................................................................................................................................... 66
Torch cap LED faults ........................................................................................................................................................... 68
Common cutting issues ...................................................................................................................................................... 69
Control board LEDs ..................................................................................................................................................................... 71
Use the control board Rest and Error LEDs to troubleshoot ..................................................................................... 72
Reset LED ...................................................................................................................................................................... 72
Error LED ........................................................................................................................................................................ 73
System tests .................................................................................................................................................................................. 73
Test 1 – voltage input .......................................................................................................................................................... 78
Test 2 – power board voltage checks ............................................................................................................................. 80
Test 3 – VBUS and voltage balance on power board ................................................................................................. 82
Test 4 – solenoid valve ........................................................................................................................................................ 84
Test 5 – torch stuck open or torch stuck closed .......................................................................................................... 85
Test 6 – plasma start ........................................................................................................................................................... 87
Test 7 – torch cap-sensor .................................................................................................................................................. 89
Test 8 – fan ............................................................................................................................................................................ 90
Test 9 – internal compressor, compressor-driver board, and power board ........................................................... 91
Test 9a – Check the diagnostic LED (D5) on the compressor-driver board ................................................. 91
Test 9b – Check the internal compressor .............................................................................................................. 92
Test 9c – Check the compressor-driver board ..................................................................................................... 93
Test 9d – Check the power board ........................................................................................................................... 95
