powermax 800 help
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  1. #1
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    powermax 800 help

    so i have this powermax 800

    as soon as you flip the breakers to power it on in the back it trips them, presuming some kind of a short somewhere that is shutting it down

    Anyone have any ideas on what to check i checked the fuses inside ( sticks ) they are good, and i also checked the continuity on the circuit breakers they are good, i am guessing maybe some output diodes or transistors are shorted ?

    If anyone is familiar I do have a volt/ohm meter and can do some troubleshooting

    Thanks in advance for any input/ideas

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  2. #2
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    Re: powermax 800 help

    The switch you are referring to on the rear panel is not a breaker, it is a magnetic trip switch. It is a safety that senses when the consumables are correct and correctly installed in the torch ...and trips for operator safety when things are not correct. First, be sure your consumables are all the correct part numbers listed in the operators manual, and are genuine Hypertherm parts. (if you do not have the manual you can download one at www.Hypertherm.com). Then ensure that the torch parts in place sensor switch is functioning. If further questions contact Hypertherm tech service at 1 800 643 9878 or technical.service@hypertherm.com Jim Colt

  3. #3
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    Re: powermax 800 help

    i unplugged the torch and tried to fire it up and it did the same thing so i would presume that would take the consumables out of the picture, they look to be the correct NEW torch tip pieces, my neighbor got this from his place of work because they said it was not repairable and sold them a new miller but honestly i dont even think they took the cover off cause it was dirty and nasty and in my opinion if someone had tried to work on it surely they would have blown the dust out and checked a few things - anyway i think i found someone in the area that can work on it, he is retired and has the ability to work on them and has in the past so hopefully he can guide me as to the issues. I will try to look up the manual for it.

    Thanks for the info Jim!!!

    I will keep ya'all posted if we get this ole girl resurrected.
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  4. #4
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    Re: powermax 800 help

    If you unplug the torch the unit will instantly shut itself off. I am 99% sure the problem is in the torch or the consumables (I do have experience with Hypertherm units, worked for them for 41 years). Best bet is to do as I suggested in my previous response. There is a parts in place sensor switch in the torch that is activated by the proper installation of consumables. If the consumables are completely worn, if they are aftermarket, if they are not the right combination of part number the power switch will not stay on. Jim Colt


    Quote Originally Posted by searcyfarms View Post
    i unplugged the torch and tried to fire it up and it did the same thing so i would presume that would take the consumables out of the picture, they look to be the correct NEW torch tip pieces, my neighbor got this from his place of work because they said it was not repairable and sold them a new miller but honestly i dont even think they took the cover off cause it was dirty and nasty and in my opinion if someone had tried to work on it surely they would have blown the dust out and checked a few things - anyway i think i found someone in the area that can work on it, he is retired and has the ability to work on them and has in the past so hopefully he can guide me as to the issues. I will try to look up the manual for it.

    Thanks for the info Jim!!!

    I will keep ya'all posted if we get this ole girl resurrected.

  5. #5
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    Re: powermax 800 help

    ok jim here is what i found for the consumables i unscrewed the torch and took pieces out i dont think i can put multiple pix on one screen so sorry about the multiple notes everyone

    But i did find a service manual online and i got out my voltmeter and according to the test on page 3-13 it says unplug the torch, measure across d2 and d3 pos/neg each direction one way should be infinity and the other should be 1.7k ohms i get 546 ohms ? bad output diodes? or from the looks of the torch itself its pretty rough but i rekon they all get that way? Name:  Torch 1.jpg
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  6. #6
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    Re: powermax 800 help

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  7. #7
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    Re: powermax 800 help

    part number 3Name:  torch 3.jpg
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  8. #8
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    Re: powermax 800 help

    same part different view Name:  torch 4.jpg
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  9. #9
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    Re: powermax 800 help

    Name:  torch 5.jpg
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  10. #10
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    Re: powermax 800 help

    Name:  torch 6.jpg
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  11. #11
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    Re: powermax 800 help

    cant quite read the words on the torch handle something like ORCH XX-60? may XL-60? And come to think of it i cant remember which way i had the leads and was getting the 546ohms on the D2/D3 bars but regardless per the manual should be infinity one way and 1.7 the other so anything else they need replacing? And i did have the torch removed when i was making those measurements.

    Name:  torch 7.jpg
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  12. #12
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    Re: powermax 800 help

    and just an fyi this unit has been abused in a commercial business on heavy truck frames/busses/stuff like that cutting up radiators/trash/scrap/whatever they wanted to and with multiple users who didnt much less give a rip cause they didnt pay for it - im surprised it lasted as long as it did. That is why we are trying to give it a nice easy home for retirement my neighbor and I will share it and WE will take good care of it!!!!
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  13. #13
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    Re: powermax 800 help

    I am curious what has been done to the machine or torch to get a Thermal Dynamics XL60 torch to fit on a hypertherm powermax 800 power supply unit ??? That is the wrong torch for that machine as far as I can tell from when the powermax was sold new. Your Torch and consumables are labled One Torch or TD which are Thermal Dynamics parts. Are you using a Thermal Dynamics ATC adapter for your machine?

    Here is a link to the One Torch and adaptors for non Thermadyne machines.

    https://weldingsupply.com/1torch.pdf
    Last edited by N2 Welding; 03-15-2019 at 06:40 AM.
    Lincoln, ESAB, Thermal Dynamics, Victor, L-tec, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.

  14. #14
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    Re: powermax 800 help

    Quote Originally Posted by searcyfarms View Post
    part number 2Name:  torch 2.jpg
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    This is suppose to be two sepparate torch parts. What you have there is a start cartridge and a nozzle. Sepparate those two. Then look at the start cartridge “ black plastic part ”. It should have a metal inner ring that is spring loaded and should move in and out freely without hanging up or sticking. I am gussing this could be the issue as those two parts are stuck together and should not be.
    Last edited by N2 Welding; 03-15-2019 at 06:44 AM.
    Lincoln, ESAB, Thermal Dynamics, Victor, L-tec, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.

  15. #15
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    Re: powermax 800 help

    oh dear well crap who knows, see that is what happens when you get a hack idiot like me that doesn't know a hypertherm from a thermal dynamics, supposedly they used it this way for a long time per my neighbor then one day it crapped and quit - not sure what kind of an adapter you mean but the torch screws right into the front with a screw lock type connection, no pigtails or short plug gender changers or anything like that. I am actually headed to the fella that is going to work on it for me so maybe he will show/tell me a thing or two and get me set straight. Thanks for your patience with me trying to learn about this stuff and clarifying my ignorance, I probably have no business having something so nice as i know these are high end machines but i would rather spend money on this one and get it going than a 300 dollar machine that might take a dump on me in 6 mos.

    Heck Jim, maybe that is my problem its the wand/torch seems like you said that twice already LOL but my neighbor assures me they used it with this torch for many many yrs - I'm beginning to wonder if someone did a switcheroo trying to get it to work and he didn't know.

    This will bring to an interesting conclusion!!!
    Stay tuned for more exciting Hypertherm/Thermal Dynamics drama from the guy that is learning much feeling humble
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  16. #16
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    Re: powermax 800 help

    The link I provided shows you the ATC connectors for different machines. This torch can be adapted to be used on many machines as well as your powermax 800 according to the literature on the page I linked. I would try sepparating the nozzle from the start cartridge as I previously mentioned before paying anyone to check it out.
    Lincoln, ESAB, Thermal Dynamics, Victor, L-tec, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.

  17. #17
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    Re: powermax 800 help

    Here is a pic from the pdf I linked above that shows the torch parts breakdown for the torch you have.

    Name:  105F2D66-5C4C-4CE8-89EC-DC973BF24CDF.jpg
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  18. #18
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    Re: powermax 800 help

    Using one of the adapters is the only way you're going to adapt a TD SL60 torch to the machine unless somebody did a really good hack job. Searcyfarms, can you post a pic of the connection end of the gun?

  19. #19
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    Re: powermax 800 help

    Looks like someone installed a Thermal Dynamics SL60 torch on that Hypertherm 800. Good luck tracking down the problem.
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  20. #20
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    Re: powermax 800 help

    supposedly the Thermal Dynamics torch that is on mine is made to fit it, per the 30 year certified hypertherm tech i spoke to Hypertherm used to make what they called PAK50 or something like that i cant remember exactly type torches for them when they were new and they were always arcing and troublesome and needing repaired because of some button on the top that detected consumable tip length in order for the torch to work, so they discontinued them and went to the TD type because TD already was making torches that fit many other branded systems Hypertherm didn't need to reinvent the wheel and had the TD torch made to work with these powermax units. It says on the handle of the torch where is screws onto the port on the powermax that it is made for hypertherm plasma cutters. This hypertherm tech said it should work fine and is a descent torch and he will test and make sure it works properly.
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  21. #21
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    Re: powermax 800 help

    Wow. Never heard that story, much less ran into that before. Not doubting you at all, just kinda shocked. You must really have some kind of bastardized-hybrid in your possession. This is what came on the original Pakmaster 50 plasma. Called a smart torch. The picture you showed looks like a PCH62 torch that came after the smart torch.
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  22. #22
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    Re: powermax 800 help

    ok so the cutter is fixed and working with no modifications done to the torch or the machine - just like i said the torch plugs right into the machine using the standard connection it came with from the factory - what was wrong..................SOMEONE.............likely one of the people that worked at the business presumably took it home and attempted to change the wiring over or ( was an even worse idiot ) and thought plugging into his home electricity would work and blew out the input diode and transistors on the control board - they were smart enough to realize that they needed to try to change the internal wiring around ( possibly after plugging it in and it didnt work at home ) and got two of the wires moved from 208 to 240 but was one wire short of a happy power supplyl!!! Poof goes the board/poof goes the input diodes. So it needed parts, fortunately this person that is fixing it had new parts from old stock he purchased and he is going to put it through some paces over the weekend but he ran it a little today and cut some things and it works great, if any of you are looking for a Hypertherm 1000 he has one for sale. I am not selling this 800 ;-)
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  23. #23
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    Re: powermax 800 help

    oh and yes he had one of those pak 50 TD units in his shop for repairs also, he had all kinds of stuff he was fixing, he is a really smart guy and i would highly recommend him to anyone needing a welder/plasma/any of that kind of stuff fixed. He works on miller/lincoln/hypertherm/thermal dynamics/esab/all the major name brand stuff that i have heard of, i didnt see any low end cheap china stuff in there.
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  24. #24
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    Re: powermax 800 help

    Location, shop name and his name might help others determine if the shop you got the 800 repaired at would work for others needing repairs. Glad to hear he was able to get it fixed up for you.
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  25. #25
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    Re: powermax 800 help

    Quote Originally Posted by searcyfarms View Post
    ok so the cutter is fixed and working with no modifications done to the torch or the machine - just like i said the torch plugs right into the machine using the standard connection it came with from the factory - what was wrong..................SOMEONE.............likely one of the people that worked at the business presumably took it home and attempted to change the wiring over or ( was an even worse idiot ) and thought plugging into his home electricity would work and blew out the input diode and transistors on the control board - they were smart enough to realize that they needed to try to change the internal wiring around ( possibly after plugging it in and it didnt work at home ) and got two of the wires moved from 208 to 240 but was one wire short of a happy power supplyl!!! Poof goes the board/poof goes the input diodes. So it needed parts, fortunately this person that is fixing it had new parts from old stock he purchased and he is going to put it through some paces over the weekend but he ran it a little today and cut some things and it works great, if any of you are looking for a Hypertherm 1000 he has one for sale. I am not selling this 800 ;-)
    so what was the final cost of repair and did you pay for the original unit?

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