Hypertherm Powermax65 SYNC Manual
  1. Manuals
  2. Brands
  3. Hypertherm Manuals
  4. Welding System
  5. powermax65
  6. Manual

Hypertherm Powermax65 SYNC Manual

Hide thumbs Also See for Powermax65 SYNC:
Table of Contents

Advertisement

Quick Links

Download this manual
Powermax65/85 SYNC™
Service Parts and Procedures Guide
810440 – REVISION 0
ENGLISH

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Powermax65 SYNC and is the answer not in the manual?

Questions and answers

Related Manuals for Hypertherm Powermax65 SYNC

Summary of Contents for Hypertherm Powermax65 SYNC

  • Page 1 Powermax65/85 SYNC™ Service Parts and Procedures Guide 810440 – REVISION 0 ENGLISH...
  • Page 2 All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.
  • Page 3 Powermax65/85 SYNC Service Parts and Procedures Guide 810440 REVISION 0 ENGLISH Original instructions October 2021 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) technicalservice.emeia@hypertherm.com (Technical Service) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.
  • Page 5 Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs. DE (DEUTSCH/GERMAN) WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die IT (ITALIANO/ITALIAN) Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla...
  • Page 6 OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu คํ า เตื อ น! ก อ นการใช ง านอุ ป กรณ ข อง Hypertherm ทั ้ ง หมด โปรดอ า นคํ า แนะนํ า ด า นความ firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi ปลอดภั...

  • Page 7: Table Of Contents

    1 Before You Begin........................11 2 Service Parts ..........................13 Plasma power supply exterior, front ........................ 14 Work leads..............................15 Powermax65 SYNC........................15 Powermax85 SYNC........................16 Plasma power supply exterior, rear ......................... 17 Power cord and strain relief........................18 Rear panel..............................19 Plasma power supply interior, rear ........................
  • Page 8 Contents Machine interface and RS-485 serial interface upgrade kits ..............35 External cables for machine interface receptacle and RS-485 serial interface receptacle .. 36 Machine interface cables ......................36 RS-485 serial interface cables ....................37 Powermax65/85/105 SYNC labels ........................ 38 Cartridge labels ............................
  • Page 9 Contents Replace the power switch..........................75 Remove the power switch........................75 Install the power switch ......................... 76 4 Service Procedures for the Gas Line..................79 Tools necessary for this section........................80 More tools necessary for some procedures ..................80 Replace the air filter bowl and filter element....................81 Remove the air filter bowl and filter element..................
  • Page 10 Contents Replace the PFC IGBT ........................114 Replace the snubber resistors and the damper resistor............. 116 How to clean the heatsink and apply thermal grease to the heatsink components ......118 Remove the grease from the heatsink..................... 118 Apply the grease to the heatsink component ................118 Replace the power PCB capacitors......................

  • Page 11: Before You Begin

    1. Get the serial number for your system from the data plate that is on the rear panel of the plasma power supply. 2. Contact your Hypertherm distributor or authorized repair facility. 3. Contact the nearest Hypertherm office shown in the front of this manual. Powermax65/85 SYNC Service Parts and Procedures...
  • Page 12 SmartSYNC™ Service Parts and Procedures Guide (810460) (hand torches and  mechanized torches for Powermax SYNC) The most recent revisions of technical documentation are available at www.hypertherm.com/docs.  Technical documentation is current as of the date of its release. Subsequent revisions are possible.

  • Page 13: Service Parts

    Service Parts Genuine Hypertherm parts are factory-recommended parts for your Hypertherm system. Any damage caused by the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty. This section gives a list of service parts for the plasma power supply. Many parts come as a kit that contains 2 or more items.

  • Page 14: Plasma Power Supply Exterior, Front

    Service Parts Plasma power supply exterior, front Item Part number Description 528009 Kit: Powermax65 SYNC plasma power supply cover with labels, CSA (no screws included) 528010 Kit: Powermax65 SYNC plasma power supply cover with labels, CE/CCC (no screws included) 528011...

  • Page 15: Work Leads

    Powermax85 SYNC by installing the 008337 hand clamp or the 428921 C-style clamp on the approved amperage ring terminal work lead from Hypertherm. Make sure that you use a work lead that is the correct amperage for your plasma power supply.

  • Page 16: Powermax85 Sync

    Powermax85 SYNC by installing the 008337 hand clamp or the 428921 C-style clamp on the approved amperage ring terminal work lead from Hypertherm. Make sure that you use a work lead that is the correct amperage for your plasma power supply.

  • Page 17: Plasma Power Supply Exterior, Rear

    Service Parts Plasma power supply exterior, rear Part Item Description and kit contents number 428352 Kit: Air filter bowl, polycarbonate (comes with plasma power supply, includes the O-ring but not the filter element) 011124 Air filter bowl, polycarbonate 428415 Kit: Air filter bowl, nylon (optional – for work sites with oily air) (includes the O-ring but not the filter element) 011128 Air filter bowl, nylon...

  • Page 18: Power Cord And Strain Relief

    229290 Power cord assembly 65 A/85 A CSA 108795 Strain relief 65 A/85 A CSA 528015 Kit: Powermax65 SYNC power cord with strain relief, CE/CCC models, 3 m (10 foot) 229950 Power cord assembly 65 A CE/CCC 108676 Strain relief 65 A/85 A CE...

  • Page 19: Rear Panel

    Self adhesive foam strip 108867 CPC port cover 110711 Label: Power switch 65 A/85 A CSA, CE, or CCC data plate for Powermax65 SYNC or Powermax85 SYNC (preapplied) For replacement procedures, refer to Replace the rear panel on page 60.

  • Page 20: Plasma Power Supply Interior, Rear

    Service Parts Plasma power supply interior, rear Part Item Description and kit contents number 228644 Kit: Powermax65 SYNC power switch CSA 005257 Power switch 075760 Screw:#8 X 1/2, flat head (4) 108858 Power switch handle 110711 Label: Power switch 65 A/85 A...

  • Page 21: Plasma Power Supply Interior, Fan Side

    Service Parts Plasma power supply interior, fan side Part Item Description and kit contents number 428942 Kit: Air filter assembly (includes air filter, air filter bowl, air filter element, and O-ring) 429017 Air filter assembly 104990 Tubing: 8 mm outer diameter X 1.75 inches 104487 Tubing: 8 mm outer diameter X 3.3 inches (optional –...
  • Page 22 Service Parts Part Item Description and kit contents number 528053 Kit: Solenoid valve (includes gas tubes and screws) 429061 Solenoid valve 101508 Bracket 104488 Tubing: 5/16 inch outer diameter X 7.75 inches 104632 Tubing: 5/16 inch outer diameter X 12 inches 104990 Tubing: 8 mm outer diameter X 1.75 inches 075711...

  • Page 23: Fan And Fan Shroud

    Service Parts Fan and fan shroud Part Item Description and kit contents number 428991 Kit: Powermax65/85 SYNC Fan assembly 429078 Fan assembly 075693 Screw: #6 X 1/2, pan head (4) 228694 Kit: Powermax65/85 SYNC Fan shroud 101030 Fan shroud For replacement procedures, refer to Replace the fan and fan shroud on page 85.

  • Page 24: Plasma Power Supply Interior, Front

    Service Parts Plasma power supply interior, front Part Item Description and kit contents number 528026 Kit: Control PCB and adjustment knob 141472 Control PCB 108797 Adjustment knob 075418 Screw: #4 X 1/4, pan head (3) 428068 Kit: Ribbon cable for control PCB, 14 cm (5.5 inches) 223024 Ribbon cable that connects the control PCB to the DSP PCB 428070 Kit: Powermax65/85 SYNC work lead receptacle...

  • Page 25: Front Panel

    Panel: Plasma power supply front 104497 Foam: Close cell black 210569 Label: Display panel 65 A/85 A 210596 Label: Hypertherm logo For replacement procedures, refer to Replace the front panel on page 59. Powermax65/85 SYNC Service Parts and Procedures 810440...

  • Page 26: Plasma Power Supply Interior, Power Pcb Side

    Part Item Description and kit contents number 228705 Kit: Powermax65/85 SYNC component barrier 528029 Kit: Powermax65 SYNC power PCB CSA 075534 Screw: #6 X 5/16, pan head (4) 141440 Power PCB, 65 A CSA 528030 Kit: Powermax65 SYNC power PCB CE/CCC...

  • Page 27: Capacitors And Dsp Pcb

    228683 Kit: Powermax65 SYNC bulk capacitor CSA 075570 Screw: M5 X 14-12, pan head (4) 109935 Capacitor: 2200uF, 500 VDC (2) 228684 Kit: Powermax65 SYNC bulk capacitor CE / CCC 075570 Screw: M5 X 14-12, pan head (4) 109947 Capacitor: 3300uF, 400 VDC (2)

  • Page 28: Plasma Power Supply Interior, Heatsink

    075567 Screw: M6 X 16-12.5, pan head (4) 128836 Thermal grease, 0.125 ounce 228742 Kit: Powermax65 SYNC (all models) and Powermax85 SYNC CE / CCC input diode bridge 109931 Input diode bridge 075524 Screw: M5 X 16, pan head (2)
  • Page 29 Service Parts Part Item Description and kit contents number 228741 Kit: Powermax85 SYNC CSA input diode bridge 109801 Input diode bridge 075524 Screw: M5 X 16, pan head (2) 075570 Screw: M5 X 14-12, pan head (5) 128836 Thermal grease, 0.125 ounce For replacement procedures, refer to the following: Replace the output diode bridge on page 106...

  • Page 30: 65 A/85 A Heatsink Igbts And Thermal Sensor

    075567 Screw: M6 X 16-12.5, pan head (2) 075570 Screw: M5 X 14-12, pan head (2) 128836 Thermal grease, 0.125 ounce 528040 Kit: Powermax65 SYNC CE/Powermax85 SYNC CSA inverter IGBT 209444 Inverter IGBT 223738 PFC to inverter cable (2) 075567 Screw: M6 X 16-12.5, pan head (3)

  • Page 31: Igbt Tester

    428990 Kit: Thermal sensor (switch) 209569 Transducer 075524 Screw: M5 X 16, pan head 075851 Screw: M6 X 18.5±0.5-12.5, pan head 528041 Kit: Powermax65 SYNC CSA PFC IGBT 109932 PFC IGBT 223738 PFC to inverter cable (2) 075567 Screw: M6 X 16-12.5, pan head (4) 075569 Screw: M6 X 14-12.5, pan head (3)

  • Page 32: 65 A/85 A Heatsink Resistors

    Service Parts 65 A/85 A heatsink resistors CE/CCC Part Item Description and kit contents number 228693 Kit: Snubber resistor, 5 Ω, 120 W 109799 Snubber resistor 5 Ω, 120 W 108868 Standoff (2) 075526 Screw: M4 X 10, pan head (2) 128836 Thermal grease, 0.125 ounce 228706 Kit: Powermax65/85 SYNC snubber resistor, 15Ω, 120W...

  • Page 33: Power Supply Interior, Magnetics

    228661 Kit: Powermax65 SYNC PFC inductor CSA 014345 Inductor: PFC 075697 Screw: M5 X 0.8 X 10-10, pan head (2) 228670 Kit: Powermax65 SYNC PFC inductor CE / CCC 014348 Inductor: PFC 075697 Screw: M5 X 0.8 X 10-10, pan head (2)
  • Page 34 228654 Kit: Powermax85 SYNC transformer CE / CCC 014342 Transformer 075697 Screw: M5 X 0.8 X 10-10, pan head (2) 528036 Kit: Powermax65 SYNC output inductor 014439 Output inductor 075697 Screw: M5 X 0.8 X 10-10, pan head (2) 528037 Kit: Powermax85 SYNC output inductor...

  • Page 35: Machine Interface And Rs-485 Serial Interface Upgrade Kits

    Powermax65/85/105 SYNC, refer to the EDGE Connect Installation and Setup Manual (809340).  EDGE Pro CNC: To connect Hypertherm’s EDGE Pro CNC with a ® Powermax65/85/105 SYNC, refer to the Phoenix Software V9 Series Installation and Setup Manual (806410).

  • Page 36: External Cables For Machine Interface Receptacle And Rs-485 Serial Interface Receptacle

    Service Parts External cables for machine interface receptacle and RS-485 serial interface receptacle Hypertherm offers a variety of external cables that connect to the machine interface receptacle and the RS-485 serial interface receptacle. For setup information refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

  • Page 37: Rs-485 Serial Interface Cables

    External RS-485 cable, unterminated, 7.6 m (25 foot) 223237 External RS-485 cable, unterminated, 15 m (50 foot) 223239 External RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 7.6 m (25 foot) 223240 External RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 15 m (50 foot) Powermax65/85 SYNC...

  • Page 38: Powermax65/85/105 Sync Labels

    Service Parts Powermax65/85/105 SYNC labels Part number Description 528018 Kit: Powermax65 SYNC labels, CSA 528020 Kit: Powermax85 SYNC labels, CSA 528022 Kit: Powermax105 SYNC labels, CSA 528019 Kit: Powermax65 SYNC labels, CE/CCC 528021 Kit: Powermax85 SYNC labels, CE/CCC 528023 Kit: Powermax105 SYNC labels, CE/CCC...

  • Page 39: Csa Warning Label

    Service Parts CSA warning label This warning label is affixed to some plasma power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. Read and follow these instructions, employer safety WARNING AVERTISSEMENT practices, and material safety data sheets.

  • Page 40: Descriptions Of Warning Label Icons

    Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter. Become trained. Only qualified www.hypertherm.com/weee www.hypertherm.com/weee personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.

  • Page 41: Parts Necessary For Safety

    Genuine Hypertherm parts are factory-recommended parts for your Hypertherm system. Any damage caused by the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty. Parts that are necessary for safety are parts that must be replaced with only genuine Hypertherm parts to maintain the warranty and system certifications.

  • Page 42: Recommended Spare Parts

    Parts that are necessary for safety are parts that must be replaced with only genuine Hypertherm parts to maintain the warranty and system certifications. You may need to revise or expand this list for your customers, based on the conditions and work environments in your region.
  • Page 43 Kit: Snubber resistor, 5 Ω, 120 W page 32 228661 Kit: Powermax65 SYNC PFC inductor CSA page 33 228670 Kit: Powermax65 SYNC PFC inductor CE / CCC page 33 228668 Kit: Powermax85 SYNC PFC inductor CSA page 33 228664 Kit: Powermax85 SYNC PFC inductor CE / CCC...

  • Page 44: Find Replacement Parts By Part Number

    Service Parts Find replacement parts by part number Use this list to find the page number for a part number in Service Parts on page 13. Part number ....................Page 008337.....................15, 16 023206......................36 023279......................36 027055......................17 123896......................36 127204......................35 128650......................35 128651......................35 128652......................35 128836......................28 128883......................31 223033.....................15, 16...
  • Page 45 Service Parts 228655......................20 228661......................33 228663......................33 228664......................33 228667......................33 228668......................33 228669......................33 228670......................33 228671......................20 228680......................18 228681......................27 228682......................27 228683......................27 228684......................27 228691......................18 228693......................32 228694......................23 228695......................17 228697......................35 228705......................26 228706......................32 228709.....................15, 16 228740......................32 228741......................29 228742......................28 228803......................28 228804......................28 228805......................31 428066......................27 428068......................24 428070......................24 428141......................14 428143......................14 428352......................17 428415......................17 428685......................17 428755......................35 428921.....................15, 16 428942......................21 428975......................35...
  • Page 46 Service Parts 528000......................25 528001......................19 528009......................14 528010......................14 528011......................14 528012......................14 528015......................18 528016......................18 528017......................22 528018......................38 528019......................38 528020......................38 528021......................38 528022......................38 528023......................38 528024......................24 528026......................24 528028......................27 528029......................26 528030......................26 528031......................26 528032......................26 528036......................34 528037......................34 528039......................30 528040......................30 528041......................31 528042......................30 528043......................30 528046......................31 528047......................31 528053......................22 528065......................22 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 47: Service Procedures For The Cover, Panels, And Connectors

    Service Procedures for the Cover, Panels, and Connectors WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you. All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

  • Page 48: Tools Necessary For This Section

    Service Procedures for the Cover, Panels, and Connectors Tools necessary for this section Assorted Phillips ® , TORX ® , and blade screwdrivers  Assorted Phillips offset screwdrivers  ® Adjustable wrench  Grounded wrist strap (or similar grounding accessory) ...

  • Page 49: Replace The Plasma Power Supply Cover And Component Barrier

    Service Procedures for the Cover, Panels, and Connectors Replace the plasma power supply cover and component barrier For kit contents, refer to Plasma power supply interior, power PCB side on page 26. Remove the plasma power supply cover and component barrier WARNING STORED ENERGY HAZARD You can get a serious electric shock from the uncontrolled release of stored...
  • Page 50 Service Procedures for the Cover, Panels, and Connectors 4. Remove the component barrier from the power-PCB side of the plasma power supply. 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 51: Install The Component Barrier And Plasma Power Supply Cover

    Service Procedures for the Cover, Panels, and Connectors Install the component barrier and plasma power supply cover WARNING SHOCK HAZARD You can get a serious electric shock if you touch exposed plasma power supply components. Electric shock can seriously injure or kill you. You must install the component barrier and the plasma power supply cover.
  • Page 52 Service Procedures for the Cover, Panels, and Connectors 3. Fold the top of the component barrier onto the top edge of the power PCB, inside the plasma power supply frame and under the end panel bracket. 4. Make sure that all of the wires that are connected to the power PCB are behind the component barrier.

  • Page 53: Replace The End Panel Bracket

    Service Procedures for the Cover, Panels, and Connectors Replace the end panel bracket Remove the end panel bracket 1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and disconnect the gas supply. 2.

  • Page 54: Install The End Panel Bracket

    Service Procedures for the Cover, Panels, and Connectors Install the end panel bracket 1. Put the end panel bracket on the top of the plasma power supply. 2. Install the plasma power supply cover and the component barrier. Refer to page 810440 Service Parts and Procedures...

  • Page 55: Loosen And Attach The Front Panel

    Service Procedures for the Cover, Panels, and Connectors Loosen and attach the front panel Loosen the front panel Some repairs are easier to make if you first loosen the front panel from the plasma power supply. To replace an old front panel with a new one, complete this procedure, then continue with step 3 Replace the front panel on page 59.

  • Page 56: Attach The Front Panel

    Service Procedures for the Cover, Panels, and Connectors Attach the front panel 1. Put the fan side of the plasma power supply on a clean, dry, and flat surface. 2. Push the front panel onto the bottom of the plasma power supply. 3.

  • Page 57: Loosen And Attach The Rear Panel

    Service Procedures for the Cover, Panels, and Connectors Loosen and attach the rear panel Loosen the rear panel Some repairs are easier to make if you first loosen the rear panel from the plasma power supply. To replace an old rear panel with a new one, complete this procedure, then continue with step 3 Replace the rear panel on page 60.

  • Page 58: Attach The Rear Panel Of The Plasma Power Supply

    Service Procedures for the Cover, Panels, and Connectors Attach the rear panel of the plasma power supply 1. Put the fan side of the plasma power supply on a clean, dry, and flat surface. 2. Push the rear panel onto the bottom of the plasma power supply. 3.

  • Page 59: Replace The Front Panel

    Service Procedures for the Cover, Panels, and Connectors Replace the front panel For kit contents, refer to Front panel on page 25. Remove the front panel 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 60: Replace The Rear Panel

    Service Procedures for the Cover, Panels, and Connectors Replace the rear panel For kit contents, refer to Rear panel on page 19. Remove the rear panel 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 61 For the procedure to replace the power cord and strain relief, refer to the Power Cord and Strain Relief Replacement Field Service Bulletin (807020). Download the file at www.hypertherm.com/docs. a. Remove the screw that attaches the ground wire to the heatsink.
  • Page 62 Service Procedures for the Cover, Panels, and Connectors 9. Remove the strain relief from the rear panel: a. On the inside of the plasma power supply, remove the nut . For some models, also remove washer. b. On the outside of the plasma power supply, remove the strain relief .

  • Page 63: Install The Rear Panel

    Service Procedures for the Cover, Panels, and Connectors Install the rear panel 1. Install the strain relief into the new rear panel: a. On the outside of the plasma power supply, put the strain relief in the hole in the rear panel of the plasma power supply.
  • Page 64 Service Procedures for the Cover, Panels, and Connectors 4. Push the 3 power wires into the inside edge of the rear panel using the guide posts . Make sure that the routing of the wires is correct. 5. From the outside of the rear panel, tighten the strain relief retention nut on the strain relief with your hand plus a quarter turn with a wrench.
  • Page 65 Service Procedures for the Cover, Panels, and Connectors c. Put the RS-485 serial interface cable behind the gas tubes and below the solenoid valve. Do not put the RS-485 serial interface cable below the fan. This can cause the wires to be pinched by the fan.
  • Page 66 Service Procedures for the Cover, Panels, and Connectors 11. If you have a machine interface receptacle, install the 2 mounting screws that attach the machine interface receptacle to the rear panel. Tighten the screws to 1.1 N∙m (10 lbf∙in). 12. Install the air filter assembly and gas inlet fitting. Refer to page 13.

  • Page 67: Replace The Work Lead Connector

    Service Procedures for the Cover, Panels, and Connectors Replace the work lead connector For kit contents, refer to Work leads on page 15. Remove the work lead connector 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 68 Service Procedures for the Cover, Panels, and Connectors 6. Align the tabs in the rubber boot with the slots in the work lead connector. CAUTION INCORRECTLY INSTALLED WORK LEAD CONNECTORS CAN OVERHEAT To prevent damage and risk of burns, make sure that the face of the work lead connector is flush with the face of the rubber boot.

  • Page 69: Replace The Work Lead Receptacle

    Service Procedures for the Cover, Panels, and Connectors Replace the work lead receptacle For kit contents, refer to Plasma power supply interior, front on page 24. Remove the work lead receptacle 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 70: Install The Work Lead Receptacle

    Service Procedures for the Cover, Panels, and Connectors Install the work lead receptacle 1. Push the new work lead receptacle into the hole in the front panel. Position the receptacle so that the key way points up. 2. From inside the plasma power supply, put the washer on the work lead receptacle.

  • Page 71: Replace The Torch Quick-Disconnect Receptacle

    Service Procedures for the Cover, Panels, and Connectors Replace the torch quick-disconnect receptacle For kit contents, refer to Plasma power supply interior, front on page 24. Remove the torch quick-disconnect receptacle 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 72 Service Procedures for the Cover, Panels, and Connectors 8. Push-to-disconnect the 90° gas inlet fitting from the torch quick-disconnect receptacle. 9. Remove the following components from the torch quick-disconnect receptacle: Retention nut  Ring terminal  Washer  10. Push the torch quick-disconnect receptacle through the torch quick-disconnect receptacle housing.

  • Page 73: Install The Torch Quick-Disconnect Receptacle

    Service Procedures for the Cover, Panels, and Connectors Install the torch quick-disconnect receptacle 1. Use the 4 new screws to install the new torch quick-disconnect receptacle into the front panel. Tighten the screws to 1.7 N∙m (15 lbf∙in). 2. From the front panel, put the small end of the new torch quick-disconnect receptacle into the center hole of the receptacle housing.
  • Page 74 Service Procedures for the Cover, Panels, and Connectors 9. Put the torch interface cable through the upper grommet on the center panel. 10. From the power PCB side, attach the nozzle wires to the power PCB. Tighten the screw to 2.3 N∙m (20 lbf∙in).

  • Page 75: Replace The Power Switch

    Service Procedures for the Cover, Panels, and Connectors Replace the power switch For kit contents, refer to Plasma power supply interior, rear on page 20. Remove the power switch 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 76: Install The Power Switch

    Service Procedures for the Cover, Panels, and Connectors Install the power switch 1. Put the power switch into the plasma power supply. 2. Push the power switch post through the hole in the rear panel. 3. Attach the power switch to the rear panel with the 4 mounting screws .
  • Page 77 Service Procedures for the Cover, Panels, and Connectors 8. Put the auxiliary wires in the auxiliary switch. Tighten the screws to 1.1 N∙m (10 lbf∙in). 9. Put the AC input wires into the bottom of the power switch. Tighten the set screws to 2.3 N∙m (20 lbf∙in) for CSA models or 0.8 N∙m (7 lbf∙in) for CE/CCC models.
  • Page 78 Service Procedures for the Cover, Panels, and Connectors 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 79: Service Procedures For The Gas Line

    Service Procedures for the Gas Line WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you. All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

  • Page 80: Tools Necessary For This Section

    Service Procedures for the Gas Line Tools necessary for this section Assorted Phillips ® , TORX ® , and blade screwdrivers  Assorted TORX offset screwdrivers  ® Adjustable wrench  Grounded wrist strap (or similar grounding accessory)  More tools necessary for some procedures Cable ties are necessary for Replace the fan and fan shroud on page 85 and...

  • Page 81: Replace The Air Filter Bowl And Filter Element

    Service Procedures for the Gas Line Replace the air filter bowl and filter element For kit contents, refer to Plasma power supply exterior, rear on page 17. Remove the air filter bowl and filter element 1. Set the power switch on the plasma power supply to OFF (O).

  • Page 82: Replace The Air Filter Bowl, O-Ring, And Filter Element

    Service Procedures for the Gas Line Replace the air filter bowl, O-ring, and filter element 1. To replace the filter element, twist and pull the plastic fittings away from the filter element, approximately a 1/4 turn. Set the fittings aside. Discard the used filter element. 2.

  • Page 83: Install The Air Filter Bowl And Filter Element

    Service Procedures for the Gas Line Install the air filter bowl and filter element 1. Vertically align the filter bowl and push it up into the receptacle in the rear panel. 2. Turn the filter bowl 45 degrees to the left until you hear a click.

  • Page 84: Install The Air Filter Assembly

    Service Procedures for the Gas Line Install the air filter assembly 1. Remove the new air filter bowl and air filter element from the new air filter assembly. 2. Put the new air filter assembly into the plasma power supply. 3.

  • Page 85: Replace The Fan And Fan Shroud

    Service Procedures for the Gas Line Replace the fan and fan shroud For kit contents, refer to Plasma power supply interior, fan side on page 21. Remove the fan and fan shroud 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 86 Service Procedures for the Gas Line 8. Use an offset TORX screwdriver to remove the 4 screws from fan. 9. Remove the old fan. 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 87: Install The Fan And Fan Shroud

    Service Procedures for the Gas Line Install the fan and fan shroud 1. Attach the new fan to the center panel with the 4 supplied screws .Tighten the screws to 1.1 N∙m (10 in∙lbf). 2. Put the fan wire through the lower left grommet 3.

  • Page 88: Replace The Solenoid Valve

    Service Procedures for the Gas Line Replace the solenoid valve For kit contents, refer to Plasma power supply interior, fan side on page 21. Remove the solenoid valve 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 89: Install The Solenoid Valve

    Service Procedures for the Gas Line 7. Remove the mounting screw from the bracket. 8. Push-to-disconnect the short gas tube and long gas tube from the solenoid valve 9. Remove the solenoid valve and bracket. 10. Push-to-disconnect the short gas tube from the air filter assembly 11.
  • Page 90 Service Procedures for the Gas Line 7. Connect the solenoid valve wire connector to J4 (CSA) or J6 (CE/CCC) near the top of the power PCB. CE/CCC 8. Bundle the fan and solenoid valve wires with a new cable tie. 9.

  • Page 91: Replace The Gas Tubes

    Service Procedures for the Gas Line Replace the gas tubes For kit contents, refer to Plasma power supply interior, fan side on page 21. This kit contains an extra gas tube. Do not make kinks or bend the gas tubes. This will damage the gas tubes. Remove the gas tubes 1.

  • Page 92: Replace The 90° Gas Tube Fitting

    Service Procedures for the Gas Line Replace the 90° gas tube fitting For kit contents, refer to Plasma power supply interior, fan side on page 21. 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 93: Service Procedures For The Pcbs And Related Components

    Service Procedures for the PCBs and Related Components WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before doing installation or maintenance. The line-disconnect switch must REMAIN in the OFF position until all installation or maintenance steps are complete. See the Safety and Compliance Manual (80669C) for more safety information.

  • Page 94: Tools Necessary For This Section

    Service Procedures for the PCBs and Related Components Tools necessary for this section Assorted Phillips ® , TORX ® , and blade screwdrivers  Assorted offset screwdrivers  Assorted hexagonal socket wrenches  Needle nose pliers  Grounded wrist strap (or similar grounding accessory) ...

  • Page 95: Replace The Dsp Pcb

    24. For the procedure to replace the DSP PCB, refer to the DSP PCB Replacement and Power Supply Data Backup Field Service Bulletin (810950). Download the file at www.hypertherm.com/docs. POSSIBLE LOSS OF DATA You can lose system-level cut data if you do not save that data before you install the new DSP PCB.

  • Page 96: Replace The Control Pcb And The Ribbon Cable

    Service Procedures for the PCBs and Related Components Replace the control PCB and the ribbon cable For kit contents, refer to Plasma power supply interior, front on page 24. The control PCB and the ribbon cable are sold as different kits. The control PCB does not come with a ribbon cable. Remove the control PCB and the ribbon cable 1.

  • Page 97: Install The Control Pcb And The Ribbon Cable

    Service Procedures for the PCBs and Related Components 8. Is it necessary to replace the ribbon cable? If yes, go to the next step.  If no, continue with Install the control PCB and the ribbon cable.  9. Remove the left mounting screw from the DSP PCB 10.

  • Page 98: Replace The Power Pcb

    Service Procedures for the PCBs and Related Components Replace the power PCB For kit contents, refer to Plasma power supply interior, power PCB side on page 26. Refer to page 100 through page 100 for an image of your power PCB. Remove the power PCB 1.
  • Page 99 Service Procedures for the PCBs and Related Components 6. Disconnect the 4 wire connectors near the top of the power PCB. CE/CCC step 7 through step 15, refer to Figure 1 Figure 7. Remove the 3 μF capacitors from near the center of the power PCB. The number of capacitors is different for each system.
  • Page 100 Service Procedures for the PCBs and Related Components Figure 1 – Powermax65/85 SYNC CSA power PCB TP10 TP11 WORK LEAD TP12 Figure 2 – Powermax65/85 SYNC CE/CCC power PCB TP11 TP12 WORK TP13 LEAD 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 101: Install The Power Pcb

    Install the power PCB 1. Make sure that you have the correct power PCB for your system, as follows: Powermax65 SYNC CSA models: Use power PCB 141440 (kit 528029).  Powermax65 SYNC CE/CCC models: Use power PCB 141477 (kit 528030).
  • Page 102 Service Procedures for the PCBs and Related Components 8. Carefully connect the following wire connectors to the power PCB. Make sure that you do not bend or damage the connectors. All models: Connect the gate drive wires at J19 and J18. ...
  • Page 103 Service Procedures for the PCBs and Related Components Figure 4 – Powermax65/85 SYNC CE/CCC power PCB TP11 TP12 WORK TP13 LEAD 9. Connect the 4 wire connectors near the top of the power PCB. CE/CCC Powermax65/85 SYNC Service Parts and Procedures 810440...
  • Page 104 Service Procedures for the PCBs and Related Components 10. Install the DSP PCB, as follows: a. Connect the ribbon cable to J6 on the DSP PCB. b. Align the 2 posts with the related holes in the power PCB. c. Carefully push the DSP PCB onto the power PCB. Do not bend the pins. d.

  • Page 105: Replace The Heatsink Components

    Service Procedures for the PCBs and Related Components Replace the heatsink components For kit contents, refer to Plasma power supply interior, heatsink on page 28. Refer to the following procedures for instructions on how to replace each heatsink component: Replace the output diode bridge on page 106 ...

  • Page 106: Replace The Output Diode Bridge

    Service Procedures for the PCBs and Related Components Replace the output diode bridge Figure 5 — Output diode bridge on heatsink CE/CCC 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. 2.
  • Page 107 Service Procedures for the PCBs and Related Components Figure 6 Powermax65/85 SYNC Service Parts and Procedures 810440...

  • Page 108: Replace The Input Diode Bridge

    Service Procedures for the PCBs and Related Components Replace the input diode bridge Figure 7 — Input diode bridge on heatsink CE/CCC 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. 2.
  • Page 109 Service Procedures for the PCBs and Related Components Figure 8 CE/CCC Powermax65/85 SYNC Service Parts and Procedures 810440...

  • Page 110: Replace The Pilot Arc Igbt

    Service Procedures for the PCBs and Related Components Replace the pilot arc IGBT Figure 9 — Pilot arc IGBT on heatsink CE/CCC 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. 2.
  • Page 111 Service Procedures for the PCBs and Related Components Figure 10 Black wire on top terminal. Red wire on bottom terminal. Powermax65/85 SYNC Service Parts and Procedures 810440...

  • Page 112: Replace The Inverter Igbt And The Thermal Sensor

    Service Procedures for the PCBs and Related Components Replace the inverter IGBT and the thermal sensor The inverter IGBT and the thermal sensor are sold as different kits. The thermal sensor does not come with the inverter IGBT. Refer to page 105.
  • Page 113 Service Procedures for the PCBs and Related Components 7. Connect the new gate drive wires to the terminals on the inverter IGBT with the correct polarity, as follows. Do not use the old gate drive wires on the new inverter IGBT. a.

  • Page 114: Replace The Pfc Igbt

    Service Procedures for the PCBs and Related Components Replace the PFC IGBT Figure 13 — PFC IGBT on heatsink CSA only 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. 2.
  • Page 115 Service Procedures for the PCBs and Related Components Figure 14 Black wires on left terminals. Red wires on right terminals. Powermax65/85 SYNC Service Parts and Procedures 810440...

  • Page 116: Replace The Snubber Resistors And The Damper Resistor

    Service Procedures for the PCBs and Related Components Replace the snubber resistors and the damper resistor The resistors are sold individually. Snubber resistors can look the same but have different resistance ratings. Refer to page 105 for the correct replacement part numbers. ...
  • Page 117 Service Procedures for the PCBs and Related Components Figure 15 — CSA models: Snubber resistors and damper resistor 5 Ohms (Ω), 120 W Damper resistor 15 Ohms (Ω), 120 W 5 Ohms (Ω), 120 W Figure 16 — CE/CCC models: Snubber resistors 5 Ohms (Ω), 120 W 15 Ohms (Ω), 120 W Powermax65/85 SYNC...

  • Page 118: How To Clean The Heatsink And Apply Thermal Grease To The Heatsink Components

    How to clean the heatsink and apply thermal grease to the heatsink components Only use the thermal grease that is supplied by Hypertherm. The amount of thermal grease that is supplied is enough for many heatsink components. Do not use a full container of thermal grease on a single heatsink component.

  • Page 119: Replace The Power Pcb Capacitors

    Service Procedures for the PCBs and Related Components Replace the power PCB capacitors For kit contents, refer to Plasma power supply interior, power PCB side on page 26. 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 120 Service Procedures for the PCBs and Related Components Figure 18 – Capacitor in CE/CCC models TP11 TP12 WORK TP13 LEAD 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 121: Replace The Bulk Capacitors

    Service Procedures for the PCBs and Related Components Replace the bulk capacitors For kit contents, refer to Plasma power supply interior, power PCB side on page 26. Remove the bulk capacitors 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 122 Service Procedures for the PCBs and Related Components Figure 20 – Bulk capacitor screws in CE/CCC models TP11 TP12 WORK TP13 LEAD 4. From the fan side, remove the fan shroud by pulling it straight off of the fan. 5. Remove the 2 bulk capacitors by pulling them straight out of the plasma power supply. 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 123: Install The Bulk Capacitors

    Service Procedures for the PCBs and Related Components Install the bulk capacitors 1. Install the new bulk capacitors from the fan side of the plasma power supply. 2. Position each capacitor so that the gray polarity dot on the capacitor aligns with the viewing hole on the power PCB.
  • Page 124 Service Procedures for the PCBs and Related Components 810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 125: Service Procedures For The Magnetics

    Service Procedures for the Magnetics WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you. All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

  • Page 126: Tools Necessary For This Section

    Service Procedures for the Magnetics Tools necessary for this section Assorted Phillips ® , TORX ® , and blade screwdrivers  Adjustable wrench  Grounded wrist strap (or similar grounding accessory)  810440 Service Parts and Procedures Powermax65/85 SYNC...

  • Page 127: Replace The Output Inductor

    Service Procedures for the Magnetics Replace the output inductor For kit contents, refer to Power supply interior, magnetics on page 33. Remove the output inductor 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 128: Install The Output Inductor

    Service Procedures for the Magnetics 9. Push-to-disconnect the 90° gas inlet fitting from the torch quick-disconnect receptacle. 10. Remove the following components from the torch quick-disconnect receptacle: Retention nut  Ring terminal  11. Remove the output inductor. Install the output inductor 1.
  • Page 129 Service Procedures for the Magnetics 5. Attach the electrode wire to the power PCB. Tighten the screw to 2.3 N∙m (20 lbf∙in). 6. Attach the output inductor wires to the power PCB. Tighten the screw to 2.3 N∙m (20 lbf∙in). WORK LEAD 7.

  • Page 130: Replace The Transformer

    Service Procedures for the Magnetics Replace the transformer For kit contents, refer to Power supply interior, magnetics on page 33. Remove the transformer 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 131: Install The Transformer

    Service Procedures for the Magnetics 7. Use an offset TORX screwdriver to remove the 4 screws from fan. 8. Remove the 2 mounting screws from the transformer. 9. Remove the transformer. Install the transformer 1. Put the transformer cables through the open space in the bottom of the center panel.
  • Page 132 Service Procedures for the Magnetics 3. Attach the transformer to the plasma power supply with the 2 supplied mounting screws. Tighten screws to 2.3 N∙m (20 lbf∙in). 4. Attach the fan to the center panel with the screws. Tighten the screws to 1.1 N∙m (10 in∙lbf). 5.
  • Page 133 Service Procedures for the Magnetics 7. Attach the 2 short transformer cables to the power PCB. Tighten the screws to 2.3 N∙m (20 lbf∙in). TP11 WORK LEAD 8. Install the end panel bracket. Refer to page 9. Install the component barrier and the plasma power supply cover. Refer to page Powermax65/85 SYNC Service Parts and Procedures...

  • Page 134: Replace The Pfc Inductor

    Service Procedures for the Magnetics Replace the PFC inductor For kit contents, refer to Power supply interior, magnetics on page 33. Remove the PFC inductor 1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

  • Page 135: Install The Pfc

    Service Procedures for the Magnetics Install the PFC 1. Put the PFC inductor wires through the open space in the bottom of the center panel. 2. Put the tabs on the rear of the PFC inductor into the slots on the bottom of the plasma power supply.
  • Page 136 Service Procedures for the Magnetics 810440 Service Parts and Procedures Powermax65/85 SYNC...

This manual is also suitable for:

Powermax85 sync

Table of Contents