Hypertherm Powermax45 SYNC Service Manual

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Powermax45 SYNC®

Service Manual

811480 - Revision 0

English

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Summary of Contents for Hypertherm Powermax45 SYNC

Page 1 Powermax45 SYNC® Service Manual 811480 - Revision 0 English...
Page 2 Hypertherm Cutting Institute. ■ Confirmation of ownership: Registration can serve as proof of purchase in case of an insurance loss. Go to www.hypertherm.com/registration for easy and fast registration. If you experience any problems with the product registration process, please contact registration@hypertherm.com.
Page 3 Powermax45 SYNC® Service Manual 811480 Revision 0 English Original Instructions October 2024 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 United States and other countries. 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.
Page 6 Contents Electromagnetic Compatibility (EMC).........15 Warranty....................17 Prepare to troubleshoot internal components......19 Where to find information for Powermax45 SYNC..................19 Troubleshooting preparation..........................19 Troubleshooting procedures and sequence..................... 21 Required test equipment............................22 Do an external inspection............................22 Do an internal inspection............................23 Attach to ground..............................23 Frequently used troubleshooting procedures....................
Page 7 The solenoid valve or power PCB is defective..................40 Gas flows when you fire the torch, but there is no plasma arc..............40 There is a problem with the Hypertherm cartridge, torch, or torch lead......... 40 The gas flow is too high or too low......................40 The gas quality is unsatisfactory......................
Page 8 Troubleshooting for missing gas input faults..................61 Fault codes and fault LEDs......................61 Corrective action for the input gas supply................. 61 Corrective action for the solenoid valve and power PCB............62 Troubleshooting for TSO and TSC faults....................64 811480 Service Manual Powermax45 SYNC®...
Page 9 Troubleshooting for temperature-related faults..................70 Fault codes and fault LEDs......................70 Corrective action for temperature faults..................71 Troubleshooting for when the Hypertherm cartridge or torch is not ready to cut......71 Fault codes and fault LEDs......................71 Corrective action for the Hypertherm cartridge and torch............. 71 Corrective action for the torch cap sensor in the torch and torch lead.......72...
Page 10 Corrective action for 0-52-0 faults....................95 Troubleshooting for an RF communication fault (0-98-1)..............96 Fault codes and fault LEDs......................96 Corrective action for the Hypertherm cartridge (0-98-1)............96 Corrective action for the torch (0-98-1)..................97 Troubleshooting for a plasma power supply or torch communication fault (0-98-2)....98 Fault codes and fault LEDs......................99...
Page 11 Plasma power supply interior, wires and EMI PCB, CE/CCC 1-phase..........120 Plasma power supply interior, wires, 3-phase....................121 Safety critical parts.............................. 122 Recommended spare parts..........................124 Powermax45 SYNC labels..........................125 Data plate................................125 Safety and EMC symbols and marks......................126 IEC symbols................................128 Service procedures for the cover, panels, and connectors..................131...
Page 12 Remove the gas supply hoses and 90 degree fitting...............169 Install the gas supply hoses and 90 degree fitting................170 Replace the gas inlet fittings..........................171 Remove the gas inlet fittings........................171 Install the gas inlet fittings........................171 811480 Service Manual Powermax45 SYNC®...
Page 13 Remove the power cord (3-phase models)..................198 Install the power cord (3-phase models).................... 200 Change system settings..............201 Overview.................................201 System settings..............................202 Change system settings............................. 204 Smart mode versus basic mode........................205 Smart mode..............................206 Basic mode..............................206 Powermax45 SYNC® Service Manual 811480...
Page 14 10 System diagrams................213 System diagrams..............................213 Powermax45 SYNC schematic — 200 V – 240 V 1-phase models............215 Powermax45 SYNC schematic — 400 V CE/CCC and 480 V CSA 3-phase models shown..216 Timing chart for torch start..........................217 811480 Service Manual...
Page 15 The introduction surrounding area may extend beyond the boundaries of the premises. Hypertherm’s CE-marked equipment is built in compliance with Methods of reducing emissions standard EN60974-10. The equipment should be installed and used...
Page 16 Installation and Use. Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications. 811480 Service Manual Powermax45 SYNC®...
Page 17 Hypertherm of its warranty. in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with Distributors/OEMs may offer different or additional warranties, but respect to the plasma power supply within a period of two (2) years...
Page 18 PowerDredge 15 months from the ship date or 12 In no event shall Hypertherm be liable for injury to persons or property abrasive removal months from the date of proven instal- damage by reason of any code violation or poor work practices.
Page 19 Prepare to troubleshoot internal components Where to find information for Powermax45 SYNC This service manual includes service parts and procedures for the Powermax45 SYNC ® plasma power supply. For related information, refer to these documents: ■ Safety and Compliance Manual (80669C) ■...
Page 20 AC input circuit and the output circuit that can cause serious injury or death. WARNING HOT PARTS CAN CAUSE SEVERE BURNS Let the temperature of the plasma power supply decrease before you do any maintenance. 811480 Service Manual Powermax45 SYNC®...
Page 21 Live voltages can stay on the DC bus for 30 seconds or more after you disconnect the input power. Let bus voltages dissipate before you start tests. While testing, do not touch the nozzle at the end of the torch. Powermax45 SYNC® Service Manual 811480...
Page 22 Before you purchase a major replacement component, make sure that you have correctly identified the problem with help from Hypertherm Technical Service or the nearest Hypertherm repair facility. Required test equipment ■...
Page 23 Make sure that the plasma power supply is grounded correctly before doing troubleshooting procedures. ■ Use either the ground clip near the top of the rear panel or the ground screw on the heatsink for all troubleshooting tests where it is necessary to attach the multimeter to ground. Powermax45 SYNC® Service Manual 811480...
Page 24 Incorrect gas pressure can cause errors that prevent cutting or that cause problems with cut quality and cut performance. Install a pressure gauge ■ Install an inline pressure gauge at the gas inlet on the rear of the plasma power supply, after all external filtration. 811480 Service Manual Powermax45 SYNC®...
Page 25 ■ Do a gas test to see if the plasma power supply’s actual output gas pressure is lower than the set pressure by more than an acceptable quantity. The set pressure is the gas pressure that the system sets to align with the type of Hypertherm cartridge and torch installed. Refer to...
Page 26 Before you begin: ■ Comply with the gas quality recommendations in Hypertherm plasma power supply ratings on page 207. ■ If you work in an environment that is extremely warm and humid, or if work site conditions let oil, vapor, or other contaminants into the gas line, install an external filtration system that cleans the gas supply before it gets into the plasma power supply.
Page 27 "ready to fire" state. In this case, pull the trigger. The system then emits the warning puffs of air and displays the actual pressure. During a gas test: ■ Air flows continuously from the torch tip. Powermax45 SYNC® Service Manual 811480...
Page 28 Do a continuity test on the FastConnect torch receptacle Use this table to help check continuity between the FastConnect torch receptacle and J19 on the power PCB. If there is no continuity between any two test points, replace the torch FastConnect ™ receptacle. 811480 Service Manual Powermax45 SYNC®...
Page 29 ■ After you locate and repair the problem, refer to Troubleshooting preparation on page 19 to do a test of the plasma power supply for correct operation. Powermax45 SYNC® Service Manual 811480...
Page 30 4. Measure the resistance across the input leads. Pull back the red insulating covers, and measure the resistance where the wires connect to the center panel (or to the Electromagnetic Interference (EMI) PCB, for CE/CCC 1-phase models). 811480 Service Manual Powermax45 SYNC®...
Page 31 CE/CCC 200 V – 240 V 1-phase 1 36.5 kiloohms (kΩ) 400 V, 480 V 3-phase (all models) 450 kiloohms (kΩ) The resistance should be consistent when measured on both sides of the EMI PCB. Powermax45 SYNC® Service Manual 811480...
Page 32 6. Disconnect the torch from the plasma power supply. 7. Measure the output resistance for the values in the table. The red nozzle wires connect to J15 (RED) on the power PCB. The white electrode wire connects to J18 (WHT). 811480 Service Manual Powermax45 SYNC®...
Page 33 9. Make sure that the resistance is approximately 10 ohms (Ω). 10. If you do not find problems during the visual inspection or the initial resistance check, and the plasma power supply continues to not operate correctly, refer to Troubleshooting for common problems on page Powermax45 SYNC® Service Manual 811480...
Page 34 System diagrams on page 213 Overview on page 207. ■ Before you purchase a major replacement component, make sure that you speak about the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility. 811480 Service Manual Powermax45 SYNC®...
Page 35 Overview on page 207. ■ Before you purchase a major replacement component, make sure that you speak about the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility. WARNING ELECTRIC SHOCK CAN KILL Let the system release internal voltages before you touch the capacitors. The capacitors can hold a charge for several minutes after the system is set to OFF.
Page 36 ■ The Hypertherm cartridge is not installed correctly. ■ The Hypertherm cartridge is at end-of-life. 1. Make sure that the Hypertherm cartridge is not too loose or too tight. 2. Examine the Hypertherm cartridge for wear or damage. 3. Replace it if it is worn or has damage.
Page 37 Increase the output current (A) as necessary. The operating mode is incorrect Use the correct operating mode for the cutting application. Use a Hypertherm gouging cartridge in Gouge mode. Use a Hypertherm cutting cartridge in Cut mode. An extension cord is not sufficient Operate the plasma power supply without using an extension cord.
Page 38 8. Use pin 1 (red) and pin 4 (black) on the J7 fan connector, and connect the fan to an external 12 V or 24 V power source. 9. Does the fan operate correctly when it is connected to an external power source? If yes... Replace the power PCB. If no... Replace the fan. 811480 Service Manual Powermax45 SYNC®...
Page 39 5. Examine the work clamp, and repair or replace the clamp if necessary. 6. Examine the work lead, and repair or replace the lead if necessary. The pierce height is too high Decrease the cut height. Powermax45 SYNC® Service Manual 811480...
Page 40 Gas flows when you fire the torch, but there is no plasma Gas flows when you fire the torch, but there is no plasma arc, or you lose the arc quickly. The Hypertherm cartridge or torch lead are worn or have damage, there is a problem with the gas flow or gas quality, or the input power is not sufficient.
Page 41 ■ Circuit breaker or fuse ■ Supply wire ■ Extension cord Refer to the installation specifications in the Powermax45 SYNC Operator Manual (811470). There is a voltage imbalance on the capacitors The bulk capacitors on the power PCB are defective.
Page 42 5. Remove the fan and fan shroud from the plasma power supply. 6. Use pin 1 (red) and pin 4 (black) on the J7 fan connector, and connect the fan to an external 12 V or 24 V power source. 811480 Service Manual Powermax45 SYNC®...
Page 43 The plasma arc stopped while cutting, but starts when you fire the torch again There is a problem with the Hypertherm cartridge, the air filter element, or the input gas pressure. The Hypertherm cartridge is worn or has damage ■ Replace the Hypertherm cartridge.
Page 44 3. Flush the gas supply line with nitrogen to remove oil and moisture. 4. If necessary, add additional, external filtration that is applicable for the work environment. Refer to the Powermax45 SYNC Operator Manual (811470). The system is not cutting at full cutting power, and the plasma arc does not time out after 5 seconds The system is not connected to ground sufficiently.
Page 45 4. Make sure that the line voltage is not too low (more than 15% below the rated voltage). Refer to the electrical specifications in the Powermax45 SYNC Operator Manual (811470). 5. Examine the fuses in the line-disconnect switch box, and replace bad fuses as necessary.
Page 46 The system does not keep changes to the output current (A) or operating mode while the torch-lock switch is in the yellow lock position or while there is an 0-50-n "Hypertherm cartridge off" fault condition. When you set the torch-lock switch to the green "ready to fire" position, the system automatically sets the amperage and operating mode to match the type of Hypertherm cartridge installed on the torch.
Page 47 The trip-coil mechanism is operating correctly. If no... Replace the power switch. Refer to Remove the power switch (1-phase) on page 152. The trip coil connects to the component side of the power PCB at J10. Powermax45 SYNC® Service Manual 811480...
Page 48 Troubleshooting for common problems 811480 Service Manual Powermax45 SYNC®...
Page 49 Fault icons and fault codes The Powermax45 SYNC power supply shows faults using a combination of fault icons and fault code numbers. Some faults are shown by the icons only, others are shown by the icons and a fault code number.
Page 50 Troubleshooting for fault codes Torch Cap sensor This icon identifies fault conditions in which the Hypertherm cartridge is loose, incorrectly installed, or missing. This icon also identifies when the SmartSYNC torch is in the yellow lock (X) position. ® Fault This icon identifies faults that cause the plasma power supply to stop cutting.
Page 51 An operational fault code can be for a notification or for a condition that stops the cutting process. Hypertherm recommends that you do the steps for all faults that occur. Troubleshooting all faults helps you to get optimal cut quality and consumable life.
Page 52 Troubleshooting for TSO and TSC faults on page Yellow Flashes quickly None • The internal temperature of the plasma power supply is too hot or too cold. • Refer to Troubleshooting for temperature-related faults on page Yellow 811480 Service Manual Powermax45 SYNC®...
Page 53 Fault LEDs Torch LED Description None • The Hypertherm cartridge was off, the torch was disconnected, or the torch was in the yellow lock (X) position during a restart. • Refer to Troubleshooting for when the Hypertherm cartridge or torch...
Page 54 Hypertherm cartridge. • The permitted operating modes for Hypertherm cutting cartridges is 1 (Cut mode). • The permitted operating mode for a Hypertherm gouging cartridge is 2 (Gouge mode). • Refer to Troubleshooting for remote controller faults (0-11-n) on...
Page 55 • Refer to Troubleshooting for torch-lock switch faults (0-50-n) on Yellow page 0-50-3 • The plasma power supply is reading data from the Hypertherm cartridge. • Refer to Troubleshooting for torch-lock switch faults (0-50-n) on page Powermax45 SYNC®...
Page 56 • Refer to Troubleshooting for torch connection faults (0-52-0) on page None 0-98-1 • A Radio Frequency (RF) communication failure occurred between the Hypertherm cartridge and the torch. • Refer to Troubleshooting for an RF communication fault (0-98-1) on page Yellow 0-98-2 •...
Page 57 • The fan speed is less than the minimum speed. • Refer to Troubleshooting for fan faults (3-10-n) on page 113. 3-10-1 • The fan is not operating correctly. • Refer to Troubleshooting for fan faults (3-10-n) on page 113. Powermax45 SYNC® Service Manual 811480...
Page 58 Troubleshooting procedures for fault LEDs and 0-nn-n fault codes Troubleshooting for AC input power that is not stable The Power ON LED can flash to identify when the AC input power is not stable and a system shutdown is necessary. 811480 Service Manual Powermax45 SYNC®...
Page 59 When the Gas Pressure fault LED and the System Fault LED both illuminate while the system is ON, the gas pressure is less than the minimum pressure for the selected process, operating mode, torch, lead length, and Hypertherm cartridge type. Fault codes and fault LEDs...
Page 60 1. Set the power switch to OFF (O), and disconnect the power cord from the power source. 2. Examine the Hypertherm cartridge for wear and damage, and replace it if necessary. 3. Make sure that the torch lead is not kinked or twisted, and replace it if necessary.
Page 61 Yellow age in the gas line. Corrective action for the input gas supply 1. Make sure that the input gas supply is connected correctly to the plasma power supply. Powermax45 SYNC® Service Manual 811480...
Page 62 4. Set the power switch to ON (I). 5. Fire the torch. If no... Continue with the next step. Solenoid valve Gas hoses 5. Measure the voltage between pin 1 and pin 7 at J8 on the power PCB. 811480 Service Manual Powermax45 SYNC®...
Page 63 Replace the solenoid valve. Refer to Remove the solenoid valve on page 166. If no... Replace the power PCB. Refer to Remove the power PCB on page 177. 11. Disconnect the J8 connector from the power PCB. Powermax45 SYNC® Service Manual 811480...
Page 64 Troubleshooting for TSO and TSC faults A flashing Torch Cap fault LED identifies either a TSO or a TSC condition. ■ TSO: The nozzle and electrode components inside the Hypertherm cartridge are not touching after a Start signal is received.
Page 65 OFF (O), correct the problem, and set the power switch to ON (I) to remove the fault. 2. Examine the Hypertherm cartridge to make sure that it is not worn and does not have damage. 3. Are you using a hand torch or a mechanized torch? Hand torch 1.
Page 66 5. If possible, do a continuity check on the torch lead with a Hypertherm cartridge installed. a. Make sure that a Hypertherm cartridge is installed on the torch and that the torch is not connected to the plasma power supply.
Page 67 □ Is there heavy equipment putting too much weight on part of the torch lead? □ Are there signs of damage to the torch lead that can cause gas pressure leaks? 3. Connect a different torch to the plasma power supply that is known to operate correctly. Powermax45 SYNC® Service Manual 811480...
Page 68 Corrective action for the plasma power supply on page 4. Do a check for continuity on the original torch: a. Make sure that a Hypertherm cartridge is installed on the torch and that the torch is not connected to the plasma power supply.
Page 69 The resistance is very low. Continue with the next step. The resistance is open. 1. Install a different Hypertherm cartridge. 2. Examine the torch lead to find if one of the wires in the lead is broken. Replace the torch lead if necessary.
Page 70 If the resistance is very low (closed circuit) with the gas flowing, the nozzle and electrode are touch- ing or a short-circuit occurred in one of the wires in the torch lead. Replace the Hypertherm cartridge or the torch lead, as necessary.
Page 71 Troubleshooting for when the Hypertherm cartridge or torch is not ready to cut The Torch Cap fault LED illuminates when the torch or Hypertherm cartridge is not ready to cut or is not able to cut. Fault codes and fault LEDs...
Page 72 Corrective action for the torch cap sensor in the torch and torch lead 1. Disconnect the torch from the plasma power supply. 2. Make sure that a Hypertherm cartridge is correctly installed on the torch and is not too loose or too tight.
Page 73 5. Is the resistance very low? If yes... Continue with the next step. If no... The cap-sensor switch in the torch is open. Continue with step 9 on page 6. Set the torch to the yellow lock (X) position. Powermax45 SYNC® Service Manual 811480...
Page 74 Replace the torch receptacle. 6. Reconnect the torch to the plasma power supply. 7. Make sure that the Hypertherm cartridge is installed correctly on the torch. 8. Make sure that the torch is set to the green "ready to fire" position.
Page 75 ON (I). This condition is also referred to as a "stuck start." Flash alter- nately Yellow Corrective action for hand torches 1. Release the torch trigger. Powermax45 SYNC® Service Manual 811480...
Page 76 Disconnect the torch from the plasma power supply, and continue with the next step. 10. Measure the resistance between pin 6 and pin 7 in the torch connector while you are pulling the torch trigger. 11. Is the resistance very high? 811480 Service Manual Powermax45 SYNC®...
Page 77 Do a check for continuity between pin 5 on the torch PCB (orange wire) and pin 2 at J19 on the power PCB. d. If you do not have continuity between the pins, replace the power PCB. G RY BR N G RY Powermax45 SYNC® Service Manual 811480...
Page 78 9. If you continue to see the same fault condition, disconnect the machine interface cable from the plasma power supply again. 10. Do a check for continuity on pin 3 and on pin 4 in the machine interface cable connector. 11. Is there continuity on both pins? 811480 Service Manual Powermax45 SYNC®...
Page 79 1. Set the power switch to OFF (O), and disconnect the power cord from the power source. 2. Remove the plasma power supply handle and cover. 3. Remove the component barrier. 4. Do a check for continuity on pin 1 (red) and pin 2 (black). Powermax45 SYNC® Service Manual 811480...
Page 80 PCB assembly (223476). If no... There is possibly a problem with the power PCB. Replace the power PCB. Troubleshooting for input voltage faults A flashing Power ON LED can identify a problem with the input voltage. 811480 Service Manual Powermax45 SYNC®...
Page 81 Have an electrical technician examine the line and increase or decrease the voltage. 3. Set the power switch to OFF (O), and disconnect the power cord from the power source. 4. Remove the plasma power supply handle and cover. 5. Remove the component barrier. Powermax45 SYNC® Service Manual 811480...
Page 82 1-phase CE/CCC models: Wait approximately 10 minutes for internal voltages to discharge, and measure the voltage at the blue and brown power switch wire connections on the right side of the EMI PCB that have the label SW OUT. 811480 Service Manual Powermax45 SYNC®...
Page 83 Remove the power cord (3-phase models) on page 198 (3-phase models). All values can be ±15%. Refer to the Powermax45 SYNC Operator Manual (811470) for the voltage requirements of each plasma power supply configuration. 10. If the power source and power cord are operating correctly, set the power switch to ON (I).
Page 84 14. Replace any wires that are frayed or have damage. 15. If the wires are in good condition and are connected securely, examine the power switch: a. Make sure that none of the wire connections or screws are loose or have damage. 811480 Service Manual Powermax45 SYNC®...
Page 85 Do not connect -VBUS (TP1) to ground. This can cause damage to the plasma power supply so that it becomes unserviceable. 3. Use a multimeter to measure the voltages in the table to make sure that the power PCB (PCB3) is operating correctly. Powermax45 SYNC® Service Manual 811480...
Page 86 Pin 5 on J8 24 VDC 24 VDC ±10% Display PCB Pin 1 on J3 3.3 VDC 3.3 VDC ±10% Pin 2 on J3 3.3 VDC 3.3 VDC ±10% Pin 4 on J3 5.0 VDC 5.0 VDC ±10% 811480 Service Manual Powermax45 SYNC®...
Page 87 1 2 3 4 J3 display PCB J8 solenoid valve J7 fan 4. Is the 48 VDC voltage for the fan correct? If yes... Continue with step 7 on page If no... Continue with the next step. Powermax45 SYNC® Service Manual 811480...
Page 88 A 0-11-n fault code identifies a problem with the remote controller. There can also be a problem with the software interface to the system. The system cannot interpret the operating mode, output current, or gas pressure information coming from the controller. 811480 Service Manual Powermax45 SYNC®...
Page 89 Description from operating? 0-11-0 The remote control operating mode is incorrect No. These fault codes use only or not permitted for the installed Hypertherm only apply to remotely cartridge. controlled plasma power supplies. The permitted operating modes for Hypertherm cutting cartridges is 1 (Cut mode). The permit- ted operating mode for a Hypertherm gouging cartridge is 2 (Gouge mode).
Page 90 5. If the fault continues, examine the gas system and the solenoid valve by doing the troubleshooting steps in Troubleshooting for low gas pressure faults on page Troubleshooting for Hypertherm cartridge installation faults (0-14-n) Symptom An 0-14-n fault identifies a condition where the Hypertherm cartridge is not functioning or recognized properly. 811480 Service Manual Powermax45 SYNC®...
Page 91 1. When this fault occurs, you can continue to cut or gouge, but you must set the output current (A) and the operating mode manually. 2. Lightly blow air into the Hypertherm cartridge to remove all dust or other contamination. Powermax45 SYNC®...
Page 92 Troubleshooting for fault codes 3. Install the Hypertherm cartridge again. 4. Make sure that the green ring inside the Hypertherm cartridge is not broken. Troubleshooting for PCB hardware protection faults (0-19-9) A 0-19-9 fault code usually means that the input power stopped. Or, power PCB hardware protection occurred for components in the plasma power supply.
Page 93 3. Wait for the plasma power supply to cool down. Troubleshooting for torch-lock switch faults (0-50-n) A 0-50-n fault code usually means the torch-lock switch is set to the yellow lock (X) position or that the system is reading data from the Hypertherm cartridge. Powermax45 SYNC® Service Manual...
Page 94 0-50-3 Yellow The system is reading data from the Hypertherm cartridge. If the system cannot read the data from the Hypertherm cartridge, a different fault code will show. The usual behavior when this happens is to see a 0-50-2 fault code after 0-50-3 goes away.
Page 95 The 0-50-2 fault code goes away. The torch is now prepared to fire a plasma arc. 3. Try a different Hypertherm cartridge. Troubleshooting for torch connection faults (0-52-0) The system usually shows a 0-52-0 fault code to indicate that the torch is not connected to the power supply.
Page 96 1. Make sure that the Hypertherm cartridge is installed correctly. 2. Make sure that the green ring inside the Hypertherm cartridge is not broken. 3. If you have a Hypertherm cartridge reader (528083), do a test to identify if the reader can pull data from the Hypertherm cartridge.
Page 97 Troubleshooting for fault codes 4. Install a new Hypertherm cartridge. Corrective action for the torch (0-98-1) 1. Disconnect the SmartSYNC torch from the plasma power supply. 2. Put the torch on its side, and remove the left side of the torch shell.
Page 98 PCB has possible damage. Replace the torch PCB. Troubleshooting for a plasma power supply or torch communication fault (0-98-2) An 0-98-2 fault code identifies a communication failure between the torch and the plasma power supply. 811480 Service Manual Powermax45 SYNC®...
Page 99 When this fault occurs, the SmartSYNC torch is not sending data to the plasma power supply, so the system cannot collect data about the Hypertherm cartridge. The problem can be with the Hypertherm cartridge or with the SmartSYNC torch. There can be a problem with: ■...
Page 100 Keep the wires from the torch connected, and measure the voltage at the rear of the receptacle, as shown. 5. Is the voltage approximately 18 VDC? If yes... Continue with the next step. If no... Continue with step 9 on page 102. 811480 Service Manual Powermax45 SYNC®...
Page 101 If there is not continuity between the pins, continue with the next step. Pin 1 and pin 2 on torch PCB Pin 7 and pin 8 on power PCB 7. Disconnect the torch from the plasma power supply. Powermax45 SYNC® Service Manual 811480...
Page 102 If there is continuity between the pins, continue with step 10 on page 103. d. If there is not continuity between the pins, replace the torch lead. MC U RFID 9. Disconnect the torch lead connector from the torch PCB. 811480 Service Manual Powermax45 SYNC®...
Page 103 16. Disconnect the DSP PCB from the power PCB. Carefully remove the conformal coating from the pins, if necessary. Too much of this coating can prevent a good connection with the power PCB. 17. If the problem continues, replace the DSP PCB. Powermax45 SYNC® Service Manual 811480...
Page 104 If restarting the plasma power supply does not remove the fault condition, it is possible that the power PCB must be replaced. Troubleshooting for an analog-to-digital converter fault (2-00-0) A 2-00-0 system fault indicates that the analog-to-digital converter value is out of range. 811480 Service Manual Powermax45 SYNC®...
Page 105 2-10-n faults could indicate that there is a problem with the power PCB. Fault codes and fault LEDs Stops the system Fault code Fault LEDs Torch LED Description from operating? 2-10-0 The inverter module temperature sensor is open. 2-10-1 The inverter module temperature sensor short- circuited. Powermax45 SYNC® Service Manual 811480...
Page 106 4. Remove the plasma power supply handle and cover. 5. Remove the component barrier. 6. Examine the rear of the quick-disconnect receptacle to see if the wires from the receptacle are pinched, twisted, or have other damage. 7. Replace the receptacle if necessary. 811480 Service Manual Powermax45 SYNC®...
Page 107 1 2 3 4 5 6 7 8 9 1 0 1 2 3 4 5. Is the voltage approximately 5 VDC? If yes... Continue with the next step. If no... Replace the power PCB. Refer to Remove the power PCB on page 177. Powermax45 SYNC® Service Manual 811480...
Page 108 Corrective action for the solenoid valve sensor and power PCB sensor (2-11-0 and 2-11-1) 1. Set the power switch to OFF (O). 2. Disconnect the solenoid valve from J8 on the power PCB. 3. Disconnect the J1 connector from the solenoid valve PCB. 811480 Service Manual Powermax45 SYNC®...
Page 109 PCB to do the test. There are labels on the rear of the power PCB for the test points (TP1, TP2, TP3). Use miniature banana plugs to connect to the test points on the power PCB as shown in this procedure. Refer to Required test equipment on page Powermax45 SYNC® Service Manual 811480...
Page 110 2. Remove the plasma power supply handle and cover. 3. Remove the component barrier. 4. Reconnect the electrical power, but keep the power switch set to OFF (O). 5. Measure the voltage between the TP1 and TP2 test points. 811480 Service Manual Powermax45 SYNC®...
Page 111 280 VDC for 400 V CE/CCC 3-phase models • 335 VDC for 480 V CSA 3-phase models All values can be ±10%. 7. Measure the voltage between the TP2 and TP3 test points. a. Set the power switch to OFF (O). Powermax45 SYNC® Service Manual 811480...
Page 112 2. Loosen the capacitor screws enough that you can disconnect the capacitors from the power PCB. 3. Measure the resistance across the capacitors, and make sure that the resistance is approximately: □ 13.5 kiloohms (kΩ) for 1-phase models □ 18 kiloohms (kΩ) for 3-phase models 811480 Service Manual Powermax45 SYNC®...
Page 113 A 3-10-0 or 3-10-1 fault code identifies a problem with the system's internal fan. Fault codes and fault LEDs Stops the system Fault code Fault LEDs Torch LED Description from operating? 3-10-0 The fan speed is less than the minimum speed. 3-10-1 The fan is not operating correctly. Powermax45 SYNC® Service Manual 811480...
Page 114 9. Does the fan operate correctly when it is connected to an external power source? If yes... Replace the power PCB. If no... Replace the fan. Troubleshooting for PFC module temperature sensor faults (3-11-n) A 3-11-n fault code indicates a problem with the PFC temperature sensor circuit. 811480 Service Manual Powermax45 SYNC®...
Page 115 180° out of phase. 3-52-0 A short circuit caused high-current distortion in Yes. the inverter IGBT. This is sometimes referred to as a shoot-through. Corrective action for 3-51-1 and 3-52-0 faults ■ Replace the power PCB if necessary. Powermax45 SYNC® Service Manual 811480...
Page 116 The system does not recognize the power PCB. Corrective action for 3-60-0 faults ■ Make sure that the correct power PCB is installed for the plasma power supply. Refer to Plasma power supply interior, power PCB on page 117. 811480 Service Manual Powermax45 SYNC®...
Page 117 For plasma power supply exterior parts, work leads, work clamps, machine interface kits, serial interface kits, and consumable part numbers, refer to the Powermax45/65/85/105 SYNC Parts Guide (810490). Plasma power supply interior, power PCB Powermax45 SYNC® Service Manual 811480...
Page 118 Kit: Capacitors (2) for 400 V CE/CCC 3-phase power PCBs 428080 Kit: Capacitors (2) for 480 V CSA 3-phase power PCBs 128836 Thermal grease, 1/8 ounce (for electronic components that mount on the heatsink) Plasma power supply interior, pneumatics and fan 811480 Service Manual Powermax45 SYNC®...
Page 119 (designator: V1) 428687 Kit: Fan assembly for 1-phase models (designator: M1) 528143 Kit: Fan assembly for 3-phase models (designator: M1) 428734 Kit: Plenum for fan 428250 Kit: 90° fitting Plasma power supply interior, wires, CSA 1-phase Powermax45 SYNC® Service Manual 811480...
Page 120 2 wires from power switch to power cord (CSA) or EMI PCB (CE/CCC) (blue and brown) with protective covers for wire terminals 3 ground wires Plasma power supply interior, wires and EMI PCB, CE/ CCC 1-phase 811480 Service Manual Powermax45 SYNC®...
Page 121 2 wires from power switch to power PCB (black and white) 2 wires from power switch to power cord (CSA) or EMI PCB (CE/CCC) (blue and brown) with protective covers for wire terminals 3 ground wires Plasma power supply interior, wires, 3-phase Powermax45 SYNC® Service Manual 811480...
Page 122 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. In addition, the following parts are safety-critical parts that must be replaced only with genuine Hypertherm parts to maintain the warranty and system certifications, including CE, CSA, and CCC certification.
Page 123 Kit: CE/CCC power cord with strain relief, 3-phase, 3 m (10 foot) (no power plug included) 428684 Kit: Air filter assembly (includes metal guard, filter bowl, filter element, and gas hose) 428721 Kit: EMI PCB for CE/CCC 1-phase models only (includes screws but not wires) (designator: PCB2) Powermax45 SYNC® Service Manual 811480...
Page 124 Kit: Power switch and knob for 3-phase models (dial switch) (designator: S1) Recommended spare parts Hypertherm recommends that service centers keep the following spare parts on hand for repairs because these parts are critical or are usually subjected to heavy and repeated wear. You may need to revise or expand this list for your customers, based on the conditions and work environments in your region.
Page 125 Data plate The data plate on the bottom of the plasma power supply contains 2 sets of ratings: ■ The HYP ratings are Hypertherm plasma power supply ratings. They reflect the capability of the system based on Hypertherm's internal testing.
Page 126 Serial number, barcode, and date made. Rated no load voltage (V) Plasma cutting ratings Duty cycle (%) Plasma gouging ratings Hypertherm internal rating Symbol for plasma cutting International Electrotechnical Commission rating Conventional welding current (A) Conventional welding voltage (V) Ingress Protection (IP) rating...
Page 127 EMC requirements for export to the Russian Federation. RCM mark CE versions of products with an RCM mark comply with the EMC and safety regulations required for sale in Australia and New Zealand. Powermax45 SYNC® Service Manual 811480...
Page 128 You can see different IEC symbols on the system. Each image has a specific meaning in the context of operating a plasma cutting system. The following symbols can appear on the data plate, control labels, and switches. Direct current (DC) Alternating current (AC) Plasma torch cutting 811480 Service Manual Powermax45 SYNC®...
Page 129 Service parts Gouging AC input power connection The terminal for the external protective (earth) (PE) conductor Power is ON Power is OFF A 1-phase or 3-phase inverter-based power source Volt/amperage curve, “drooping” characteristic Powermax45 SYNC® Service Manual 811480...
Page 130 Service parts 811480 Service Manual Powermax45 SYNC®...
Page 131 All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician. Refer to the Safety and Compliance Manual (80669C) for more safety information. Powermax45 SYNC® Service Manual 811480...
Page 132 You may need to gently pull up on the handle to remove the screws. 3. Remove the 2 screws from the bottom of the front and rear panels. 4. Gently tilt the tops of the front and rear panels away from the unit to pull the handle out. 811480 Service Manual Powermax45 SYNC®...
Page 133 1. Set the front and rear panels in place. 2. Make sure the ground clip is connected to the ground wire. The clip should be set in place to accept the screw from the handle. Powermax45 SYNC® Service Manual 811480...
Page 134 3. Make sure the component barrier is in place and secured to the main power PCB with 2 plastic pins. 4. Slide the cover back on. □ Make sure the louvers in the cover align with the fan. □ Be careful not to pinch any wires. 811480 Service Manual Powermax45 SYNC®...
Page 135 Remove the plasma power supply cover and handle on page 132. 3. Remove the 2 plastic pins that secure the component barrier to the main power PCB. Slide the component barrier off. Powermax45 SYNC® Service Manual 811480...
Page 136 Service procedures for the cover, panels, and connectors Install the component barrier 1. Set the component barrier in place. 811480 Service Manual Powermax45 SYNC®...
Page 137 3. Wrap the extended portion over the power cord connection points and behind the air hose. If the machine interface port and RS-485 serial interface are installed, it may be easier to tuck the extended portion of the barrier into the middle of the gas hose loop. Powermax45 SYNC® Service Manual 811480...
Page 138 5. Use a blade screwdriver to push in the 2 tabs at the bottom of the panel until the panel detaches from the base. 6. Pull the front panel slightly away from the unit. 811480 Service Manual Powermax45 SYNC®...
Page 139 □ 1-phase models: Remove the 2 screws that secure the power switch to the panel. □ 3-phase models: Hold down the red latch on the power switch body, and pull the assembly out from the shaft on the knob. Powermax45 SYNC® Service Manual 811480...
Page 140 Work lead screw and washers Torch receptacle and screws Gas supply hose 90° fitting Work lead Brass torch fitting 1. Attach the screw and washers to secure the work lead wire to the work lead receptacle. 811480 Service Manual Powermax45 SYNC®...
Page 141 11. Complete the following procedures: Install the plasma power supply cover and handle on page 133. b. Reconnect the torch and the work lead to the front panel. c. Reconnect the gas supply and the power cord. Powermax45 SYNC® Service Manual 811480...
Page 142 Remove the rear panel To separate and remove the rear panel from the plasma power supply, complete this procedure. Loosen the rear panel on page 142. 2. Push-to-disconnect the gas supply hose from the air filter assembly. 811480 Service Manual Powermax45 SYNC®...
Page 143 6. Remove the 2 screws that attach the machine interface port to the rear panel if installed. Remove the connector from the panel. 7. Remove the power cord ground wire from the heatsink. Figure 3 - Power cord connection points Powermax45 SYNC® Service Manual 811480...
Page 144 CE/CCC models: wires are brown (BRN) and blue (BLU). b. Disconnect 3 wires for the 3-phase models: • CSA models: wires are white (WHT), red (RED), and black (BLK). • CE/CCC models: wires are blue (BLU), brown (BRN), and gray (GRY). 811480 Service Manual Powermax45 SYNC®...
Page 145 3. Attach the power cord leads to the appropriate terminal. Tighten to 2.3 N·m (20 lbf·in). Figure 4 - Power cord connection points Power cord ground wire to heatsink Power cord pass-through CSA 1-phase CE/CCC 1-phase CSA 3-phase Powermax45 SYNC® Service Manual 811480...
Page 146 Ground clip Ground wire Machine interface port screws 5. Plug the serial interface cable into the RS-485 PCB if installed. 6. Connect the ground wire to the air filter assembly. Tighten to 2.3 N·m (20 lbf·in). 811480 Service Manual Powermax45 SYNC®...
Page 147 1. Complete the following procedures: a. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. Remove the plasma power supply cover and handle on page 132. Powermax45 SYNC® Service Manual 811480...
Page 148 Position the receptacle so the notch faces to the right (when you face the front of the power supply). Refer to Figure 6 on page 148. 2. Install the nut and washer onto the back of the work lead receptacle. 811480 Service Manual Powermax45 SYNC®...
Page 149 Reconnect the power cord. e. Reconnect the gas supply. Replace the torch quick-disconnect receptacle Remove the torch quick-disconnect receptacle Power board J19 connection Red wire pair (J15 connection) Center panel slot Brass torch fitting Torch quick-disconnect receptacle Powermax45 SYNC® Service Manual 811480...
Page 150 5. Push the brass torch fitting out through the torch quick-disconnect receptacle. 6. Separate the torch quick-disconnect receptacle from the front panel. Install the torch quick-disconnect receptacle 1. Slide the red wire pair from the new quick-disconnect receptacle through the braided fiberglass sleeve. 811480 Service Manual Powermax45 SYNC®...
Page 151 Attach the front panel on page 140. Install the component barrier on page 136. Install the plasma power supply cover and handle on page 133. d. Reconnect the gas supply and the power cord. Transformer ring terminal Large plastic washer Powermax45 SYNC® Service Manual 811480...
Page 152 4. Remove the black (BLK) and white (WHT) AC input wires from the screw terminals near the top of the switch. 5. Remove the blue (BLU) and brown (BRN) power wires from the screw terminals near the base of the switch. Figure 7 - 1-phase power switch wiring 811480 Service Manual Powermax45 SYNC®...
Page 153 5. Set the power switch to the OFF (O) position. 6. Complete the following procedures: Attach the front panel on page 140. Install the plasma power supply cover and handle on page 133. c. Reconnect the gas supply. d. Reconnect the power cord. Powermax45 SYNC® Service Manual 811480...
Page 154 Secure the knob to the front panel using the plastic nut. Tighten to 2.3 N·m (20 lbf·in). 2. Connect the wires to the power switch assembly. Tighten to 2.3 N·m (20 lbf·in). Figure 8 - 3-phase power switch wiring 811480 Service Manual Powermax45 SYNC®...
Page 155 3. Set the power switch to the OFF (O) position. 4. Complete the following procedures: Attach the front panel on page 140. Install the plasma power supply cover and handle on page 133. c. Reconnect the gas supply. d. Reconnect the power cord. Powermax45 SYNC® Service Manual 811480...
Page 156 Service procedures for the cover, panels, and connectors 811480 Service Manual Powermax45 SYNC®...
Page 157 DIRTY, OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL Some air compressors use synthetic lubricants that contain esters. Esters can cause damage to the polycarbonates in the air filter bowl. Add more gas filtration if necessary. Powermax45 SYNC® Service Manual 811480...
Page 158 3. Remove the air filter bowl from the metal guard. 4. Gently pry the filter element out of the filter bowl. Be careful not to damage the O-ring at the top of the bowl. 811480 Service Manual Powermax45 SYNC®...
Page 159 A yellow residue on the filter bowl often indicates that oil is getting into the gas supply line. 8. Examine the O-ring. Replace it if it is cracked or damaged. Place the O-ring at the top of the filter bowl. Powermax45 SYNC® Service Manual 811480...
Page 160 Make sure the air filter bowl and metal guard remain straight as you install them. Otherwise, you may damage the threads on the metal guard. 12. Reconnect the gas supply. 13. Reconnect the power cord. 14. Set the power switch to ON (I). 811480 Service Manual Powermax45 SYNC®...
Page 161 7. Push-to-disconnect the brass bulkhead fitting from the side of the air filter. Air filter bowl and air filter Gas hose Air filter body Gas connection nut Brass bulkhead fitting Ground wire Brass bulkhead side of the air filter connection Powermax45 SYNC® Service Manual 811480...
Page 162 Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. Remove the plasma power supply cover and handle on page 132. 2. Detach the fan wire connector from J7 on the power PCB. 811480 Service Manual Powermax45 SYNC®...
Page 163 5. Remove the fan by pushing back the 2 clips on the right side of the fan until the fan assembly is released. The fan does not use any mounting screws to attach to the center panel. Powermax45 SYNC® Service Manual 811480...
Page 164 Before you begin: To confirm you have the right fan, check the barcode sticker on the side of the fan. Fans for 3-phase models have a 6-digit Hypertherm part number (429225) on the sticker. Fans for 1-phase models have only the barcode on the sticker.
Page 165 2. Route the wires for the fan as follows. □ Behind the gas tube and the wires from the solenoid valve. □ Through the clip on the center panel. □ Through the pass-through labeled "FAN" at the top of the center panel. Powermax45 SYNC® Service Manual 811480...
Page 166 Work the wires free from the center panel pass-through and from the plastic clip. 4. Press up from underneath the solenoid valve assembly to release it from the center panel. Press on the plastic housing to remove the valve. Do not press on the valve assembly PCB. 811480 Service Manual Powermax45 SYNC®...
Page 167 1. Align the top corner tabs of the solenoid valve assembly to the slots in the center panel. Hold the valve at approximately a 45° angle. 2. Push the top corner tabs into the center panel slots, then rotate the bottom of the valve assembly Powermax45 SYNC® Service Manual 811480...
Page 168 If a gas supply hose is kinked, discard it and replace it with a new hose. The integrity of the hose is compromised once the hose is kinked. 7. Complete the following procedures: Install the fan and fan shroud on page 164. 811480 Service Manual Powermax45 SYNC®...
Page 169 3. Push-to-disconnect the gas supply hose from the solenoid valve assembly and from the 90° fitting. 4. Push-to-disconnect the 90° fitting from the brass torch fitting. Gas supply from the air filter assembly Air filter assembly Solenoid valve assembly Gas supply hose from the solenoid valve assembly 90° fitting Powermax45 SYNC® Service Manual 811480...
Page 170 7. Make sure the looped gas supply hose is not kinked. If the gas supply hose is kinked, discard it and replace it with a new hose. The integrity of the hose is compromised once the hose is kinked. 811480 Service Manual Powermax45 SYNC®...
Page 171 3. From the outside of the rear panel, remove the nut from the brass bulkhead fitting. 4. Push-to-disconnect the brass bulkhead fitting from the side of the air filter. 5. Discard the fittings that need to be replaced. Install the gas inlet fittings Powermax45 SYNC® Service Manual 811480...
Page 172 2. Attach the nut onto the brass bulkhead fitting from the outside of the rear panel. 3. Tighten to 13.5 N·m (120 lbf·in). 4. Push-to-connect the air filter to the brass bulkhead fitting. 5. Apply thread sealant if needed. 811480 Service Manual Powermax45 SYNC®...
Page 173 1/4 NPT quick-disconnect nipple Tighten to 11.3 N·m (100 lbf·in). 7. Complete the following procedures: Install the plasma power supply cover and handle on page 133. b. Reconnect the gas supply. c. Reconnect the power cord. Powermax45 SYNC® Service Manual 811480...
Page 174 Service procedures for the gas supply 811480 Service Manual Powermax45 SYNC®...
Page 175 Service procedures for the PCBs and related com- ponents Replace the display PCB and ribbon cable Remove the display PCB and ribbon cable Ribbon cable Powermax45 SYNC® Service Manual 811480...
Page 176 4. Make sure you plug the ribbon cable into the power PCB as you reattach the front panel. 5. Complete the following procedures: Attach the front panel on page 140. Install the plasma power supply cover and handle on page 133. c. Reconnect the gas supply. d. Reconnect the power cord. 811480 Service Manual Powermax45 SYNC®...
Page 177 Before you begin: When replacing the power , also check the snubber resistors. Refer to Do an initial resistance check on page 1. Complete the following procedures: a. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. Powermax45 SYNC® Service Manual 811480...
Page 178 □ 1-phase models: Unplug the J10 2-wire connector from the power . □ 3-phase models: There is no J10 connection. 11. Remove the power from the unit. Install the power PCB Refer to this image as you do the steps in this procedure. 811480 Service Manual Powermax45 SYNC®...
Page 179 Power transformer secondary – red (J12) Work lead wire (J23) Power transformer primary – black (J6) PFC inductor Power switch connections (J1 and J2 for 1-phase; Power transformer J1, J2, and J4 for 3-phase) Before you begin: Powermax45 SYNC® Service Manual 811480...
Page 180 Clean the screw holes of the IGBT component with a cotton swab. Use a paper towel with isopropyl alcohol to clean any unwanted grease from the edges of the 811480 Service Manual Powermax45 SYNC®...
Page 181 Connector type Solenoid valve assembly 8-pin 4-pin RS-485 serial interface 5-pin Machine interface port 4-pin Voltage divider PCB 2-pin Torch receptacle 10-pin Display PCB Ribbon cable Figure 12 - More component connections on the power PCB Powermax45 SYNC® Service Manual 811480...
Page 182 Tighten to 2.3 N·m (20 lbf·in). As you connect the capacitors to the power PCB, rotate each capacitor until the polarity dot aligns with the viewing hole on the power PCB. 12. Complete the following procedures: Install the component barrier on page 136. 811480 Service Manual Powermax45 SYNC®...
Page 183 Slide the covers down the wires out of the way. 3. Remove the screws securing the 4 power wire ring terminals. 4. Remove the 2 screws that secure the EMI PCB to the center panel. Powermax45 SYNC® Service Manual 811480...
Page 184 4. Slide the 4 insulating covers back into place over the power wire screws. 5. Complete the following procedures: Install the component barrier on page 136. Install the plasma power supply cover and handle on page 133. c. Reconnect the gas supply. d. Reconnect the power cord. 811480 Service Manual Powermax45 SYNC®...
Page 185 2 corner clips before working the bottom 2 clips free from the fan casing. NOTICE DO NOT BREAK THE CLIPS Be careful not to apply too much pressure to the clips as you disconnect the plenum from the fan. Powermax45 SYNC® Service Manual 811480...
Page 186 See the figure found in this section. 3. Attach the capacitors to the power PCB with the 4 mounting screws. Secure the transformer wire to the RED location. Start the 4 screws by hand then tighten to 2.3 N·m (20 lbf·in). 811480 Service Manual Powermax45 SYNC®...
Page 187 1. Complete the following procedures: a. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. Remove the plasma power supply cover and handle on page 132. Powermax45 SYNC® Service Manual 811480...
Page 188 2. Remove the mounting screws and washers from the snubber resistors. Thermal grease Snubber resistors M4 X 10 screws 3. Remove the snubber resistors from the heatsink. M4 X 10 screws Snubber resistors Heatsink Thermal grease Install the snubber resistors 811480 Service Manual Powermax45 SYNC®...
Page 189 Install the component barrier on page 136. Install the plasma power supply cover and handle on page 133. d. Reconnect the gas supply. e. Reconnect the power cord. Replace internal wires (1-phase models) Remove internal wires (1-phase models) Ground wires Powermax45 SYNC® Service Manual 811480...
Page 190 □ CSA models: Power cord connection points on the center panel □ CE/CCC models: "SW OUT" side of the EMI PCB 3. Tighten to 2.3 N·m (20 lbf·in). 4. Slide the red insulating covers up into place so that they cover the screws. 811480 Service Manual Powermax45 SYNC®...
Page 191 Blue wire on CSA models Black power PCB wire White power PCB wire 9. Connect the 3 green ground wires to the ground stud on the center panel. Tighten the screws to 1.7 N·m (15 lbf·in). Powermax45 SYNC® Service Manual 811480...
Page 192 12. Connect the push-on connector for the third ground wire to the ground clip on the rear panel. Figure 13 - Internal ground wire connections Ground stud Ground clip Air filter ground Magnetics assembly ground 811480 Service Manual Powermax45 SYNC®...
Page 193 Remove the power switch (3-phase) on page 154. 2. From the power PCB side, disconnect the 3 wires that go from the power switch to the power PCB: □ Brown wire with white stripe □ Black wire with white stripe Powermax45 SYNC® Service Manual 811480...
Page 194 4. From the fan side, connect the following 3 wires to the power cord connection points on the center panel. Tighten to 2.3 N·m (20 lbf·in). □ Brown wire □ White wire □ Black wire 811480 Service Manual Powermax45 SYNC®...
Page 195 Install the component barrier on page 136. Install the plasma power supply cover and handle on page 133. d. Reconnect the gas supply. e. Reconnect the power cord. Figure 14 - The 3-phase wire connections in the plasma power supply Powermax45 SYNC® Service Manual 811480...
Page 196 1. Complete the following procedures: a. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. Remove the plasma power supply cover and handle on page 132. 811480 Service Manual Powermax45 SYNC®...
Page 197 7. If you are not installing a new power cord strain relief, remove the strain relief inner nut. Separate the strain relief from the rear panel. Figure 15 - Components of 1-phase power cords Two power cord wires Ground wire Outer nut Toroid (CE/CCC only) Strain relief Inner nut Rear panel Powermax45 SYNC® Service Manual 811480...
Page 198 1. Complete the following procedures: a. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. Remove the plasma power supply cover and handle on page 132. 811480 Service Manual Powermax45 SYNC®...
Page 199 Separate the strain relief from the rear panel. Figure 16 - Components of the 3-phase power cords Power cord wires Ground wire Strain relief outer nut Toroid (CE/CCC only) Strain relief Strain relief inner nut Rear panel Powermax45 SYNC® Service Manual 811480...
Page 200 Attach the rear panel on page 145. Install the component barrier on page 136. Install the plasma power supply cover and handle on page 133. d. Reconnect the gas supply. e. Reconnect the power cord. 811480 Service Manual Powermax45 SYNC®...
Page 201 Change system settings Overview The Powermax45 SYNC plasma power supply lets you configure and view these system settings: ■ Gas pressure units of measure ■ Start signal detection on the machine interface port ■ Firmware version ■ Torch mode (smart or basic) ■...
Page 202 Smart mode. basic mode. In smart mode, the plasma power supply auto- matically sets the operating mode, gas pressure, and amperage based on the type of Hypertherm cartridge installed. Refer to Smart mode versus basic mode on page 205 for details.
Page 203 Enable or disable the duty cycle clamp. Enabled • H.0 – enabled • H.1 – disabled Reset all settings to factory defaults. • r.0 – Do not reset. • r.1 – Reset. Exit the settings menu. Powermax45 SYNC® Service Manual 811480...
Page 204 Change system settings Change system settings Use the Powermax45 SYNC setup menu to change system settings. 1. Push and hold the mode button until S.U. shows in the LED display. Mode button LED display Control knob 2. Release the mode button.
Page 205 9. Do a cold restart of the plasma power supply. Smart mode versus basic mode By default the system is in smart mode. Hypertherm recommends that you keep the system in smart mode. But very experienced operators or qualified service technicians can use basic mode to help with troubleshooting if necessary.
Page 206 Change system settings Smart mode When the system is in smart mode and you use a Hypertherm cartridge with a SmartSYNC torch, the system does many things for you automatically: ■ It sets the operating mode and the output current (A) to the correct settings for your Hypertherm cartridge.
Page 207 Theory of operation Overview In addition to the functional descriptions in these topics, refer to: ■ System diagrams on page 213 Hypertherm plasma power supply ratings Rated open-circuit voltage (U 200 V – 240 V, CSA/CE/CCC 275 VDC 400 V, CE/CCC...
Page 208 4.1 bar (60 psi) Defined as a plot of output voltage versus output current. An output current setting of 9 A to 19 A is reserved for marking, and is only available when a FineCut Hypertherm cartridge is installed on the torch.
Page 209 9 A – 45 A. The system compares the set-point to the output current by monitoring the current sensors and adjusting the pulse-width output of each inverter IGBT (Q1). A trip coil on the power switch provides over-voltage protection. Powermax45 SYNC® Service Manual 811480...
Page 210 PCB (PCB1) is used to set the output current to the desired value between 9 A – 45 A. The system compares the set-point to the output current by monitoring the current sensors and adjusting the pulse-width output of the inverter IGBT (Q1). 811480 Service Manual Powermax45 SYNC®...
Page 211 Output diode and pilot arc IGBT (Q10) AC input wire – black (J2) Inverter IGBT (Q1) Serial communication (RS-485) interface (J11) PFC IGBT (Q2) Fan interface (J7) Snubber resistors (2) Solenoid valve interface (J8) Input diode bridge (D6) Powermax45 SYNC® Service Manual 811480...
Page 212 AC input wire – white with black stripe (J1) Inverter IGBT (Q1) Fan interface (J7) Snubber resistors (2) Solenoid valve interface (J8) Input diode bridge (D48) Serial communication (RS-485) interface (J11) Work lead wire (J23) 811480 Service Manual Powermax45 SYNC®...
Page 213 Powermax45 SYNC schematic — 200 V – 240 V 1-phase models on page 215 ■ Powermax45 SYNC schematic — 400 V CE/CCC and 480 V CSA 3-phase models shown on page ■ Timing chart for torch start on page 217 Powermax45 SYNC®...
Page 214 System diagrams 811480 Service Manual Powermax45 SYNC®...
Page 215 System diagrams Powermax45 SYNC schematic — 200 V – 240 V 1-phase models Powermax45 SYNC® Service Manual 811480...
Page 216 System diagrams Powermax45 SYNC schematic — 400 V CE/CCC and 480 V CSA 3-phase models shown 811480 Service Manual Powermax45 SYNC®...
Page 217 System diagrams Timing chart for torch start Powermax45 SYNC® Service Manual 811480...
Page 218 System diagrams 811480 Service Manual Powermax45 SYNC®...

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