Hypertherm POWERMAX 45 Reference manual

Field Service Bulletin
Bulletin de service sur le terrain
806200 – Revision 4 – July 2014
Révision 4 – Juillet 2014
Powermax45® Raw Arc Voltage Kit
Kit de tension d’arc brute
Powermax45

Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[e-mail] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax
© Hypertherm Inc. 2014. All rights reserved. Tous droits réservés.
Powermax and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and/or other countries. All other trademarks
are the property of their respective holders.
Powermax et Hypertherm sont des marques d’Hypertherm Inc. qui peuvent être déposées aux États-Unis et/ou dans d’autres pays. Toutes les autres
marques commerciales sont la propriété de leurs détenteurs respectifs.

Powermax45 Field Service Bulletin 806200 3
Powermax45 Raw Arc Voltage Kit
Introduction
Purpose
This field service bulletin explains how to install a customer-supplied machine interface cable that does not use the
internal 50:1 voltage divider on the Powermax45.
Notice: Installation of the system at the installed site is subject to the approval of the Local Inspection Authorities
(LIA). Without approval of the LIA, modification of the factory installed wiring voids the safety test marks (for example,
cCSAus, CCC, CE, GOST-TR, UkrSEPRO, C-Tick, Kvalitet, EAC) applied to the product in the Hypertherm factory,
and the safety certificates provided by Hypertherm become invalid after modification.
Tools and materials needed
Wire strippers
Wire crimpers
Assorted Phillips®and TORX®screwdrivers
Electric drill with a 15 mm or 19/32 inch drill bit
0.75 mm2or 18 AWG, 2 wire, non-shielded cable similar to OLFLEX®190 (601802)
M4 (#8) insulated ring terminals
M5 (#10) insulated ring terminals
228352 Kit contents
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. See the
Safety and Compliance Manual (80669C) for more safety precautions.
Part number Description Quantity
008279 Strain relief 1

4Powermax45 Field Service Bulletin 806200
Powermax45 Raw Arc Voltage Kit
Accessing raw arc voltage
Connecting a cable to the Powermax45 power board to bypass the voltage divider and access raw arc voltage must
be done by trained service personnel.
To access raw arc voltage on a Powermax45, you will need the strain relief in kit number 228352 and an 0.75 mm2
(18 AWG), 2 wire, non-shielded cable similar to OLFLEX 190 (601802) in the length needed to go between the power
supply and the CNC or other equipment plus an additional 45.72 cm (18 inches) to connect inside the power supply.
1. On the end of the cable that will be attached to the power supply, strip the outer jacket 11.43 cm (4.5 inches). Cut
6.35 cm (2.5 inches) off of wire 2 so that wire 1 is 11.43 cm (4.5 inches) long and wire 2 is 5.08 cm (2 inches) long.
Then strip 1.27 cm (0.5 inches) of wire insulation off of each wire.
2. Crimp an M4 (#8) insulated ring on the end of wire 1 (negative lead) and an M5 (#10) insulated ring on the end
of wire 2 (positive lead).
3. Remove the 2 screws from the handle on the top of the power supply. Tip the end panels back slightly so that you
can get the edges of the handle out from underneath them. Lift the cover off the power supply. Remove the Mylar®
barrier that protects the power board.
4. Separate the rear panel from the Powermax45 by removing the screw from the bottom and backing the panel away
from the base so that there is enough room to drill out the access point without risk of hitting the interior components.
WARNING!
HIGH VOLTAGE AND CURRENT
SHOCK HAZARD, ENERGY HAZARD, AND FIRE HAZARD
Connecting directly to the plasma circuit for access to raw arc voltage
increases the risk of shock hazard, energy hazard, and fire hazard in the
event of a single fault. The output voltage and the output current of the
circuit are specified on the data plate.

Powermax45 Field Service Bulletin 806200 5
Powermax45 Raw Arc Voltage Kit
5. Use a drill with a 15 mm (19/32 inch) drill bit to drill out the access point on the rear panel.
6. Route the cable through the strain relief so that 45.72 cm (18 inches) of insulated wire is on the side of the strain
relief that will go inside the power supply.
7. Thread the 45.72 cm (18 inches) of wire through the hole you drilled in the rear panel and fit the strain relief into the
hole. If necessary, drill out any remaining rough spots so that the strain relief fits snugly.
8. Tighten the strain relief nut on the inside of the rear panel to hold the strain relief in place.
Access point
Rear panel
12345
78
6
Cable direction
1Strain relief retention nut (outside power supply)
2Strain relief
3Rear panel
4Strain relief nut (inside power supply)
5Wire 1 (-)
6M4 (#8) ring
7Wire 2 (+)
8M5 (#10) ring

6Powermax45 Field Service Bulletin 806200
Powermax45 Raw Arc Voltage Kit
9. Find the grommet closest to the rear panel and at the bottom of the center panel. Route the 2 wires through the
grommet to the power board side of the power supply.
10. Route the wires along the base of the unit and behind the cables connected to the power board.
11 . Remove the work lead connector screw at J21 and the white wire connector screw at J19 (J18 for 400 V CE and
480 V CSA power supplies).
12. Connect wire 1 to J19 (J18 for 400 V CE and 480 V CSA power supplies). Orient the wires such that the ring
connector for wire 1 is closest to the power board, and the connector for the white wire is closest to the head of the
screw. Turn the ring connector for wire 1 upside down so that the slight bend in the ring connector base creates a
little space between the wire and the board. Tighten the screw to 23.0 kg∙cm (20 inch∙pounds).
Grommet in center panel
Rear panel pulled slightly
away from the base

Powermax45 Field Service Bulletin 806200 7
Powermax45 Raw Arc Voltage Kit
13. Connect wire 2 to J21. This time, put the connector for the work lead closest to the power board, and put the ring
connector for wire 2 closest to the head of the screw. Torque the screw to 23.0 kg∙cm (20 inch∙pounds).
14. Replace the rear panel and secure it with the screw. Replace the Mylar barrier in front of the power board.
Replace the cover.
15. Tighten the strain relief retention nut onto the strain relief on the outside of the power supply.
16. Connect the other end of the cable to the equipment according to the manufacturer’s instructions. Remember to
observe polarity.
Notice: The output of the internal voltage divider board is designed to prevent shock, energy and fire hazards, and
is intended to satisfy most codes and standards for external wiring outside the electrical enclosure. All external
wiring practices for an unprotected raw arc voltage should be reviewed and approved by the Local
Inspection Authorities (LIA) at the time of installation prior to operation and use.
Raw arc voltage wiring terminals and connections should not be exposed to accidental contact
under normal and single fault conditions.
External wiring from an unprotected (that is, no voltage divider used in the power source) raw arc
voltage routed inside conduit between electrical enclosures will normally satisfy all electrical codes
and standards worldwide. Failure to address the hazards associated with live contact,
accessibility and single fault failures to this unprotected output can result in death
or fire.
A voltage divider board inside the CNC protects only the CNC and does NOT protect the external interconnecting
wiring between the power source and the CNC. Overcurrent protection may be required to protect the user and/or
machine in fault conditions.
External wiring outside the electrical enclosure should be suitable for the installation and meet national and local
regulations (for example, NFPA 70 NEC, NFPA 79, Canadian Electrical Code, CSA/CAN E60974-1, IEC 60204-1,
BS 7671) or other codes and/or standards applicable to the installed site where the equipment will be operated.
TP 19
W
-
+-
+
TP 18
R
TP 17
B
192 VDC 192 VDC
J19 or J18
(white wire)
J21 (work lead)

8Powermax45 Field Service Bulletin 806200
Powermax45 Raw Arc Voltage Kit

Powermax45 Bulletin de service sur le terrain 806200 9
Kit de tension d’arc brute Powermax45
Introduction
Objet
Le présent bulletin de service sur le terrain décrit comment installer un câble d’interface de machine fourni par le client
n’utilisant pas le diviseur de tension interne 50:1 sur le Powermax45.
Avis : l’installation du système sur le site doit être approuvée par le service d’inspection local (LIA). Sans
l’approbation de la LIA, la modification du câblage fait en usine annule le marquage des essais de sécurité
(comme par exemple le cCSAus, CCC, CE, GOST-TR, UkrSEPRO, C-Tick, Kvalitet, EAC) apposé au produit
à l’usine Hypertherm. Les certificats de sécurité fournis par Hypertherm seront également déclarés nuls et non
avenus après ladite modification.
Outils et matériel requis
Pince à dénuder
Pince à sertir
Tournevis Phillips®et TORX®assortis
Perceuse électriques avec mèche de 15 mm
0,75 mm2, câble non blindé, à 2 fils, similaire au OLFLEX®190 (601802)
Cosses rondes isolées M4 (nº 8)
Cosses rondes isolées M5 (nº 10)
Contenu du kit 228352
AVERTISSEMENT !
UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL
Avant tout entretien, débrancher l’alimentation électrique. Se reporter
au Manuel de sécurité et de conformité (80669C) pour des mesures
de sécurité supplémentaires.
Numéro de référence Description Quantité
008279 Serre-câble 1

10 Powermax45 Bulletin de service sur le terrain 806200
Kit de tension d’arc brute Powermax45
Accès à la tension de l’arc brute
Le branchement d’un câble au panneau d’alimentation du Powermax45 afin de contourner le diviseur de tension
et accéder à la tension d’arc brute doit être effectué par un technicien de maintenance qualifié.
Pour accéder à la tension d’arc brute d'un Powermax45, il faut utiliser le serre-câble du kit numéro 228352 et un câble
non blindé à deux fils de calibre 0,75 mm2de type OLFLEX 190 (601802) d’une longueur suffisante pour relier la source
de courant et la CNC ou les autres équipements, en prévoyant une longueur supplémentaire de 45,72 cm pour le
connecter à l’intérieur de la source de courant.
1. Sur l’extrémité du câble devant être branchée à la source de courant, dénuder la gaine extérieure du fil sur une
longueur de 11,43 cm. Raccourcir de 6,35 cm la longueur du fil 2 de sorte à ce que le fil 1 mesure 11,43 cm
et le fil 2 mesure 5,08 cm de long. Dénuder ensuite 1,27 cm d’isolant sur chaque fil.
2. Sertir une cosse ronde isolée M4 (nº 8) à l’extrémité du fil 1 (fil négatif) et une cosse ronde isolée M5 (nº 10)
à l’extrémité du fil 2 (fil positif).
3. Déposer les deux vis de la poignée en haut de la source de courant. Basculer légèrement les panneaux d’extrémité
de façon à en extraire les bords de la poignée d’en dessous. Retirer le couvercle de la source de courant en le levant.
Déposer la barrière Mylar®qui protège le circuit imprimé d’alimentation.
4. Retirer le panneau arrière du Powermax45 en retirant la vis du bas et en écartant le panneau d’extrémité
du socle de manière à laisser suffisamment d’espace pour percer le point d’accès sans endommager
les composants internes.
AVERTISSEMENT !
HAUTE TENSION ET COURANT ÉLEVÉ
DANGER D’ÉLECTROCUTION, D’ÉNERGIE ET D’INCENDIE
Le raccordement direct au circuit plasma pour accéder à la tension de
l’arc brute augmente le danger d’électrocution, de problèmes d’énergie
et d’incendie s’il y a le moindre défaut. La tension de sortie et le courant
de sortie du circuit sont indiqués sur la plaque signalétique.