Hypertherm Powermax 65 Reference manual

Powermax65/85/105 Digital Signal
Processor (DSP) Board Replacement
Remplacement du circuit imprimé
du processeur de signal numérique
(DSP) du Powermax65/85/105
Field Service Bulletin
Bulletin de service sur le terrain
806700 – Revision 2 – June 2013
Révision 2 — Juin 2013

DSP boarD rePlacement
Field Service Bulletin 1
Introduction
Purpose
This Field Service Bulletin describes the procedure for replacing the digital signal processor (DSP) board in the power
supply.
Powermax105 systems: Complete instructions for installing this repair kit are included in the Powermax105 Service
Manual. To download the Service Manual, go to www.hypertherm.com and click the “Downloads library” link.
Materials and tools
#2 Phillips screwdriver
Blade screwdriver
T15 and T20 TORX screwdrivers
Kit 228909 contents
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. See the
Safety and Compliance Manual included with your system for more safety
precautions.
Part number Description Quantity
075766 M3 x 16 mm machine screw 2
141269 DSP board 1

DSP boarD rePlacement
2Field Service Bulletin
Remove the power supply cover and Mylar barrier
Front of
power supply
1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Using a TORX or blade screwdriver, remove the 8 small screws (2) from the power supply cover.
3. Using a TORX or blade screwdriver, remove the 8 large screws (1) from the power supply cover.
4. Lift the cover (3) off the power supply.
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2
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5. Remove the Mylar barrier from the power-board side of the power supply. The Mylar barrier is flexible and can be
bent slightly for removal.
The power supply board is visible with the DSP board attached to the upper-left corner of the power board.

DSP boarD rePlacement
Field Service Bulletin 3
Remove the DSP board
1. Disconnect the DSP connector (1) from the top of the DSP board (3).
Note: This step is only required on systems that have an RS485 communication board installed. Systems
without an RS485 communication board installed will not have a connector plugged into the top of the
DSP board.
2. Use a #2 Phillips screwdriver to remove the 2 screws (2) from the DSP board.
Two rows of connector pins (4) are located on the back of the DSP board (3) as shown in the figures below. The
dashed rectangle identifies the location of the pins on the back of the board.
3. Carefully pull the DSP board (3) straight out from the power board (5). Do not bend the pins.
4. Disconnect the ribbon cable from the ribbon cable connector (6) on the back of the DSP board.
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DSP back viewDSP front view

DSP boarD rePlacement
4Field Service Bulletin
Install the new DSP board
1. Connect the ribbon cable to the ribbon cable connector (6) on the back of the new DSP board (3).
2. Align the two alignment pins (7) with the corresponding holes on the power board.
3. Carefully push the DSP board straight onto the power board. Do not bend the pins (4).
4. Use a #2 Phillips screwdriver to secure the DSP board to the power board using the 2 screws (2).
5. Connect the DSP connector (1) to the top of the DSP board if there is an RS485 communication board installed.
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3
DSP back view
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DSP front view

DSP boarD rePlacement
Field Service Bulletin 5
Replace the Mylar barrier
1. Carefully push in the sides (1) of the Mylar barrier so that the barrier bends out slightly at the top and bottom (2).
2. Slide the sides of the Mylar barrier behind the power supply frame (3). Be careful to get the barrier between the
frame and the power wires on the right side of the power board (4).
3. Gently bend the top of the barrier at the perforation so that the top bends over the top of the power supply.
4. Slide the barrier down so that the bottom edge fits inside the power supply frame (5).
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5
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2

DSP boarD rePlacement
6Field Service Bulletin
Replace the power supply cover
1. Place the cover (3) over the power supply. Be careful not to pinch any wires.
2. Using a TORX or blade screwdriver, install the 8 small screws (2) into the power supply cover. Tighten the screws
to 15 in lbs (17.3 kg cm).
3. Using a TORX or blade screwdriver, install the 8 large screws (1) into the power supply cover. Tighten the screws
to 15 in lbs (17.3 kg cm).
Front of
power supply
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2
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Remplacement du ciRcuit impRimé du pRocesseuR de signal numéRique
Bulletin de service sur le terrain a-1
Introduction
Objet
Le présent bulletin de service sur le terrain décrit la procédure de remplacement du circuit imprimé du processeur
designal numérique (DSP) de la source de courant.
Systèmes Powermax105: Les instructions complètes pour l’installation de ce kit de réparation sont incluses dans
le Manuel de service du Powermax105. Pour télécharger le Manuel de service, se rendre sur www.hypertherm.com
etcliquer sur le lien «Bibliothèque des téléchargements».
Matériel et outils requis
Tournevis cruciforme n° 2
Tournevis plat
Tournevis T15 et T20 TORX
Contenu du kit228909
AVERTISSEMENT
UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL
Débrancher l’alimentation électrique avant tout entretien. Se reporter
auManuel de sécurité et de conformité compris avec votre système
pourd’autres précautions de sécurité.
Numéro de référence Description Quantité
075766 Vis mécanique M3 x 16mm 2
141269 Circuit imprimé du processeur de signal numérique 1

Remplacement du ciRcuit impRimé du pRocesseuR de signal numéRique
a-2 Bulletin de service sur le terrain
Dépose du couvercle de la source de courant et de la barrière Mylar
Devant
de la source
de courant
1. Couper l’alimentation (OFF), débrancher le cordon d’alimentation et débrancher l’alimentation en gaz.
2. À l’aide d’un tournevis plat ou TORX, déposer les 8petites vis (2) du couvercle de la source de courant.
3. À l’aide d’un tournevis plat ou TORX, déposer les 8grandes vis (1) du couvercle de la source de courant.
4. Retirer le couvercle (3) de la source de courant.
5. Déposer la barrière Mylar du côté circuit imprimé de la source de courant. Cette barrière est flexible et peut être
pliée légèrement pour être enlevée.
Le circuit imprimé de la source de courant est visible sous le circuit imprimé du processeur de signal numérique
fixé au coin supérieur gauche du circuit imprimé de la source de courant.
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