Hypertherm Powermax105 Reference manual

Power Cord and Strain Relief Replacement
Powermax105 SYNC™
Remplacement du cordon d’alimentation
et du serre-câble
Powermax105 SYNC™
Field Service Bulletin
Bulletin de service sur le terrain
810420
Revision 0 | Révision 0
June 2021 | Juin 2021

Hypertherm, Inc.
21 Great Hollow 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)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service)
800-737-2978 Tel (Customer Service)
customer.ser[email protected] (Customer Service)
Hypertherm México, S.A. de C.V.
52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)
Hypertherm Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected] (Technical Service)
Hypertherm (Singapore) Pte Ltd.
Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[email protected] (Marketing)
[email protected] (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
[email protected] (Main Office)
[email protected] (Technical Service)
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected] (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
86-21-80231128 Tel (Technical Service)
[email protected] (Technical Service)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[email protected] (Technical Service)
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[email protected] (Marketing)
[email protected] (Technical Service)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[email protected] (Main Office)
[email protected] (Technical Service)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[email protected] (Main Office)
[email protected] (Technical Service)
© 2021 Hypertherm, Inc. All rights reserved.
Powermax, SYNC, 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.
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sont la propriété de leurs détenteurs respectifs.
Une bonne gestion environnementale est l’une des valeurs fondamentales d’Hypertherm. www.hypertherm.com/environment

Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 3
Introduction
Purpose
Powermax105 SYNC: This field service bulletin gives you the replacement procedures for the
3-phase power cord.
Powermax105 and Powermax125: For replacement procedures for the 3-phase power cord, refer
to the Powermax105 Service Manual (807580) or the Powermax125 Service Manual (808070).
Technical documentation is available at www.hypertherm.com/docs.
Tools and materials needed
Assorted Phillips®offset screwdrivers
Blade screwdrivers
Assorted TORX®drivers
Large adjustable wrench
WARN ING
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.
Refer to the Safety and Compliance Manual (80669C) for more safety
information.
NOTICE
Static electricity can cause damage to printed circuit boards (PCBs). Use correct
precautions when you touch PCBs.
Keep PCBs in antistatic containers.
Put on a grounded wrist strap when you touch PCBs.

Power Cord and Strain Relief Replacement
4810420 Field Service Bulletin Powermax105 SYNC
Kit contents
Kit 228885 contents (Powermax105 SYNC 200 V – 600 V CSA)
Kit 228915 contents (Powermax105 SYNC 200 V – 600 V CSA)
Item Part number Description Quantity
1104675 Hex nut 1
2108697 Strain relief with retention nut 1
3229443 Power cord, 3 m (10 feet) 1
Item Part number Description Quantity
1104675 Hex nut 1
2108697 Strain relief with retention nut 1
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Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 5
Kit 228886 contents (Powermax105 SYNC 230 V – 400 V CE)
Kit 228913 contents (Powermax105 SYNC 230 V – 400 V CE)
Item Part number Description Quantity
1104675 Hex nut 1
2108691 Strain relief with retention nut 1
3229449 Power cord, 3 m (10 feet) 1
Item Part number Description Quantity
1104675 Hex nut 1
2108691 Strain relief with retention nut 1
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Power Cord and Strain Relief Replacement
6810420 Field Service Bulletin Powermax105 SYNC
Kit 428949 contents (Powermax105 SYNC 380 V CCC / 400 V CE)
Kit 228914 contents (Powermax105 SYNC 380 V CCC / 400 V CE)
Item Part number Description Quantity
1104629 Strain relief adapter 1
2075819 Washer 1
3108795 Strain relief with retention nut 1
4429052 Power cord, 3 m (10 feet) 1
Item Part number Description Quantity
1075819 Washer 1
2108795 Strain relief with retention nut 1
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Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 7
Remove the plasma power supply cover and component barrier
1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and
disconnect the gas supply.
2. Remove the 16 screws from the plasma power supply cover.
3. Remove the plasma power supply cover.
WARN ING
STORED ENERGY HAZARD
You can get a serious electric shock from the uncontrolled release of stored
energy in capacitors. Electric shock can seriously injure or kill you.
Before you remove the plasma power supply cover, disconnect electrical
input power and wait 1 minute to allow stored energy to discharge.

Power Cord and Strain Relief Replacement
8810420 Field Service Bulletin Powermax105 SYNC
4. Remove the component barrier from the power-PCB side of the plasma power supply.

Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 9
Loosen the rear panel of the plasma power supply
1. Remove the end panel bracket . Some models have 2 screws on the end panel bracket
that you must first remove.
2. Put the fan side of the plasma power supply on a clean, dry, and flat surface.
3. Remove the screws that attach the rear panel to the bottom of the plasma power supply.
Some models have 2 screws on the bottom of the plasma power supply, and other models have
3 screws on the rear panel instead.
4. Move the bottom of the rear panel off of the bottom of the plasma power supply to get
access to the power cord inside the plasma power supply. Use a blade screwdriver to carefully
pry the rear panel away from the bottom of the plasma power supply.
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Power Cord and Strain Relief Replacement
10 810420 Field Service Bulletin Powermax105 SYNC
5. Put the plasma power supply in an upright position.

Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 11
Remove the power cord
1. Remove the screw that attaches the ground wire to the heatsink.
2. Use an offset Phillips® screwdriver to loosen the screws that attach the 3 power wires to
the top of the power switch.
3. Pull the 3 power wires from the power switch.
4. On the outside of the plasma power supply, remove the strain relief retention nut from the
strain relief. Move the retention nut away from the plasma power supply.
5. Remove the power cord.
CSA: From the outside of the plasma power supply , pull the power cord and power
wires through the strain relief in the rear panel.
CCC/CE: From the inside of the plasma power supply , pull the power wires and the full
length of the power cord through the strain relief in the rear panel.
CCC/CE models have ferrite cores on the power wires and the
ground wire. To maintain CCC/CE certification, install a CCC/CE power
cord kit.
CSA
CCC/CE
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Power Cord and Strain Relief Replacement
12 810420 Field Service Bulletin Powermax105 SYNC
Remove the strain relief
1. On the inside of the plasma power supply, remove the hex nut . Some models also have a
washer that you must remove.
2. On the outside of the plasma power supply, remove the strain relief . Some models also have
a strain relief adapter that you must remove.
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Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 13
Attach the strain relief
1. If the retaining nut is on the strain relief , remove the retaining nut.
2. On the outside of the plasma power supply, put the strain relief in the hole in the rear panel of
the plasma power supply. If your model has a strain relief adapter , first put the strain relief in
the adapter.
3. On the inside of the plasma power supply, install the hex nut on the strain relief. If your model
has a washer , first put the washer on the strain relief. Tighten the hex nut with your hand.
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Power Cord and Strain Relief Replacement
14 810420 Field Service Bulletin Powermax105 SYNC
Install the power cord
Color
Power Wire Position CSA CCC/CE
L1 Black Brown
L2 White Black
L3 Red Grey
CSA
CCC/CE
L1 L2 L3
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Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 15
1. Put the power cord in the strain relief.
CSA: From the outside of the plasma power supply, put the power wires and ground wire
through the retention nut . Then put the power wires and ground wire through the strain
relief .
CCC/CE: From the inside of the plasma power supply, put the wires at the line-disconnect
end of the power cord through the strain relief . From the outside of the plasma power
supply, pull the full length of the power cord through the strain relief. Then put the wires at
the line-disconnect end of the power cord through the retention nut .
CCC/CE models have ferrite cores on the power wires and the
ground wire. To maintain CCC/CE certification, install a CCC/CE power
cord kit.
2. Attach the ground wire to the heatsink with the screw you removed previously. Tighten the
screw to 4 N·m (35 lbf·in).
3. Put the 3 power wires in the power switch. Tighten the set screws to 2.3 N·m (20 lbf·in).
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.
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Power Cord and Strain Relief Replacement
16 810420 Field Service Bulletin Powermax105 SYNC
Install the rear panel of the plasma power supply
1. Put the fan side of the plasma power supply on a flat surface.
2. Push the rear panel onto the bottom of the plasma power supply.
3. Install the screws that attach the rear panel to the bottom of the plasma power supply. Some
models have 2 screws on the bottom of the plasma power supply, and other models have
3 screws on the rear panel instead.
4. Put the plasma power supply in an upright
position.
5. Put the end panel bracket into position. If
your model requires screws to attach the end
panel bracket, install the 2 screws that you
removed previously.
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Power Cord and Strain Relief Replacement
Powermax105 SYNC Field Service Bulletin 810420 17
Install the component barrier and plasma power supply cover
1. Push in the sides of the
component barrier so that the
component barrier bends out
slightly down the center.
2. Put the sides of the component
barrier inside the plasma power
supply frame .
WARN ING
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.
Never operate the plasma power supply unless the component barrier and the
plasma power supply cover are in position.
WARN ING
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.
Never operate the plasma power supply unless the component barrier and the
plasma power supply cover are in position.
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Power Cord and Strain Relief Replacement
18 810420 Field Service Bulletin Powermax105 SYNC
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.
5. Put the cover on the plasma power supply.
Do not pinch any wires.
6. Install the 16 screws on the plasma power
supply cover. Tighten the screws to 1.7 N·m
(15 lbf·in).
Connect to electrical power
The power cord does not come with a plug.
Connect the power cord to the line-disconnect switch.
For more information about connecting to electrical
power, refer to the Powermax65/85/105 SYNC
Operator Manual (810470).
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Remplacement du cordon d’alimentation et du serre-câble
Powermax105 SYNC Bulletin de service sur le terrain 810420 19
Introduction
Objectif
Système Powermax105 SYNC : Le présent Bulletin de service sur le terrain décrit la procédure
de remplacement du cordon d’alimentation triphasé.
Systèmes Powermax105 et Powermax125 : Pour connaître les procédures de remplacement du
cordon d’alimentation triphasé, se reporter au Powermax105 Service Manual (Manuel de service
du système Powermax105) (807580) ou au Powermax125 Service Manual (Manuel de service
du système Powermax125) (808070). Il est possible de consulter les documents techniques
à l’adresse www.hypertherm.com/docs.
Outils et matériel requis
Tournevis Phillips®coudés assortis
Tournevis plats
Tournevis TORX®assortis
Grande clé réglable
AVERTISSEMENT
UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL
Débrancher l’alimentation électrique avant toute installation et tout entretien.
Il est possible de recevoir une décharge électrique importante si l’alimentation
électrique n’est pas coupée. Un choc électrique peut causer des blessures
graves ou la mort.
Tous les travaux nécessitant le retrait du couvercle ou des panneaux
extérieurs de la source de courant plasma doivent être effectués par
un technicien qualifié.
Se reporter au Safety and Compliance Manual (Manuel de conformité et de
sécurité) (80669C) pour obtenir des consignes de sécurité supplémentaires.
AV I S
L’électricité statique peut endommager les cartes à circuits imprimés. Prendre les bonnes
précautions lors de la manipulation des circuits imprimés.
Conserver les circuits imprimés dans des récipients antistatiques.
Porter un bracelet antistatique avant de manipuler les cartes à circuits imprimés.

Remplacement du cordon d’alimentation et du serre-câble
20 810420 Bulletin de service sur le terrain Powermax105 SYNC
Contenu du kit
Contenu du kit 228885 (Powermax105 SYNC 200 V – 600 V CSA)
Contenu du kit 228915 (Powermax105 SYNC 200 V – 600 V CSA)
Article Numéro de
référence Description Quantité
1104675 Écrou hexagonal 1
2108697 Serre-câble avec écrou de retenue 1
3229443 Cordon d’alimentation, 3 m 1
Article Numéro de
référence Description Quantité
1104675 Écrou hexagonal 1
2108697 Serre-câble avec écrou de retenue 1
12
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