Hypertherm Powermax45 XP Reference manual

Field Service Bulletin
Bulletin de service sur le terrain
809520 | Revision 1 | December 2016
| Révision 1 | Decembre 2016
Powermax45 XP®Raw Arc Voltage Kit
Kit de tension d’arc brute Powermax45 XP

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 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
[e-mail] (Technical Service Email)
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 Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[email protected] (Marketing Email)
TechSupportAP[email protected] (Technical Service Email)
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
[e-mail] (Main Office Email)
TechSupportAP[email protected] (Technical Service Email)
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 Email)
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 Email)
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 Email)
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)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[email protected] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
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
[e-mail] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
1/28/16
© 2016 Hypertherm Inc. 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.
One of Hypertherm’s long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and our customers’,
success. We are always striving to become better environmental stewards; it is a process we care deeply about.
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 de commerce sont la propriété de leurs détenteurs respectifs.
Une des valeurs fondamentales d’Hypertherm depuis toujours est l’accent mis sur la minimisation de notre impact sur l’environnement. Cet objectif est
essentiel pour notre réussite et celle de nos clients. Nous nous efforçons de devenir de meilleurs gestionnaires environnementaux, c’est une chose qui
nous tient à cœur.

Raw Arc Voltage Kit
Powermax45 XP Field Service Bulletin 809520 3
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 XP.
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,
RCM, 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 terminal crimper
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 (manufacturer’s part number 601802)
M3 (#5) insulated ring terminals, quantity 2
428689 Kit contents
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
All work requiring removal of the power supply cover must be performed
by a qualified technician.
See the safety information provided with your product for more safety
precautions.
Part number Description Quantity
008279 Strain relief 1
075529 M3 x 10 mm machine screw with lock washer 2

Raw Arc Voltage Kit
4809520 Field Service Bulletin Powermax45 XP
Install the interface cable
Connecting a cable to the power board to bypass the voltage divider board and access raw arc
voltage must be done by trained service personnel.
Remove cover and component barrier
1. Turn OFF the power. Disconnect the power cord and gas supply.
2. Remove the two screws from the power supply handle . Remove the two screws from the
bottom of the front and rear panels. Tilt the tops of the front and rear panels away from the
unit to pull the handle out .
WARNING
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.
1
2
3
4
3
2
4
1
3
1
2

Raw Arc Voltage Kit
Powermax45 XP Field Service Bulletin 809520 5
3. Slide the cover off.
4. Remove the two plastic pins that secure the component barrier to the main power board. Slide
the component barrier off.

Raw Arc Voltage Kit
6809520 Field Service Bulletin Powermax45 XP
Prepare the interface cable
1. Use 2 conductor, non-shielded 18 AWG wires to connect to the power supply. Measure the
distance needed to connect from the CNC to the power supply. Add an additional 51.5 cm
(20.25 inches) to make the connection inside the power supply.
2. Cut back the outer jacket 48.3 cm (19 inches) from one end of the cable. Make sure you do not
cut into the insulation on the two 18 AWG wires.
Do not strip the wire ends until after they have been routed through the
power supply.
Install the strain relief
1. Pull the rear panel slightly away from the unit leaving enough space to drill a hole while avoiding
any contact with internal components or wires when drilling.
2. Use a 15 mm (19/32 inch) drill to drill out the interface cable entry point on the panel. Clean the
area of any chips from drilling.
48.3 cm (19 inches)

Raw Arc Voltage Kit
Powermax45 XP Field Service Bulletin 809520 7
3. Attach the strain relief (008279) and tighten the inner nut to secure it to the panel. Attach the
outer retention nut but do not tighten.
Connect the interface cable
1. Pass the cable through the strain relief. The outer jacket should slightly protrude through the
back of the strain relief. Make sure the wire length is 48.3 cm (19 inches) inside the power
supply.
2. Tighten the outer retention nut on the strain relief. Make sure the strain relief closes on the
outer jacket of the cable and holds it securely in place.
3. Insert the interface cable wires through the pass-through holes used by the transformer to
reach the other side of the unit.
Different power supply configurations will have the transformer wires
routed differently. Use the pass-through holes that are not utilized by the
transformer.
1
2
1
2
1
2
3
3
1
2

Raw Arc Voltage Kit
8809520 Field Service Bulletin Powermax45 XP
4. Route the wires to bring the ends to the (-) and (+) threaded inserts on the main circuit board.
5. Strip the insulation 1.27 mm (0.5 inches) from the ends of the wires.
6. Crimp an M3 insulated terminal ring connector on the end of each wire. Make sure there are no
loose wire strands.
7. Connect the positive lead to the (+) threaded insert (J22) on the power supply board. Use one
of the screws included in the kit (075529). Tighten the screw to 23.0 kg∙cm (20 inch·pounds).
Make sure the wire runs downward and the insulated part of the ring terminal is off the board.
8. Connect the negative lead to the (-) threaded insert (J9) on the power supply board. Use one of
the screws included in the kit (075529). Tighten the screw to 23.0 kg∙cm (20 inch-pounds).
Make sure the wire runs downward and the insulated part of the ring terminal is off the board.
9. Make sure to mark on the other end of the cable which wire is positive (+) and which is
negative (-).
10. Replace the component barrier and secure it to the main circuit board with the two plastic pins.
11 . Set the front and rear panels back in place.
( + )
( - )
(-) (+)
( + )
( - )
( + )
( - )
( + )
( - )

Raw Arc Voltage Kit
Powermax45 XP Field Service Bulletin 809520 9
12. 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.
13. Slide the cover back on.
14. Tilt the front and rear panels to reattach the handle.
15. Secure the front and rear panel bottom screws.
16. Secure the front and rear panel top screws.
17. 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.

Raw Arc Voltage Kit
10 809520 Field Service Bulletin Powermax45 XP
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. Over-current
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.