Hypertherm powermax65 Reference manual

Machine Interface Receptacle with Voltage
Divider PCB
Powermax65/85/105/125®, Powermax65/85/105 SYNC™
Câble d’interface de machine avec panneau
diviseur de tension
Powermax65/85/105/125®, Powermax65/85/105 SYNC™
Field Service Bulletin
Bulletin de service sur le terrain
806980
Revision 4 | Révision 4
October 2021 | Octobre 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)
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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)
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Détenue à 100 % par les associés

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 3
Introduction
Purpose
This Field Service Bulletin gives the procedure for installing an internal machine interface
receptacle, cables, and voltage divider printed circuit board (PCB).
The systems and components shown are for reference. Your system could be different in
appearance.
Tools and materials
Assorted Phillips®, TORX®, and blade screwdrivers
Grounded wrist strap (or similar grounding accessory)
7 mm wrench (Powermax105/125 and Powermax105 SYNC only)
WARNING
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.

Machine Interface Receptacle with Voltage Divider PCB
4806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
Kit 228697 contents (Powermax65/85 and Powermax65/85 SYNC)
Kit 228884 contents (Powermax105 and Powermax125)
Kit 528045 contents (Powermax105 SYNC)
Figure 1 – Machine interface receptacle with cables, voltage divider PCB, and screws
Part number Description Quantity
075534 Thread-forming, #6 X 5/16 pan head screw 4
223036 Machine interface receptacle with cables and voltage divider PCB 1
Part number Description Quantity
075534 Thread-forming, #6 X 5/16 pan head screw 4
223263 Machine interface receptacle with cables and voltage divider PCB 1
Part number Description Quantity
075534 Thread-forming, #6 X 5/16 pan head screw 4
223741 Machine interface receptacle with cables and voltage divider PCB 1
7
8
1
2
34
5
6
1Machine interface receptacle
2Screws (4)
3Ground wire to air filter assembly
4Voltage divider PCB wire
5Voltage divider PCB
6Ground wire to middle panel
7Power PCB 4-pin connector
8Power PCB 2-pin connector

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 5
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.
WARNING
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.

Machine Interface Receptacle with Voltage Divider PCB
6806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
4. Remove the component barrier from the power-PCB side of the plasma power supply.
Remove the end panel bracket
Remove the end panel bracket . Some models have
2 screws on the end panel bracket that you must first
remove.
1
2 2
1
2

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 7
Install the machine interface receptacle with voltage divider PCB
1. Remove the protective cover from the rear panel.
2. Remove the fan shroud from the fan.

Machine Interface Receptacle with Voltage Divider PCB
8806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
3. Attach the voltage divider PCB to the right of the fan with 2 screws (075534).
Torque the screws to 1.1 N·m (10 in·lb).
4. Make sure that the cables attached to the voltage divider PCB are installed below the solenoid
valve .
Powermax65/85 and Powermax65/85 SYNC
Powermax105/125 and Powermax105 SYNC
1
2
2
1
2
1

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 9
5. Make sure that the green and
yellow ground wire is at
the bottom of the machine
interface receptacle.
6. From the inside of the rear
panel, install the machine
interface receptacle in the
opening.
7. Install 2 screws (075534) in
opposite corners of the
machine interface receptacle,
as shown.
Torque the screws to 1.1 N·m
(10 in·lb).
8. Remove the screw that
attaches the green and
yellow ground wire from the
middle panel to the air filter.
9. Attach the green and yellow
ground wire from the machine
interface receptacle to the air
filter with the screw that you
removed in step 8.
Torque the screw to 1.7 N·m
(15 in·lb).
10. Make sure that the green and
yellow ground wire from the
middle panel is also attached
to the air filter with the screw
that you removed in step 8.
4
3
4
3
5
5

Machine Interface Receptacle with Voltage Divider PCB
10 806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
11 . Attach the green ground wire from the voltage divider PCB to the middle panel. Use the
screw that is in the middle panel.
Powermax65/85 and
Powermax65/85 SYNC:
a. Install the ground wire
above the voltage divider
PCB and behind the
other cables, as shown.
b. Do you have the serial
interface port installed? If
you do, attach the green
and yellow ground wire
from the RS-485 serial
interface PCB to the
middle panel with the
same screw.
c. Torque the screw to
1.7 N·m (15 in·lb).
Powermax105/125 and
Powermax105 SYNC:
a. Remove the nut and
washer from the screw.
Use a 7 mm wrench.
b. Install the ground wire
above the voltage divider
PCB and behind the
other cables, as shown.
c. Do you have the serial
interface port installed? If
you do, attach the green
and yellow ground wire
from the RS-485 serial
interface PCB to the
middle panel with the
same screw.
d. Install the washer.
e. Torque the nut to 1.7 N·m (15 in·lb).
6
6
6