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
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603-643-5352 Fax (All Departments)
[email protected] (Main Office)
800-643-9878 Tel (Technical Service)
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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)
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Solaris @ Kallang 164
164 Kallang Way #03-13
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Osaka 550-0002 Japan
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Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
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55 11 2409 2636 Tel
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Sydney NSW 2001, Australia
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Mohan Co-Operative Industrial Estate,
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91-11 40521204 Fax
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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

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 11
Attach the machine interface cables to the power PCB
If you have a Powermax105, Powermax125, or Powermax105 SYNC, go to page 14.
Powermax65/85 and Powermax65/85 SYNC
1. From the fan side of the plasma power supply, put the 2-pin connector and the 4-pin connector
through the right grommet .
a. Remove the grommet from the middle
panel.
b. Put the cables in the slot in the
grommet.
c. Put the connectors through the hole in
the middle panel.
d. Install the grommet in the middle panel.
1
1

Machine Interface Receptacle with Voltage Divider PCB
12 806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
2. Optional: If it is necessary to move the front panel to get access to the connections on the
power PCB, do the following:
a. Carefully put the plasma power supply
onto the fan side.
b. Remove the 2 screws that hold the
front panel to the bottom of the plasma
power supply.
c. Disconnect the front panel from the
bottom of the plasma power supply
with a blade screwdriver.
d. Put the plasma power supply in the
upright position.
e. Remove the gas hose from the
push-to-disconnect fitting on the
solenoid valve.
f. Tilt the front panel away from the body
of the plasma power supply as
necessary. The front panel is still
attached to the plasma power supply
and can move only a short distance.

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 13
3. From the power PCB side, do the following:
a. Connect the 4-pin connector to the power PCB at J21.
b. CSA models: Connect the 2-pin connector to the power PCB at J32.
CE/CCC models: Connect the 2-pin connector to the power PCB at J33.
c. For the 2-pin and 4-pin connectors, make sure that the red wire aligns with RED on the
power PCB.
4. If you disconnected the front panel in step 2 on page 12, do the following steps to attach the
front panel to the plasma power supply:
a. Carefully put the plasma power supply onto the fan
side.
b. Push the bottom of the front panel onto the bottom
of the plasma power supply. Make sure that you do
not pinch wires between the front panel and the
heatsink in the plasma power supply.
c. Install the 2 screws that hold the front panel to the
bottom of the plasma power supply.
Torque the screws to 2.3 N·m (20 in-lb).
d. Put the plasma power supply in the upright position.
e. Put the gas hose in the push-to-connect fitting in
the solenoid valve.
5. Install the fan shroud on the fan.
RED
J32 (CSA)
J33 (CE)
RED
J21
Red wire = top pin
Red wire = bottom pin

Machine Interface Receptacle with Voltage Divider PCB
14 806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
Powermax105/125 or Powermax105 SYNC
1. From the fan side of the plasma power supply, put the 2-pin connector and the 4-pin connector
through the right grommet .
a. Remove the grommet from the middle
panel.
b. Put the cables in the slot in the
grommet.
c. Put the connectors through the hole in
the middle panel.
d. Install the grommet in the middle panel.
1
1

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 15
2. From the power PCB side, do the following:
a. Connect the 4-pin connector to the power PCB at J18.
b. Connect the 2-pin connector to the power PCB at J32.
c. For the 2-pin and 4-pin connectors, make sure that the red wire aligns with RED on the
power PCB.
3. Install the fan shroud on the fan.
J22
J27
WORK
LEAD
J26
RED
J18
ORG
J17
J32
J11
B
R
J28
RED
Red wire = top pin
Red wire = bottom pin

Machine Interface Receptacle with Voltage Divider PCB
16 806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
Set the voltage divider PCB
The factory setting on the voltage divider PCB is 50:1.
To change the voltage divider to a different setting, set the DIP switches to one of the following:
For more information, refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide
(810480).
NOTICE
The voltage divider PCB is a simple resistive divider of raw arc voltage. To prevent ground loops and
electrical interference, you must isolate the divided arc signal.
NOTICE
The factory-installed voltage divider PCB supplies a voltage that is in proportion to the arc voltage. The
DIP switch settings on the voltage divider PCB control the output in open circuit conditions, to a
maximum output of one of the following voltages: 18 V for Powermax65/85, 15 V for Powermax105 and
Powermax65/85/105 SYNC, 16 V for Powermax125. This output is an impedance-protected,
functional extra-low voltage (ELV) output. This type of output prevents shock, energy, and fire under
normal conditions at the machine interface receptacle and in single-fault conditions with the machine
interface wiring. The voltage divider PCB is not fault tolerant and ELV outputs do not comply with safety
extra-low voltage (SELV) requirements for direct connection to electrical devices.
L1
X12 R1
R2
R3
R7
R5
R6
R4
C3
C2
C1 C4
L1
BLK
RED
J1
J3 J4
RED
BLK
J2
21.1 30 40 50
GRN
S1
ALL DOWN = 20
D1
J5
20:1 21.1:1 30:1 40:1 50:1

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 17
Machine interface receptacle sockets
Arc voltage sockets 5 and 6 are used for pin for pin connection to legacy
cables.
Sockets 1 and 2 are duplicate arc voltage sockets for future use. Sockets
1 and 2 are not used for most installations.
For more information, refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide
(810480).
13
14
12
6
5
3
4
Plasma start
Plasma start
Arc voltage (+)
Legacy
Arc voltage (–)
Legacy
Arc transfer
Ground
Arc transfer
1
2
Arc voltage (-)
Future use
Arc Voltage (+)
Future use

Machine Interface Receptacle with Voltage Divider PCB
18 806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 SYNC
Install the end panel bracket
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.
1
22
1
2

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125, Powermax65/85/105 SYNC Field Service Bulletin 806980 19
Install the plasma power supply cover and component barrier
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 .
WARNING
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.
1
2
1
2

Machine Interface Receptacle with Voltage Divider PCB
20 806980 Field Service Bulletin Powermax65/85/105/125, Powermax65/85/105 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).
3
4
5
3
4
5