Hypertherm powermax65 Reference manual

Machine Interface Receptacle with Voltage
Divider PCB
Powermax65/85/105/125®
Câble d’interface de machine avec panneau
diviseur de tension
Powermax65/85/105/125®
Field Service Bulletin
Bulletin de service sur le terrain
806980
Revision 3 | Révision 3
July 2020 | Juillet 2020

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)
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PR China
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91-11 40521204 Fax
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México, D.F. C.P. 01780
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Osaka 550-0002 Japan
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81 6 6225 1184 Fax
HT[email protected] (Main Office Email)
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Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125 Field Service Bulletin 806980 3
Introduction
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 only)
WAR NING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before doing installation or maintenance.
All work requiring removal of the plasma power supply outer cover or panels
must be done by a qualified technician.
See the Safety and Compliance Manual (80669C) for more safety
precautions.
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
Kit 228697 contents (Powermax65 and Powermax85)
Kit 228884 contents (Powermax105 and Powermax125)
Figure 1 – Kit contents for kits 228697 and 228884
Disconnect the power and gas supply
1. Set the plasma power supply
to OFF (O) .
2. Disconnect the power cord
from the power source .
3. Disconnect the gas
supply .
Part number Description Quantity
075534 Plastite #6 X 5/16 pan head screw 4
223036 Machine interface receptacle with cables and voltage divider PCB 1
Part number Description Quantity
075534 Plastite #6 X 5/16 pan head screw 4
223263 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
2
1
3
1
2
3

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125 Field Service Bulletin 806980 5
Remove the plasma power supply cover and component barrier
1. Remove the 16 screws from
the plasma power supply
cover.
2. Lift the cover up to remove it.
3. Remove the component
barrier .
4. Powermax105/125: Remove
the 2 mounting screws
from the end panel bracket.
5. Lift the end panel bracket
to remove it.
2
1
3
1
2
3

Machine Interface Receptacle with Voltage Divider PCB
6806980 Field Service Bulletin Powermax65/85/105/125
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
Powermax65/85/105/125 Field Service Bulletin 806980 7
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
Powermax105/125
1
2
2
1
2
1

Machine Interface Receptacle with Voltage Divider PCB
8806980 Field Service Bulletin Powermax65/85/105/125
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
Powermax65/85/105/125 Field Service Bulletin 806980 9
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:
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:
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
10 806980 Field Service Bulletin Powermax65/85/105/125
Attach the machine interface cables to the power PCB
If you have a Powermax105 or Powermax125, go to page 13.
Powermax65/85
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 Field Service Bulletin 806980 11
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
12 806980 Field Service Bulletin Powermax65/85/105/125
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 11, 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
Powermax65/85/105/125 Field Service Bulletin 806980 13
Powermax105/125
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
14 806980 Field Service Bulletin Powermax65/85/105/125
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
Powermax65/85/105/125 Field Service Bulletin 806980 15
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:
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,
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
16 806980 Field Service Bulletin Powermax65/85/105/125
Machine interface receptacle sockets
Pin 1 and Pin 2 are wired but not used.
13
14
12
6
5
3
4
Plasma start
Plasma start
Arc voltage (+)
Arc voltage (–)
Arc transfer
Ground
Arc transfer

Machine Interface Receptacle with Voltage Divider PCB
Powermax65/85/105/125 Field Service Bulletin 806980 17
Install the plasma power supply cover and component barrier
1. Install the end panel bracket .
Powermax65/85: Push the
4 pins on the bracket into the
front panel and rear panel.
Powermax105/125: Install the
2 mounting screws to attach
the bracket.
Torque the screws to 1.1 N·m
(10 in·lb).
2. Install the component barrier .
a. Make sure that the sides and the
bottom of the component barrier
are inside the frame of the plasma
power supply.
b. Carefully bend the top of the
component barrier at the
perforation so that the top bends
over the top of the power PCB.
3. Install the cover over the plasma
power supply. Do not pinch the wires.
4. Install the 16 screws .
Torque the screws to 1.7 N·m
(15 in·lb).
2
3
1
1
2
3
3
4
5
5 5
5
4
5

Machine Interface Receptacle with Voltage Divider PCB
18 806980 Field Service Bulletin Powermax65/85/105/125

Câble d’interface de machine avec panneau diviseur de tension
Powermax65/85/105/125 Bulletin de service sur le terrain 806980 19
Introduction
Le présent Bulletin de service sur le terrain décrit la procédure d’installation d’un câble d’interface
de machine interne, d’autres câbles ainsi que du panneau diviseur de tension à circuit imprimé.
Les systèmes et les composants illustrés sont présentés à titre de référence. Votre système pourrait
avoir un autre aspect.
Outils et matériel
Tournevis Phillips®, TORX®et à lame plate assortis
Bracelet antistatique (ou accessoire de mise à la terre similaire)
Clé de 7 mm (Powermax105/125 uniquement)
AVERTISSEMENT
UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL
Débrancher l’alimentation électrique avant toute installation et tout entretien.
Tous les travaux nécessitant le retrait du couvercle ou des panneaux 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 connaître les mesures 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.

Câble d’interface de machine avec panneau diviseur de tension
20 806980 Bulletin de service sur le terrain Powermax65/85/105/125
Contenu du kit 228697 (Powermax65 et Powermax85)
Contenu du kit 228884 (Powermax105 et Powermax125)
Figure 1 – Contenu des kits 228697 et 228884
Numéro de
référence Description Quantité
075534 Vis à tête cylindrique bombée Plastite n° 6 x 5/16 4
223036 Câble d’interface machine avec câbles et panneau diviseur de tension 1
Numéro de
référence Description Quantité
075534 Vis à tête cylindrique bombée Plastite n° 6 x 5/16 4
223263 Câble d’interface machine avec câbles et panneau diviseur de tension 1
7
8
1
2
34
5
6
1Câble d’interface de machine
2Vis (4)
3Fil de mise à la terre vers l’ensemble
de filtre à air
4Câble du panneau diviseur de tension
5Panneau diviseur de tension
6Fil de mise à la terre vers le panneau central
7Connecteur à 4 contacts de la carte à circuits
imprimés de la source de courant
8Connecteur à 2 contacts de la carte à circuits
imprimés de la source de courant