Hypertherm powermax65 Referenzhandbuch
Powermax65®
Powermax85®
Powermax105®
Powermax125®
Machine Interface for Raw Arc Voltage
Interface de machine pour accès
à la tension d’arc brute
Field Service Bulletin
Bulletin de service sur le terrain
807060 – Revision3 – December 2013
Révision3 – Décembre 2013
Machine interface for raw arc Voltage
Field Service Bulletin 1
Introduction
Purpose
This Field Service Bulletin explains how to install a customer-supplied machine interface cable for accessing raw arc
voltage instead of using the internal voltage divider board.
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, Ukr, C-tick) applied to the product in the Hypertherm factory, and the safety certificates provided by
Hypertherm become invalid after modification.
Materials and tools
• Wire stripper
• Wire crimper
• Powermax65/85: M4 (#8), M6 (1/4 in.) insulated ring terminals
• Powermax105/125: M4 (#8), M8 (5/16 in.) insulated ring terminals
• Blade screwdriver
• Assorted Phillips®and TORX®screwdrivers
• Electric drill with a 19/32 drill bit
• 18 AWG, 2 wire, non-shielded cable similar to OLFLEX®190 (OLFLEX 190 part number 601802)
• Adjustable wrench
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance. See the
Safety and Compliance Manual included with your system for more safety
precautions.
Part number Description Quantity
008279 Strain relief 1
Kit 228711 contents
Machine interface for raw arc Voltage
2Field Service Bulletin
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.
Remove the power supply cover and component barrier
Connecting a cable to the power board to bypass the voltage divider and access raw arc voltage must be done by
trained service personnel.
1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Remove the screws from the power supply cover.
Note: Powermax65/85 system covers have 8 small screws (2) and 8 large screws (1). All 16 screws for
Powermax105/125 covers are the same size.
3. Lift the cover (3) off the power supply.
4. Remove the component barrier from the power-board side of the power supply. The component barrier is flexible
and can be bent slightly for removal.
1
1 1
2
2
1
2
2
1
3
Machine interface for raw arc Voltage
Field Service Bulletin 3
Accessing raw arc voltage (Powermax65/85 systems)
To access raw arc voltage, you must install the strain relief (part number 008279) in kit number 228711. You must also
connect an 18 AWG, 2-wire, non-shielded cable similar to OLFLEX®190 (601802) in the length needed to extend
between the power supply and the CNC or other equipment plus approximately 60 cm (2 feet) of cable to connect
inside the power supply.
1. On the end of the cable to be connected inside the power supply, strip the outer jacket 7.6 cm (3 inches). Then
strip 1.3 cm (0.5 inch) of wire insulation off of each wire.
2. Crimp an M4 (#8) insulated ring terminal on the end of Wire #1 (negative lead) and an M6 (1/4 in.) insulated ring
terminal on the end of Wire #2 (positive lead).
3. Use a drill with a 19/32 drill bit to drill out the access point on the rear panel. Be careful not to damage internal
components.
Rear panel
Access point
Machine interface for raw arc Voltage
4Field Service Bulletin
Access point
Fan shroud Transformer
4. Remove the fan shroud by pulling it straight off the fan housing.
5. Loosen the transformer below the lower-right corner of the fan by removing the two screws that secure the
transformer to the base of the power supply.
Machine interface for raw arc Voltage
Field Service Bulletin 5
WORK
LEAD
Wire #1 connects to
red wire (-) terminal
(J28 on CSA models,
J29 on CE models) Wire #2 connects to
work lead (+) terminal
(J26 on CSA models,
J27 on CE models)
Transformer
wires
Cable passes through
opening under power board
6. On the power board side of the power supply, remove the screws that secure the transformer wires to the power
board.
7. Carefully separate the transformer wires to provide access to the opening under the power board.
8. Connect Wire #1 to the red wire (-) terminal (J28 on CSA models, J29 on CE models). Refer to the figure below.
Put the ring connector for the red wire closest to the power board and put the ring connector for Wire #1 on top of
the red wire connector. Tighten the screw to 11.5 kg cm (10 in.-lbs).
9. Connect Wire #2 to the work lead (+) terminal (J26 on CSA models, J27 on CE models). Put the connector for
the work lead closest to the power board and put the ring connector for Wire #2 on top of the work lead ring
connector. Tighten the screw to 34.6 kg cm (30 in.-lbs).
10. Locate the opening under the power board (between the two transformer wires). Route the end of the cable through
the opening and push the cable into the fan side of the power supply.
Note: It is much easier to route the cable from the power board side than from the fan side. Do not use a
wire to “fish” the cable from the fan side because the wire can damage components.
Powermax65/85
Machine interface for raw arc Voltage
6Field Service Bulletin
11. From the fan side of the power supply, grasp the end of the cable. Carefully pull the entire length of the cable
through the opening while pushing the cable through the opening from the power board side. Leave enough cable
on the power board side to route the wires along the base of the power supply.
12. Route the cable through the strain relief nut, rear panel access point, strain relief, and strain relief retention nut. Pull
the cable through the strain relief leaving enough cable to rest in the bottom of the power supply without tension.
13. Secure the strain relief on the inside of the power supply using the strain relief nut. Hand tighten the nut and then
over-tighten slightly more.
14. Tighten the strain relief retention nut onto the strain relief to secure the cable.
Strain relief
retention nut
Cable direction
Strain relief
Wire #1 (-)
M4 (#8) ring
M6 (1/4 in.)
ring
Wire #2 (+)
Rear panel of
power supply Strain relief nut
inside power supply
15. Secure the transformer to the base of the power supply with the two screws. Tighten the screws to 23.0 kg cm
(20in.-lbs).
16. Push the fan shroud onto the fan housing.
17. Reconnect the two transformer wires to the power board. Tighten the screws to 34.6 kg cm (30 in.-lbs).
18. After you replace the component barrier and power supply cover in the sections that follow, you may connect the
other end of the cable to the equipment according to the manufacturer’s instructions. Remember to observe polarity.
Note 1: 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 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.
Note 2: 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. Overcurrent protection may be
required to protect the user and/or machine in fault conditions.
Note 3: 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.
Machine interface for raw arc Voltage
Field Service Bulletin 7
To access raw arc voltage, you must install the strain relief (part number 008279) in kit number 228711. You must also
supply and connect an 18 AWG, 2-wire, non-shielded cable similar to OLFLEX®190 (601802) in the length needed
to extend between the power supply and the CNC or other equipment plus approximately 60 cm (2 feet) of cable to
connect inside the power supply.
1. On the end of the cable to be connected inside the power supply, strip the outer jacket 7.6 cm (3 inches). Then
strip 1.3 cm (0.5 inches) of wire insulation off of each wire.
2. Crimp an M4 (#8) insulated ring terminal on the end of Wire #1 (negative lead) and an M8 (5/16 inch) insulated
ring terminal on the end of Wire #2 (positive lead).
3. Use a drill with a 19/32 drill bit to drill out the access point on the rear panel. Be careful not to damage internal
components.
4. Remove the screw securing the electrode wire (J28) to the power board.
5. Place the ring terminal of Wire #1 (negative lead) on top of the electrode wire ring terminal.
6. Secure the two wires to the power board using the previously removed screw. Tighten the screw to 23 kg cm
(20 in.-lbs).
Rear panel
Access point
Accessing raw arc voltage (Powermax105/125 systems)
Machine interface for raw arc Voltage
8Field Service Bulletin
7. Remove the bolt securing the work lead wire (J27) to the power board.
8. Place the ring terminal of Wire #2 (positive lead) on top of the work lead wire ring terminal.
9. Secure the two wires to the power board using the previously removed bolt. Tighten the bolt to 63.4 kg cm
(55 in.-lbs).
10. Locate the opening in the bottom of the center panel that the transformer wires pass through and push the end of
the cable through the opening.
11. From the fan side of the power supply, pull the entire length of the cable through the opening in the bottom of the
center panel. Leave enough cable on the power board side to route the wires along the base of the power supply.
12. Route the end of the cable through the strain relief nut, rear panel access point, strain relief, and strain relief
retention nut. Pull the cable through the strain relief leaving enough cable to rest in the bottom of the power supply
without tension.
J22 J21 J20 J19
J27
J28
WORK
LEAD
J26
J25
+
_+
_
RED
J18
ORG
J17
RED
J32
J11
B
R
Wire #1 connects
to electrode wire (-)
terminal (J28) Wire #2 connects to work
lead (+) terminal (J27)
Transformer
wires
Cable passes through opening
in bottom of center panel
Powermax105/125
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