Hypertherm Powermax65 SYNC User Manual

Powermax65/85 SYNC™
Service Parts and Procedures Guide
810440 – REVISION 0
ENGLISH

Hypertherm Powermax65 SYNC Specifications

General

Rated Output Current	65 A
Maximum Open-Circuit Voltage (OCV)	300 VDC
Input Voltage	200-600V, 3-phase
Air Flow	127 l/min
Gas Supply	Clean, dry air or nitrogen
Torch Lead Length	25' (7.6 m)
Engine Drive Requirement	12 kW
Certifications	CSA
Max Cutting Thickness	3/4" (20 mm)

Summary

Before You Begin

Service Parts

Plasma power supply exterior, front

Details front external components and their part numbers.

Work leads

Information and part numbers for work leads and connectors.

Plasma power supply exterior, rear

Details rear external components, including air filter fittings.

Power cord and strain relief

Part numbers for power cords and associated strain relief components.

Rear panel

Components and labels associated with the rear panel.

Plasma power supply interior, rear

Internal components located on the rear side of the power supply.

Plasma power supply interior, fan side

Internal components on the fan side, including air filter.

Plasma power supply interior, front

Internal components on the front side, including PCBs and connectors.

Plasma power supply interior, power PCB side

Internal components on the power PCB side, including component barrier.

Plasma power supply interior, heatsink

Internal components on the heatsink, including diode bridges.

65 A/85 A heatsink IGBTs and thermal sensor

Details IGBTs and thermal sensors mounted on the heatsink.

65 A/85 A heatsink resistors

Details of snubber and damper resistors on the heatsink.

Power supply interior, magnetics

Internal magnetic components like inductors and transformers.

Find replacement parts by part number

Index of replacement parts listed by their part number.

Service Procedures for the Cover, Panels, and Connectors

Tools necessary for this section

Lists tools required for cover, panel, and connector service procedures.

Replace the plasma power supply cover and component barrier

Procedure to remove and install the outer cover and internal component barrier.

Replace the end panel bracket

Procedure to remove and install the end panel bracket.

Loosen and attach the front panel

Steps to loosen and reattach the front panel for access.

Loosen and attach the rear panel

Steps to loosen and reattach the rear panel for access.

Replace the front panel

Detailed steps for removing and installing the front panel.

Replace the rear panel

Detailed steps for removing and installing the rear panel.

Replace the work lead connector

Procedure to replace the connector for the work lead cable.

Replace the work lead receptacle

Procedure to replace the receptacle for the work lead.

Replace the torch quick-disconnect receptacle

Procedure to replace the torch quick-disconnect receptacle.

Replace the power switch

Procedure to remove and install the main power switch.

Service Procedures for the Gas Line

Tools necessary for this section

Lists tools required for gas line service procedures.

Replace the air filter bowl and filter element

Procedure to replace the air filter bowl and its element.

Replace the air filter assembly

Procedure to remove and install the entire air filter assembly.

Replace the fan and fan shroud

Procedure to remove and install the cooling fan and its shroud.

Replace the solenoid valve

Procedure to remove and install the gas solenoid valve.

Replace the gas tubes

Procedure to replace the tubes in the gas line assembly.

Replace the 90° gas tube fitting

Procedure to replace the 90-degree fitting for gas tubes.

Service Procedures for the PCBs and Related Components

Tools necessary for this section

Lists tools required for PCB and related component service.

Replace the DSP PCB

Procedure to replace the Digital Signal Processor (DSP) Printed Circuit Board.

Replace the control PCB and the ribbon cable

Procedure to replace the control PCB and its connecting ribbon cable.

Replace the power PCB

Procedure to remove and install the main power Printed Circuit Board.

Replace the heatsink components

Procedures for replacing various components mounted on heatsinks.

Replace the output diode bridge

Procedure to replace the output diode bridge on the heatsink.

Replace the input diode bridge

Procedure to replace the input diode bridge on the heatsink.

Replace the pilot arc IGBT

Procedure to replace the pilot arc Insulated Gate Bipolar Transistor (IGBT).

Replace the inverter IGBT and the thermal sensor

Procedure to replace the inverter IGBT and its thermal sensor.

Replace the PFC IGBT

Procedure to replace the Power Factor Correction (PFC) IGBT.

Replace the snubber resistors and the damper resistor

Procedure to replace snubber and damper resistors.

Replace the power PCB capacitors

Procedure to replace the capacitors on the power PCB.

Replace the bulk capacitors

Procedure to replace the large bulk capacitors.

Service Procedures for the Magnetics

Tools necessary for this section

Lists tools required for magnetic component service.

Replace the output inductor

Procedure to remove and install the output inductor.

Replace the transformer

Procedure to remove and install the main transformer.

Replace the PFC inductor

Procedure to remove and install the Power Factor Correction (PFC) inductor.