Hypertherm Powermax65 SYNC Troubleshooting Guide

System Diagrams
8
Powermax65/85/105 SYNC Troubleshooting Guide 810430 175
Powermax65/85 SYNC schematic – CSA models
MICRO SD
CARD READER
(HYPERTHERM
USE ONLY)
DIAGNOSTIC LEDs
(INTERNAL-FACING SIDE OF DSP BOARD)
D10 – POWER (GRN)
D5 – RESET (RED)
D4 – STATUS (BLU)
C152
+
C151
+
+
0.1 A MAX
J31 J30
24 V
J29
PFC IGBT
Q11
INVERTER IGBT
Q12
J23
J26
J28
D48
D51
PWR
XFR
SEC
OUTPUT
DIODES
I
FB
BLK
BLK
BLK
RED
TO
J12
TRANSFER
SENSOR
PILOT ARC IGBT
Q13
R197
R194
DSP BOARD
PCB2 / 141421
5 4 3 2 1
3
&
%
#
-
,
#
3
/
8
)
5
(
3
/
J2
J1
RS-485 TX + (RED)
RS-485 TX - (BLK)
RS-485 RX + (BRN)
RS-485 RX - (WHT)
RS-485 GND (GRN)
SERIAL CONNECTOR
(POWER SUPPLY
REAR PANEL)










J3
123 4
#
-
,
AUX
SW
IN S1
+24
PWR SW
ON
321
8
)
5
8
)
5
HEATSINK
TEMP
J1J2
123
3
&
%
(
3
/
#
-
6
FAN
J3
J6
CONTROL BOARD
PCB1 / 141474
LCD
DISPLAY
J6
10 POSITION RIBBON CABLE
GRN/YEL

5
GAS
CON
HEATSINK
THERMISTOR
THRM1
#
-
,
4
+48
FAN
SPEED
FAN PWM
DRVD
#
-
,
J4
BLK
RED
TO
PILOT
IGBT
J12
1
2
PILOT ARC COMMON
PILOT ARC IGBT DRIVE
TO
3 OHM
8
7
6
5
4
3
2
1
CAP SENSOR SWITCH INPUT
+18 VOLTS
TRIGGER SWITCH INPUT
MECH TORCH INDICATOR PIN
LEAD LENGTH PIN 0
LEAD LENGTH PIN 1
485A
485B
J20
BLU
ORG
VIO
YEL
WHT
RED
BRN
GRY
9
COMMON
BLK
J21
1
RED
2
3
4
BLK
WHT
GRN
MECH START
TRANSFER
+24
/MACHINE MOTION
12
4
5
6
7
3
9
81011
121314
OPTIONAL
MACHINE
INTERFACE
KIT 228697
BLK
CONNECTOR
LOCATED ON
REAR PANEL
(EXTERIOR VIEW)
JI
BLK
J2
BLK
J3
RED
J5
GRN
VOLTAGE DIVIDER
BOARD
PCB4
RED
TO
J32
GRN/YEL
FACTORY SET
50:1
NOZZLE
ELECTRODE
WORK
CLAMP
12
TORCH
SOCKET
TORCH
SOCKET
CENTER
PIN
QUICK-
DISCONNECT
RED
WHITE
RED
J19
#
-
,
3
&
%
#
-
,
3
&
%
J17 J16
R198
15 OHM
TO OUTPUT
DIODES
PRIMARY
PWR XFR
PFC INDUCTOR
AC
+
~~~
J18
D50
#
-
,
3
&
%
#
-
,
3
&
%
1
2
BLK
RED
TO
PCB4
20:1
J32
PE
PE GROUND
TO HEATSINK
L1 L2 L3
T1 T2 T3
AUX
SW
S1
TO
J1
#
-
,
3
&
%
L1 BLK
L2 WHT
L3 RED
GRN
CONTROL GND
TO HEATSINK
MTG8
TP11 (W)
TP10 (R)
TP12
(B)
OUTPUT
INDUCTOR
SEE TORCH
BELOW
TORCH SOCKET
FRONT PANEL
EXTERIOR VIEW
POWER BOARD
PCB 3
141440 (65 A)
141443 (85 A)
FERRITE CORES
BLK
BLK
1
2
3
4
5
BLU
6
VIO
7
ORG
8
BLK
9
BRN
10
GRY
11
YEL
12
WHT
13
RED
14
15
16
17
OPTIONAL RS-485 BOARD
PCB5 / 141109
KIT 228539
(TP = TEST POINT)
J18
J4
RED
8910
8
)
5
8
)
5
8
)
5
+5
GAS
PRESSURE
4321567
#
-
,
8
)
5
3
&
%
:
&
-
ELECTRONIC
REGULATOR ER1
VALVE
ID
+24
FILL
ACTIVATE
DUMP
ACTIVATE
+48
SOLENOID VALVE
CAP SENSOR
RFID ANTENNA
654321
485 A
485 B
COMMON
INTERLOCK
+18V
CAP SENSOR
TORCH SOCKET
FRONT PANEL
EXTERIOR VIEW
654321
485 A
485 B
COMMON
INTERLOCK
+18V
CAP SENSOR
1
2
CURRENT SELECT
STATUS LED DISPLAY
TORCH-LOCK
SWITCH
TORCH-LOCK
SWITCH
RFID ANTENNA
TORCH SOCKET
FRONT PANEL
EXTERIOR VIEW
CAP SENSOR
START
BLU ORG VIO BLK GRY BRN BLU ORG RED BLK GRY BRN
BLK
BLK
1
2
3
4
5
BLU
6
VIO
7
ORG
8
BLK
9
BRN
10
GRY
11
YEL
12
WHT
13
RED
14
15
16
17
BLK
BLK
1
2
3
4
5
BLU
6
VIO
7
ORG
8
BLK
9
BRN
10
GRY
11
YEL
12
WHT
13
RED
14
15
16
17
MECHANIZED
TORCH
BOARD
(STANDARD
TORCH)
HAND
TORCH
BOARD
(STANDARD TORCH SHOWN –
MINI MECHANIZED TORCH
DOES NOT HAVE
TORCH-LOCK SWITCH)
MCU
RFID

Hypertherm Powermax65 SYNC Specifications

General

Brand	Hypertherm
Model	Powermax65 SYNC
Category	Welding System
Language	English