Hypertherm Powermax65 SYNC Troubleshooting Guide

System Diagrams
8
Powermax65/85/105 SYNC Troubleshooting Guide 810430 177
Powermax105 SYNC schematic – CSA models and 230 V – 400 V CE models
MICRO SD
CARD READER
(HYPERTHERM
USE ONLY)
DIAGNOSTIC LEDs
(INTERNAL-FACING SIDE OF DSP BOARD)
D10 – POWER (GRN)
D5 – RESET (RED)
D4 – STATUS (BLUE)
+
+
+–
~~~
+–
DSP BOARD
PCB2 / 141421
5 4321
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
1234
3
&
%
:
&
-
#
-
6
#
-
,
SYSTEM
FAN
(F1)
+48
FAN
SPEED
FAN
DRIVE
321
8
)
5
8
)
5
HEATSINK
THERMISTOR
THRM1
HEATSINK
TEMP
J1J2
1234
#
-
,
+24
GAS
CONNECTED
J5
5
SWITCH
STATE
#
-
,
AUX
SWITCH
IN S1
J6
J6
CONTROL BOARD
PCB1 / 141472
LCD
DISPLAY
J6
10 POSITION RIBBON CABLE
J11
1
2
BLK
RED
TO
PILOT
IGBT
PILOT ARC COMMON
PILOT ARC IGBT DRIVE
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
J17
J18
BLU
ORG
VIO
YEL
WHT
RED
BRN
GRY
1
RED
2
3
4
BLK
WHT
GRN
MECH START
TRANSFER
12
4
5
6
7
3
9
81011
121314
PWR
XFR
SEC
OPTIONAL
MACHINE
INTERFACE
KIT 528045
BLK
CONNECTOR
LOCATED ON
REAR PANEL
(EXTERIOR VIEW)
JI
BLK
J2
BLK
J3
RED
J5
GRN
VOLTAGE DIVIDER
BOARD
PCB4
RED
TO
J32
R180 5 OHM
D37
D36
OUTPUT
DIODES
I
FB
BLK
BLK
BLK
RED
TO
J11
TRANSFER
SENSOR
PILOT ARC IGBT
Q13
J27
J28
1
2
BLK
RED
TO
PCB4
RED
NOZZLE
ELECTRODE
OUTPUT
INDUCTOR
TO OUTPUT
DIODES
PRIMARY
PWR XFR
R201
15 OHM
3
&
%
J22
3
&
%
J21
INVERTER IGBT Q12
3
&
%
J20
3
&
%
J19
J26
C152 C151
760 VDC
R202 5 OHM
PFC INDUCTOR
J25
SOFT START
TO D38 +
S1
TO
J5
AUX
SW
J12
J16
J14
J13
D38
TO J12
3 OHM
TO
3 OHM
PE
PE GROUND
TO HEATSINK
AC
FERRITE CORES
230 V – 400 V CE MODELS ONLY
PFC
TEMP
SENSOR
PFC IGBT Q11
WORK
CLAMP
12
+24
/MM
GRN/YEL
230 V – 400 V CE MODELS
CONNECT WIRES
TO J13, J14, J16
CSA MODELS
CONNECT
WIRES TO
D38
EMI FILTER
230 V – 400 V CE
MODELS ONLY
J31 J30
24 V / 0.1 A MAX
GRN/YEL

0
20:1
TORCH
SOCKET
TORCH
SOCKET
CENTER
PIN
FACTORY SET
50:1
J32
QUICK-
DISCONNECT
+
–
RED
WHITE
9
COMMON
BLK
SEE TORCH
BELOW
TP9
(B)
TP7
(R)
TP8
(W)
TORCH SOCKET
FRONT PANEL
EXTERIOR VIEW
POWER BOARD
PCB 3
141458 (CSA)
141409 (230 V – 400 V CE)
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)
L1 BLK (CSA) / BRN (CE/CCC)
L2 WHT (CSA) / BLK (CE/CCC)
L3 RED (CSA) / GRY (CE/CCC)
L1 L2 L3
T1 T2 T3
#
-
,
3
&
%
J4
RED
SOLENOID VALVE
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
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