Hypertherm Powermax65 SYNC Troubleshooting Guide

System Diagrams
8
178 810430 Troubleshooting Guide Powermax65/85/105 SYNC
Powermax105 SYNC schematic – 380 V CCC models and 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 (BLU)
+
+
+
–
~~~
+–
+
–
(TP = TEST POINT)
DSP BOARD
PCB2 / 141421
5 4 3 2 1
3
&
%
#
-
,
#
3
/
8
)
5
(
3
/
J2
J1
OPTIONAL RS-485 BOARD
PCB5 / 141109
KIT 228539
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)










1234
3
&
%
:
&
-
#
-
6
#
-
,
SYSTEM
FAN
(F1)
+48
FAN
SPEED
FAN
DRIVE
321
8
)
5
8
)
5
HEATSINK
THERMISTOR
THRM1
HEATSINK
TEMP
J1J2
8910
8
)
5
8
)
5
8
)
5
+5
GAS
PRESSURE
1234
#
-
,
+24
GAS
CONNECTED
J5
5
SWITCH
STATE
#
-
,
AUX
SWITCH
IN S1
J6
4321567
#
-
,
8
)
5
3
&
%
:
&
-
ELECTRONIC
REGULATOR ER1
VALVE
ID
+24
FILL
ACTIVATE
DUMP
ACTIVATE
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
9
10
8
7
6
5
4
3
2
1
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
J4
RED
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
#
-
,
J21
INVERTER IGBT Q12
J26
C152 C151
PFC INDUCTOR
J25
SOFT START
S1
TO
J5
AUX
SW
J16
J14
J13
D38
PE
PE GROUND
TO HEATSINK
AC
FERRITE CORES
WORK
CLAMP
12
+24
/MM
GRN/YEL
J31 J30
24 V / 0.1 A MAX
GRN/YEL

20:1
TORCH
SOCKET
TORCH
SOCKET
CENTER
PIN
FACTORY SET
50:1
J32
+48
QUICK-
DISCONNECT
APPROX 540 VDC
EMI FILTER
J3
RED
WHITE
CAP SENSOR SWITCH INPUT
+18 VOLTS
TRIGGER SWITCH INPUT
MECH TORCH INDICATOR PIN
LEAD LENGTH PIN 0
LEAD LENGTH PIN 1
485A
485B
COMMON
BLK
POWER BOARD
PCB3
141460
SEE TORCH
BELOW
TORCH SOCKET
FRONT PANEL
EXTERIOR VIEW
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
3
&
%
#
-
,
TP8 (W)
TP9 (B)
TP7 (R)
L1 BRN
L2 BLK
L3 GRY
L1 L2 L3
T1 T2 T3
#
-
,
3
&
%
J5
GRN
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