Hypertherm Powermax65 SYNC

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Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Powermax65/85 SYNC

Service Parts and Procedures Guide

810440

REVISION 0

ENGLISH

Original instructions

October 2021

Main Page

Table of Contents7
Before You Begin11
Service Parts13
Plasma Power Supply Exterior, Front14
Work Leads15
Powermax65 SYNC15
Powermax85 SYNC16
Plasma Power Supply Exterior, Rear17
Power Cord and Strain Relief18
Rear Panel19
Plasma Power Supply Interior, Rear20
Plasma Power Supply Interior, Fan Side21
Fan and Fan Shroud23
Plasma Power Supply Interior, Front24
Front Panel25
Plasma Power Supply Interior, Power PCB Side26
Capacitors and DSP PCB27
Plasma Power Supply Interior, Heatsink28
65 A/85 a Heatsink Diode Bridges28
65 A/85 a Heatsink Igbts and Thermal Sensor30
IGBT Tester31
65 A/85 a Heatsink Resistors32
Power Supply Interior, Magnetics33
Machine Interface and RS-485 Serial Interface Upgrade Kits35
External Cables for Machine Interface Receptacle and RS-485 Serial Interface Receptacle36
Machine Interface Cables36
RS-485 Serial Interface Cables37
Powermax65/85/105 SYNC Labels38
Cartridge Labels38
CSA Warning Label39
Descriptions of Warning Label Icons40
Parts Necessary for Safety41
Recommended Spare Parts42
Find Replacement Parts by Part Number44
Service Procedures for the Cover, Panels, and Connectors47
Tools Necessary for this Section48
More Tools Necessary for some Procedures48
Replace the Plasma Power Supply Cover and Component Barrier49
Remove the Plasma Power Supply Cover and Component Barrier49
Install the Component Barrier and Plasma Power Supply Cover51
Replace the End Panel Bracket53
Remove the End Panel Bracket53
Install the End Panel Bracket54
Loosen and Attach the Front Panel55
Loosen the Front Panel55
Attach the Front Panel56
Loosen and Attach the Rear Panel57
Loosen the Rear Panel57
Attach the Rear Panel of the Plasma Power Supply58
Replace the Front Panel59
Remove the Front Panel59
Install the Front Panel59
Replace the Rear Panel60
Remove the Rear Panel60
Install the Rear Panel63
Replace the Work Lead Connector67
Remove the Work Lead Connector67
Install the Work Lead Connector67
Replace the Work Lead Receptacle69
Remove the Work Lead Receptacle69
Install the Work Lead Receptacle70
Replace the Torch Quick-Disconnect Receptacle71
Remove the Torch Quick-Disconnect Receptacle71
Install the Torch Quick-Disconnect Receptacle73
Replace the Power Switch75
Remove the Power Switch75
Install the Power Switch76
Service Procedures for the Gas Line79
Tools Necessary for this Section80
More Tools Necessary for some Procedures80
Replace the Air Filter Bowl and Filter Element81
Remove the Air Filter Bowl and Filter Element81
Replace the Air Filter Bowl, O-Ring, and Filter Element82
Install the Air Filter Bowl and Filter Element83
Replace the Air Filter Assembly83
Remove the Air Filter Assembly83
Install the Air Filter Assembly84
Replace the Fan and Fan Shroud85
Remove the Fan and Fan Shroud85
Install the Fan and Fan Shroud87
Replace the Solenoid Valve88
Remove the Solenoid Valve88
Install the Solenoid Valve89
Replace the Gas Tubes91
Remove the Gas Tubes91
Install the Gas Tubes91
Replace the 90° Gas Tube Fitting92
Service Procedures for the Pcbs and Related Components93
Tools Necessary for this Section94
More Tools Necessary to for some Procedures94
Replace the DSP PCB95
Replace the Control PCB and the Ribbon Cable96
Remove the Control PCB and the Ribbon Cable96
Install the Control PCB and the Ribbon Cable97
Replace the Power PCB98
Remove the Power PCB98
Install the Power PCB101
Replace the Heatsink Components105
Replace the Output Diode Bridge106
Replace the Input Diode Bridge108
Replace the Pilot Arc IGBT110
Replace the Inverter IGBT and the Thermal Sensor112
Replace the PFC IGBT114
Replace the Snubber Resistors and the Damper Resistor116
How to Clean the Heatsink and Apply Thermal Grease to the Heatsink Components118
Remove the Grease from the Heatsink118
Apply the Grease to the Heatsink Component118
Replace the Power PCB Capacitors119
Replace the Bulk Capacitors121
Remove the Bulk Capacitors121
Install the Bulk Capacitors123
Service Procedures for the Magnetics125
Tools Necessary for this Section126
Replace the Output Inductor127
Remove the Output Inductor127
Install the Output Inductor128
Replace the Transformer130
Remove the Transformer130
Install the Transformer131
Replace the PFC Inductor134
Remove the PFC Inductor134
Install the PFC135

Hypertherm Powermax65 SYNC - Page 3

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