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Hypertherm Powermax65 SYNC User Manual
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Hypertherm, Inc.
Hanover
, N
H 03
755 U
SA
www
.hypertherm.com
Powerma
x6
5
/85
SY
N
C
Service P
arts and Procedures Guide
8
1
0440
R
EVI
S
I
ON
0
EN
GL
IS
H
Original instructions
October
2021
2
4
Table of Contents
Table of Contents
7
Before You Begin
11
Service Parts
13
Plasma Power Supply Exterior, Front
14
Work Leads
15
Powermax65 SYNC
15
Powermax85 SYNC
16
Plasma Power Supply Exterior, Rear
17
Power Cord and Strain Relief
18
Rear Panel
19
Plasma Power Supply Interior, Rear
20
Plasma Power Supply Interior, Fan Side
21
Fan and Fan Shroud
23
Plasma Power Supply Interior, Front
24
Front Panel
25
Plasma Power Supply Interior, Power PCB Side
26
Capacitors and DSP PCB
27
Plasma Power Supply Interior, Heatsink
28
65 A/85 a Heatsink Diode Bridges
28
65 A/85 a Heatsink Igbts and Thermal Sensor
30
IGBT Tester
31
65 A/85 a Heatsink Resistors
32
Power Supply Interior, Magnetics
33
Machine Interface and RS-485 Serial Interface Upgrade Kits
35
External Cables for Machine Interface Receptacle and RS-485 Serial Interface Receptacle
36
Machine Interface Cables
36
RS-485 Serial Interface Cables
37
Powermax65/85/105 SYNC Labels
38
Cartridge Labels
38
CSA Warning Label
39
Descriptions of Warning Label Icons
40
Parts Necessary for Safety
41
Recommended Spare Parts
42
Find Replacement Parts by Part Number
44
Service Procedures for the Cover, Panels, and Connectors
47
Tools Necessary for this Section
48
More Tools Necessary for some Procedures
48
Replace the Plasma Power Supply Cover and Component Barrier
49
Remove the Plasma Power Supply Cover and Component Barrier
49
Install the Component Barrier and Plasma Power Supply Cover
51
Replace the End Panel Bracket
53
Remove the End Panel Bracket
53
Install the End Panel Bracket
54
Loosen and Attach the Front Panel
55
Loosen the Front Panel
55
Attach the Front Panel
56
Loosen and Attach the Rear Panel
57
Loosen the Rear Panel
57
Attach the Rear Panel of the Plasma Power Supply
58
Replace the Front Panel
59
Remove the Front Panel
59
Install the Front Panel
59
Replace the Rear Panel
60
Remove the Rear Panel
60
Install the Rear Panel
63
Replace the Work Lead Connector
67
Remove the Work Lead Connector
67
Install the Work Lead Connector
67
Replace the Work Lead Receptacle
69
Remove the Work Lead Receptacle
69
Install the Work Lead Receptacle
70
Replace the Torch Quick-Disconnect Receptacle
71
Remove the Torch Quick-Disconnect Receptacle
71
Install the Torch Quick-Disconnect Receptacle
73
Replace the Power Switch
75
Remove the Power Switch
75
Install the Power Switch
76
Service Procedures for the Gas Line
79
Tools Necessary for this Section
80
More Tools Necessary for some Procedures
80
Replace the Air Filter Bowl and Filter Element
81
Remove the Air Filter Bowl and Filter Element
81
Replace the Air Filter Bowl, O-Ring, and Filter Element
82
Install the Air Filter Bowl and Filter Element
83
Replace the Air Filter Assembly
83
Remove the Air Filter Assembly
83
Install the Air Filter Assembly
84
Replace the Fan and Fan Shroud
85
Remove the Fan and Fan Shroud
85
Install the Fan and Fan Shroud
87
Replace the Solenoid Valve
88
Remove the Solenoid Valve
88
Install the Solenoid Valve
89
Replace the Gas Tubes
91
Remove the Gas Tubes
91
Install the Gas Tubes
91
Replace the 90° Gas Tube Fitting
92
Service Procedures for the Pcbs and Related Components
93
Tools Necessary for this Section
94
More Tools Necessary to for some Procedures
94
Replace the DSP PCB
95
Replace the Control PCB and the Ribbon Cable
96
Remove the Control PCB and the Ribbon Cable
96
Install the Control PCB and the Ribbon Cable
97
Replace the Power PCB
98
Remove the Power PCB
98
Install the Power PCB
101
Replace the Heatsink Components
105
Replace the Output Diode Bridge
106
Replace the Input Diode Bridge
108
Replace the Pilot Arc IGBT
110
Replace the Inverter IGBT and the Thermal Sensor
112
Replace the PFC IGBT
114
Replace the Snubber Resistors and the Damper Resistor
116
How to Clean the Heatsink and Apply Thermal Grease to the Heatsink Components
118
Remove the Grease from the Heatsink
118
Apply the Grease to the Heatsink Component
118
Replace the Power PCB Capacitors
119
Replace the Bulk Capacitors
121
Remove the Bulk Capacitors
121
Install the Bulk Capacitors
123
Service Procedures for the Magnetics
125
Tools Necessary for this Section
126
Replace the Output Inductor
127
Remove the Output Inductor
127
Install the Output Inductor
128
Replace the Transformer
130
Remove the Transformer
130
Install the Transformer
131
Replace the PFC Inductor
134
Remove the PFC Inductor
134
Install the PFC
135
Other manuals for Hypertherm Powermax65 SYNC
Troubleshooting Guide
180 pages
Reference Guide
79 pages
4
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Hypertherm Powermax65 SYNC Specifications
General
Brand
Hypertherm
Model
Powermax65 SYNC
Category
Welding System
Language
English
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