Hypertherm Manual Family Service Manual (SM)

Powermax65/85 SYNC™

Service Parts and Procedures Guide

810440 – REVISION 0

ENGLISH

Powermax, SYNC, SmartSYNC, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.

100% Associate-owned

Powermax65/85 SYNC

Service Parts and Procedures Guide

810440

REVISION 0

ENGLISH

Original instructions

October 2021

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel 52 55 5681 7978 Tel soporte.tecnico@hypertherm.com (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5 63452 Hanau Germany 00 800 33 24 97 37 Tel 00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164 164 Kallang Way #03-13 Singapore 349248, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax marketing.asia@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax htjapan.info@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road Shanghai, 200231 PR China 86-21-80231122 Tel 86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

techsupport.china@hypertherm.com (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil CEP 07115-030 55 11 2409 2636 Tel tecnico.sa@hypertherm.com (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan. Korea 48060 82 (0)51 747 0358 Tel 82 (0)51 701 0358 Fax marketing.korea@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Pty Limited

GPO Box 4836 Sydney NSW 2001, Australia 61 7 3103 1695 Tel 61 7 3219 9010 Fax au.sales@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension, Mohan Co-Operative Industrial Estate, Mathura Road, New Delhi 110044, India 91-11-40521201/ 2/ 3 Tel 91-11 40521204 Fax htindia.info@hypertherm.com (Main Office) technicalservice.emeia@hypertherm.com (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment. Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple languages at www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité (80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C) et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme électronique ou papier. Les manuels sous forme électronique se trouvent également sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues à www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен и в печатен формат. Тези в електронен формат са достъпни също на уебсайта ни. Много ръководства са налице на няколко езика на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C), Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C), og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format. Elektroniske kopier findes også på vores hjemmeside. Mange manualer er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für HochfrequenzWarnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C). El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C), Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend (80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna. Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισό της Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις ραδιοσυχνότητες (80945C).

Το προϊόν πορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική και έντυπη ορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό ας. Πολλά εγχειρίδια είναι διαθέσια σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan (80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità (80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されています。電子コピーは当社ウェブサイトにも掲載されています。説明書の多くは www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (한국어 /KOREAN)

경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수 설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선 주파수 경고 설명서(80945C)에 나와 있는 안전 지침을 읽으십시오.

전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될 수 있습니다. 전자 사본도 Hypertherm 웹사이트에서 보실 수 있으며 설명서 사본은

www.hypertherm.com/docs 에서 여러 언어로 제공됩니다.

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C). De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form. Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker er tilgjengelig i flere språk på www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format. Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C), podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C) oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej. Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança e de Conformidade do Waterjet (80943C) e no Manual de Advertência de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso. Cópias eletrônicas também são encontradas em nosso website. Muitos manuais estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citii instruciunile de sigurană din manualul produsului, manualul de siguranță și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C) și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoit de copii ale manualelor în format tipărit și electronic. Exemplarele electronice sunt disponibile și pe site-ul nostru web. Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь с инструкциями по безопасности, представленными в руководстве, которое поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для водоструйной резки (80943C) и Руководстве по предупреждению о радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть представлены в электронном и бумажном виде. Электронные копии также доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/S LOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade snormami pre systém rezania vodou (80943C) avManuáli sinformáciami orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe. Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

TH (ภาษาไทย/THAI)

คําเตือน! กอนการใชงานอุปกรณของ Hypertherm ทั้งหมด โปรดอานคําแนะนําดานความ ปลอดภัยในคูมือการใชสินคา คูมือดานความปลอดภัยและการปฏิบัติตาม (80669C), คูมือ ดานความปลอดภัยและการปฏิบัติตามสําหรับการใชหัวตัดระบบวอเตอรเจ็ต (80943C) และ คูมือคําเตือนเกี่ยวกับความถี่วิทยุ (80945C) การไมปฏิบัติตามคําแนะนําดานความ ปลอดภัยอาจสงผลใหเกิดการบาดเจ็บหรือเกิดความเสียหายตออุปกรณ

สําเนาคูมือทั้งในรูปแบบอิเล็กทรอนิกสและแบบสิ่งพิมพจะถูกแนบมาพรอมกับ ผลิตภัณฑ สําเนาคูมือในรูปแบบอิเล็กทรอนิกสของผลิตภัณฑและสําเนาคูมือตาง ๆ ในหลากหลายภาษานั้นยังมีใหบริการบนเว็บไซต www.hypertherm.com/docs ของเราอีกดวย

TR (TÜRKÇE/TURKISH)

UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda (80945C) yer alan güvenlik talimatlarını okuyun.

Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir. Elektronik kopyalar web sitemizde de yer alır. Kılavuzların birçoğu www.hypertherm.com/docs adresinde birçok dilde mevcuttur.

VI (TIẾNG VIỆT/VIETNAMESE)

CẢNH BÁO! Trước khi vận hành bất kỳ thiết bị Hypertherm nào, hãy đọc các hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn,

và Tuân thủ dẫn Cảnh báo Tần số Vô tuyến

có thể dẫn đến thương tích cá nhân hoặc hư hỏng thiết bị. Bản sao của sổ tay có thể đi kèm với sản phẩm ở định dạng điện tử và in. Bản

điện tử cũng có trên trang web của chúng tôi. Nhiều sổ tay có sẵn bằng nhiều ngôn ngữ tại www.hypertherm.com/docs.

ZH-CN (简体中文/CHINESE SIMPLIFIED)

警告！在操作任何海宝设备之前，请阅读产品手册、《安全和法规遵守手册》 (80669C)、《水射流安全和法规遵守手册》 (80943C) 以及《射频警告手册》 (80945C) 中的安全操作说明。

随产品提供的手册可提供电子版和印刷版两种格式。电子版本同时也在我们的网站上提供。很多手册有多种语言版本，详见 www.hypertherm.com/docs.

ZH-TW (繁體中文/CHINESE TRADITIONAL)

警告！在操作任何Hypertherm設備前，請先閱讀您產品手冊內的安全指示，包括《安全和法規遵從手冊》(80669C)、《水刀安全和法規遵從手冊》

（80943C），以及《無線電頻率警示訊號手冊》（80945C）。

電子版和印刷版手冊複本可能隨產品附上。您也可以前往我們的網站下載電子版手冊。我們的網站上還以多種語言形式提供多種手冊，請造訪

www.hypertherm.com/docs。

(80669C),

Sổ tay An toàn và Tuân thủ Tia nước

(80945C). Không tuân thủ các hướng dẫn an toàn

Sổ tay An toàn

(80943C), và

Hướng

SL (S LOVENŠČINA/ SLOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C), v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C) in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном формату. Електронске копије су такође доступне на нашем веб-сајту. Многи приручници су доступни на више језика на адреси www.hypertherm.com/docs.

1 Before You Begin....................................................................................................................... 11

2 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

Powermax65/85 SYNC Service Parts and Procedures 810440 7

Contents

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

3 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

8 810440 Service Parts and Procedures Powermax65/85 SYNC

Contents

Replace the power switch................................................................................................................................. 75

Remove the power switch..................................................................................................................... 75

Install the power switch ......................................................................................................................... 76

4 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

5 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

Powermax65/85 SYNC Service Parts and Procedures 810440 9

Contents

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

6 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

10 810440 Service Parts and Procedures Powermax65/85 SYNC

Before You Begin

This manual has service parts and procedures for the plasma power supply only. For torch service parts and procedures, refer to SmartSYNC™ Service Parts and Procedures Guide (810460).

This manual helps you do the following:

 Install replacement parts that you already have

 Refer to Service Procedures for the Cover, Panels, and Connectors on page 47.  Refer to Service Procedures for the Gas Line on page 79.  Refer to Service Procedures for the PCBs and Related Components on page 93.  Refer to Service Procedures for the Magnetics on page 125.

 Find the part number that you need to order

 Refer to Service Parts on page 13.  Refer to Find replacement parts by part number on page 44.

For assistance with repairing or replacing internal components, do the following:

1. Get the serial number for your system from the data plate that is on the rear panel of the plasma power supply.

2. Contact your Hypertherm distributor or authorized repair facility.

3. Contact the nearest Hypertherm office shown in the front of this manual.

Powermax65/85 SYNC Service Parts and Procedures 810440 11

Before You Begin

For related information, refer to the following documents:

 Powermax65/85/105 SYNC Troubleshooting Guide (810430)  SmartSYNC™ Service Parts and Procedures Guide (810460) (hand torches and

mechanized torches for Powermax SYNC)

The most recent revisions of technical documentation are available at www.hypertherm.com/docs.

Technical documentation is current as of the date of its release.



Subsequent revisions are possible.

12 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Parts

NOTICE

Genuine Hypertherm parts are factory-recommended parts for your Hypertherm system. Any damage caused by the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty.

This section gives a list of service parts for the plasma power supply. Many parts come as a kit that contains 2 or more items.

To find part numbers with kit contents, by location, refer to the following:

 Plasma power supply exterior, front on page 14  Plasma power supply exterior, rear on page 17  Plasma power supply interior, rear on page 20  Plasma power supply interior, fan side on page 21  Plasma power supply interior, front on page 24  Plasma power supply interior, power PCB side on page 26  Plasma power supply interior, heatsink on page 28  Power supply interior, magnetics on page 33  Machine interface and RS-485 serial interface upgrade kits on page 35  Powermax65/85/105 SYNC labels on page 38

To see a list of parts in order by part number, refer to Find replacement parts by part number on page 44.

Powermax65/85 SYNC Service Parts and Procedures 810440 13

Service Parts

Plasma power supply exterior, front

Item Part number Description

1 528009 Kit: Powermax65 SYNC plasma power supply cover with labels, CSA (no screws

included)

1 528010 Kit: Powermax65 SYNC plasma power supply cover with labels, CE/CCC (no screws

included)

1 528011 Kit: Powermax85 SYNC plasma power supply cover with labels, CSA (no screws

included)

1 528012 Kit: Powermax85 SYNC plasma power supply cover with labels, CE/CCC (no screws

included)

2 428143 Kit: Adjustment knob only

3 428141 Kit: Replacement screws (16) for plasma power supply cover

For replacement procedures, refer to Replace the plasma power supply cover and component

barrier on page 49.

14 810440 Service Parts and Procedures Powermax65/85 SYNC

Work leads

Hand clamp C-style clamp Ring terminal

2 3

4 5

Service Parts

NOTICE

Work leads are approved for specific amperages, lengths, and connectors. Make sure that you use a work lead that is approved for your plasma power supply. The amperage of a work lead is identified near the rubber boot of the work lead connector.

Powermax65 SYNC

Item Part number Description

1 223125 65 A work lead with hand clamp, 7.6 m (25 foot)

1 223126 65 A work lead with hand clamp, 15 m (50 foot)

1 223033 65 A / 85 A work lead with hand clamp, 23 m (75 foot)

2 223194 65 A work lead with C-style clamp, 7.6 m (25 foot)

3 223200 65 A work lead with ring terminal, 7.6 m (25 foot)

3 223201 65 A work lead with ring terminal, 15 m (50 foot)

3 223211 65 A / 85 A work lead with ring terminal, 23 m (75 foot)

4 008337 Ground hand clamp: 300 A

5 428921 Kit: C-style clamp with hardware

228709 Kit: Work lead connector

You can make a work lead for the Powermax65 SYNC and



Powermax85 SYNC by installing the 008337 hand clamp or the 428921

Powermax65/85 SYNC Service Parts and Procedures 810440 15

C-style clamp on the approved amperage ring terminal work lead from Hypertherm. Make sure that you use a work lead that is the correct amperage for your plasma power supply.

Service Parts

Powermax85 SYNC

Item Part number Description

1 223035 85 A work lead with hand clamp, 7.6 m (25 foot)

1 223034 85 A work lead with hand clamp, 15 m (50 foot)

1 223033 65 A / 85 A work lead with hand clamp, 23 m (75 foot)

3 223209 85 A work lead with ring terminal, 7.6 m (25 foot)

3 223210 85 A work lead with ring terminal, 15 m (50 foot)

3 223211 65 A / 85 A work lead with ring terminal, 23 m (75 foot)

4 008337 Ground hand clamp: 300 A

5 428921 Kit: C-style clamp with hardware

228709 Kit: Work lead connector

You can make a work lead for the Powermax65 SYNC and



Powermax85 SYNC by installing the 008337 hand clamp or the 428921 C-style clamp on the approved amperage ring terminal work lead from Hypertherm. Make sure that you use a work lead that is the correct amperage for your plasma power supply.

For replacement procedures, refer to Replace the work lead connector on page 67.

16 810440 Service Parts and Procedures Powermax65/85 SYNC

Plasma power supply exterior, rear

Service Parts

Item

Part number

1 428352 Kit: Air filter bowl, polycarbonate (comes with plasma power supply, includes the O-ring but not

2* 428415 Kit: Air filter bowl, nylon (optional – for work sites with oily air) (includes the O-ring but not the

3 228695 Kit: Air filter element and O-ring (compatible with both filter bowl types)

4 428685 Kit: Gas inlet fittings

027055 Silicone lubricant, 0.25 ounces

* The polycarbonate filter bowl that comes with the plasma power supply is compatible with most gas supply

systems, but it is important to keep the gas line clean. Organic solvents, chemicals, cutting oil, synthetic oil, alkali, and thread lock solutions can cause damage to the polycarbonate filter bowl over time. You can use the optional nylon bowl (428415) if conditions at your work site make it difficult to prevent harsh chemicals from getting into the gas line.

Description and kit contents

the filter element)

011124 Air filter bowl, polycarbonate

filter element)

011128 Air filter bowl, nylon

011093 Air filter element

011125 O-ring

015145 British Pipe Thread adapter G-1/4 BSPP with 1/4 NPT threads

015337 Industrial interchange quick-disconnect nipple with 1/4 NPT threads

For replacement procedures, refer to Replace the air filter bowl and filter element on page 81.

Powermax65/85 SYNC Service Parts and Procedures 810440 17

Service Parts

Power cord and strain relief

Item

Part number

5 228691 Kit: Powermax65/85 SYNC power cord with strain relief, CSA models, 3 m (10 foot)

6 528015 Kit: Powermax65 SYNC power cord with strain relief, CE/CCC models, 3 m (10 foot)

6 528016 Kit: Powermax85 SYNC power cord with strain relief, CE/CCC models, 3 m (10 foot)

7, 8 228680 Kit: Strain relief for Powermax65/85 SYNC power cords (all models)

Description and kit contents

229290 Power cord assembly 65 A/85 A CSA

108795 Strain relief 65 A/85 A CSA

229950 Power cord assembly 65 A CE/CCC

10 867 6 Strain relief 65 A/85 A CE

104456 Strain relief adapter

075765 Aluminum washer

229957 Power cord assembly 85 A CE/CCC

108676 Strain relief 65 A/85 A CE

10 445 6 Strain relief adapter

075765 Aluminum washer

108795 Strain relief 65 A/85 A CSA

10 867 6 Strain relief 65 A/85 A CE

104456 Strain relief adapter 65 A/85 A CE

075765 Aluminum washer

18 810440 Service Parts and Procedures Powermax65/85 SYNC

Rear panel

Service Parts

Item

Part number

9 528001 Kit: Powermax65/85 SYNC plasma power supply rear panel with screws and CPC port cover

Description and kit contents

010586 Label: Protect earth

075524 Screw: M5 X 16, pan head (2)

1010 33 Plasma power supply rear panel

104497 Self adhesive foam strip

10 88 67 CPC port cover

110711 Label: Power switch 65 A/85 A

CSA, CE, or CCC data plate for Powermax65 SYNC or Powermax85 SYNC (preapplied)

For replacement procedures, refer to Replace the rear panel on page 60.

Powermax65/85 SYNC Service Parts and Procedures 810440 19

Service Parts

Plasma power supply interior, rear

Item

Part number

1 228644 Kit: Powermax65 SYNC power switch CSA

1 228655 Kit: Powermax85 SYNC power switch CSA

1 228671 Kit: Powermax65/85 SYNC power switch CE/CCC

Description and kit contents

005257 Power switch

075760 Screw:#8 X 1/2, flat head (4)

10 885 8 Power switch handle

110711 Label: Power switch 65 A/85 A

003206 Power switch

075760 Screw: #8 X 1/2, flat head (4)

108858 Power switch handle

110711 Label: Power switch 65 A/85 A

005650 Power switch

075760 Screw: #8 X 1/2, flat head (4)

10 885 8 Power switch handle

110711 Label: Power switch 65 A/85 A

For replacement procedures, refer to Replace the power switch on page 75.

20 810440 Service Parts and Procedures Powermax65/85 SYNC

Plasma power supply interior, fan side

Service Parts

Item

Part number

428942 Kit: Air filter assembly (includes air filter, air filter bowl, air filter element, and O-ring)

Description and kit contents

429017 Air filter assembly

104990 Tubing: 8 mm outer diameter X 1.75 inches

10 44 87 Tubing: 8 mm outer diameter X 3.3 inches (optional – not shown)

Powermax65/85 SYNC Service Parts and Procedures 810440 21

Service Parts

Item

Part number

Description and kit contents

528053 Kit: Solenoid valve (includes gas tubes and screws)

429061 Solenoid valve

101508 Bracket

104488 Tubing: 5/16 inch outer diameter X 7.75 inches

104632 Tubing: 5/16 inch outer diameter X 12 inches

104990 Tubing: 8 mm outer diameter X 1.75 inches

075711 Screw: M4 X 12, pan head

528017 Kit: 90° gas tube fitting

015921 90° gas tube fitting

528065 Kit: Powermax65/85/105 SYNC Gas tubes

104487 Tubing: 8 mm outer diameter X 3.3 inches (optional – not shown)

104488 Tubing: 5/16 inch outer diameter X 7.75 inches

104632 Tubing: 5/16 inch outer diameter X 12 inches

104990 Tubing: 8 mm outer diameter X 1.75 inches

For replacement procedures, refer to the following:

 Replace the air filter assembly on page 83  Replace the solenoid valve on page 88  Replace the 90° gas tube fitting on page 92  Replace the gas tubes on page 91

22 810440 Service Parts and Procedures Powermax65/85 SYNC

Fan and fan shroud

Service Parts

Item

Part

number

428991 Kit: Powermax65/85 SYNC Fan assembly

228694 Kit: Powermax65/85 SYNC Fan shroud

Description and kit contents

429078 Fan assembly

075693 Screw: #6 X 1/2, pan head (4)

1010 30 Fan s h roud

For replacement procedures, refer to Replace the fan and fan shroud on page 85.

Powermax65/85 SYNC Service Parts and Procedures 810440 23

Service Parts

Plasma power supply interior, front

Item

1 528026 Kit: Control PCB and adjustment knob

2 428068 Kit: Ribbon cable for control PCB, 14 cm (5.5 inches)

3 428070 Kit: Powermax65/85 SYNC work lead receptacle

4 528024 Kit: Powermax65/85 SYNC torch quick-disconnect receptacle

Part

number

Description and kit contents

141472 Control PCB

108797 Adjustment knob

075418 Screw: #4 X 1/4, pan head (3)

223024 Ribbon cable that connects the control PCB to the DSP PCB

228364 Work lead receptacle

229884 Torch quick-disconnect receptacle housing

015920 Torch quick-disconnect receptacle

075899 Retention nut

075693 Screw: #6 X 1/2, pan head (4)

10 807 6 Grommet

For replacement procedures, refer to the following:

 Replace the control PCB and the ribbon cable on page 96  Replace the work lead receptacle on page 69  Replace the torch quick-disconnect receptacle on page 71

24 810440 Service Parts and Procedures Powermax65/85 SYNC

Front panel

Service Parts

Item

5 528000 Kit: Powermax65/85 SYNC plasma power supply front panel with screws

Part

number

Description and kit contents

002540 Gasket: LCD 65 A/85 A

075524 Screw: M5 X 16, pan head (2)

1010 6 3 Panel: Lens 65 A/85 A/105 A/125 A

101460 Panel: Plasma power supply front

10 44 97 Foam: Close cell black

210569 Label: Display panel 65 A/85 A

210596 Label: Hypertherm logo

For replacement procedures, refer to Replace the front panel on page 59.

Powermax65/85 SYNC Service Parts and Procedures 810440 25

Service Parts

Plasma power supply interior, power PCB side

Item

1 228705 Kit: Powermax65/85 SYNC component barrier

2 528029 Kit: Powermax65 SYNC power PCB CSA

2 528030 Kit: Powermax65 SYNC power PCB CE/CCC

2 528031 Kit: Powermax85 SYNC power PCB CSA

2 528032 Kit: Powermax85 SYNC power PCB CE/CCC

Part

number

Description and kit contents

075534 Screw: #6 X 5/16, pan head (4)

141440 Power PCB, 65 A CSA

075534 Screw: #6 X 5/16, pan head (4)

141477 Power PCB 65 A CE/CCC

075534 Screw: #6 X 5/16, pan head (4)

141443 Power PCB 85 A CSA

075534 Screw: #6 X 5/16, pan head (4)

141453 Power PCB 85 A CE/CCC

For replacement procedures, refer to the following:

 Replace the plasma power supply cover and component barrier on page 49  Replace the power PCB on page 98

26 810440 Service Parts and Procedures Powermax65/85 SYNC

Capacitors and DSP PCB

Service Parts

Item

3 428066 Kit: Power PCB capacitor

4 528028 Kit: DSP PCB

5 228683 Kit: Powermax65 SYNC bulk capacitor CSA

5 228684 Kit: Powermax65 SYNC bulk capacitor CE / CCC

Part

number

Description and kit contents

075569 Screw: M6 X 14-12.5, pan head (2)

075570 Screw: M5 X 14-12, pan head (2)

10 993 0 Capacitor: 3uF, 850 VDC

075766 Screw: M3 X 16, pan head (2)

108855 2-pin jumper (preinstalled on PCB)

141421 DSP PCB

210775 Label: “Save system data before you install this part” (not shown)

075570 Screw: M5 X 14-12, pan head (4)

109935 Capacitor: 2200uF, 500 VDC (2)

075570 Screw: M5 X 14-12, pan head (4)

109947 Capacitor: 3300uF, 400 VDC (2)

5 228681 Kit: Powermax85 SYNC bulk capacitor CSA

075570 Screw: M5 X 14-12, pan head (4)

109797 Capacitor: 3300uF, 500 VDC (2)

5 228682 Kit: Powermax85 SYNC bulk capacitor CE / CCC

075570 Screw: M5 X 14-12, pan head (4)

109948 Capacitor: 4400uF, 400 VDC (2)

For replacement procedures, refer to the following:

 Replace the power PCB capacitors on page 119  Replace the DSP PCB on page 95  Replace the bulk capacitors on page 121

Powermax65/85 SYNC Service Parts and Procedures 810440 27

Service Parts

CSA

CE/CCC

Plasma power supply interior, heatsink

You can purchase thermal grease separately.

Part number Description

128836 Thermal grease, 0.125 ounce

For replacement procedures, refer to How to clean the heatsink and apply thermal grease to the

heatsink components on page 118.

65 A/85 A heatsink diode bridges

Item

1 228803 Kit: Powermax65 SYNC output diode bridge

1 228804 Kit: Powermax85 SYNC output diode bridge

2 228742 Kit: Powermax65 SYNC (all models) and Powermax85 SYNC CE / CCC input diode bridge

Part

number

Description and kit contents

109804 Output diode (2)

075567 Screw: M6 X 16-12.5, pan head (4)

128836 Thermal grease, 0.125 ounce

109980 Output diode (2)

075567 Screw: M6 X 16-12.5, pan head (4)

128836 Thermal grease, 0.125 ounce

109931 Input diode bridge

075524 Screw: M5 X 16, pan head (2)

075570 Screw: M5 X 14-12, pan head (5)

128836 Thermal grease, 0.125 ounce

28 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Parts

Item

2 228741 Kit: Powermax85 SYNC CSA input diode bridge

Part

number

Description and kit contents

109801 Input diode bridge

075524 Screw: M5 X 16, pan head (2)

075570 Screw: M5 X 14-12, pan head (5)

128836 Thermal grease, 0.125 ounce

For replacement procedures, refer to the following:

 Replace the output diode bridge on page 106  Replace the input diode bridge on page 108

Powermax65/85 SYNC Service Parts and Procedures 810440 29

Service Parts

CSA

CE/CCC

5 5

65 A/85 A heatsink IGBTs and thermal sensor

Item

3 528042 Kit: Powermax65 SYNC pilot arc IGBT

3 528043 Kit: Powermax85 SYNC pilot arc IGBT

4 528040 Kit: Powermax65 SYNC CE/Powermax85 SYNC CSA inverter IGBT

Part

number

Description and kit contents

109239 Pilot arc IGBT

223739 Pilot arc cable

075567 Screw: M6 X 16-12.5, pan head (2)

075570 Screw: M5 X 14-12, pan head (2)

128836 Thermal grease, 0.125 ounce

109238 Pilot arc IGBT

223739 Pilot arc cable

075567 Screw: M6 X 16-12.5, pan head (2)

075570 Screw: M5 X 14-12, pan head (2)

128836 Thermal grease, 0.125 ounce

209444 Inverter IGBT

223738 PFC to inverter cable (2)

075567 Screw: M6 X 16-12.5, pan head (3)

075569 Screw: M6 X 14-12.5, pan head (3)

075851 Screw: M6 X 18.5±0.5 12.5, pan head

128836 Thermal grease, 0.125 ounce

4 528039 Kit: Powermax65 SYNC CSA inverter IGBT

109933 Inverter IGBT

223738 PFC to inverter cable (2)

075524 Screw: M5 X 16, pan head (2)

075570 Screw: M5 X 14-12, pan head (3)

128836 Thermal grease, 0.125 ounce

30 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Parts

Item

4 528046 Kit: Powermax85 SYNC CE inverter IGBT

5 428990 Kit: Thermal sensor (switch)

6 528041 Kit: Powermax65 SYNC CSA PFC IGBT

Part

number

Description and kit contents

209445 Pilot arc IGBT

223738 PFC to inverter cable (2)

075569 Screw: M6 X 14-12.5, pan head (3)

075851 Screw: M6 X 18.5±0.5-12.5, pan head (4)

128836 Thermal grease, 0.125 ounce

209569 Transducer

075524 Screw: M5 X 16, pan head

075851 Screw: M6 X 18.5±0.5-12.5, pan head

109932 PFC IGBT

223738 PFC to inverter cable (2)

075567 Screw: M6 X 16-12.5, pan head (4)

075569 Screw: M6 X 14-12.5, pan head (3)

128836 Thermal grease, 0.125 ounce

6 528047 Kit: Powermax85 SYNC CSA PFC IGBT

109 802 PF C IG BT

223738 PFC to inverter cable (2)

075567 Screw: M6 X 16-12.5, pan head (4)

075569 Screw: M6 X 14-12.5, pan head (3)

128836 Thermal grease, 0.125 ounce

For replacement procedures, refer to the following:

 Replace the pilot arc IGBT on page 110  Replace the inverter IGBT and the thermal sensor on page 112  Replace the PFC IGBT on page 114

IGBT tester

You can purchase the IGBT tester separately for troubleshooting.

Part number Description

128883 IGBT tester

Powermax65/85 SYNC Service Parts and Procedures 810440 31

Service Parts

CSA

CE/CCC

65 A/85 A heatsink resistors

Item

7 228693 Kit: Snubber resistor, 5 , 120 W

8 228706 Kit: Powermax65/85 SYNC snubber resistor, 15, 120W

9 228740 Kit: Powermax65/85 SYNC CSA damper resistor

Part

number

Description and kit contents

109799 Snubber resistor 5 , 120 W

108868 Standoff (2)

075526 Screw: M4 X 10, pan head (2)

128836 Thermal grease, 0.125 ounce

109950 Snubber resistor, 15, 120W

108868 Standoff (2)

075526 Screw: M4 X 10, pan head (2)

128836 Thermal grease, 0.125 ounce

109944 Damper resistor

075529 Screw: M3 X 10, pan head (2)

128836 Thermal grease, 0.125 ounce

For replacement procedures, refer to Replace the snubber resistors and the damper resistor on page 116.

32 810440 Service Parts and Procedures Powermax65/85 SYNC

Power supply interior, magnetics

2 3

Service Parts

Item

Part number

1 228661 Kit: Powermax65 SYNC PFC inductor CSA

1 228670 Kit: Powermax65 SYNC PFC inductor CE / CCC

1 228668 Kit: Powermax85 SYNC PFC inductor CSA

1 228664 Kit: Powermax85 SYNC PFC inductor CE / CCC

2 228663 Kit: Powermax65 SYNC transformer CSA

Description and kit contents

014345 Inductor: PFC

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

014348 Inductor: PFC

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

014337 Inductor: PFC

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

014341 Inductor: PFC

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

014346 Transformer

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

2 228669 Kit: Powermax65 SYNC transformer CE / CCC

014349 Transformer

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

2 228667 Kit: Powermax85 SYNC transformer CSA

014338 Transformer

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

Powermax65/85 SYNC Service Parts and Procedures 810440 33

Service Parts

Item

Part number

2 228654 Kit: Powermax85 SYNC transformer CE / CCC

3 528036 Kit: Powermax65 SYNC output inductor

3 528037 Kit: Powermax85 SYNC output inductor

Description and kit contents

014342 Transformer

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

014439 Output inductor

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

014440 Output inductor

075697 Screw: M5 X 0.8 X 10-10, pan head (2)

For replacement procedures, refer to the following:

 Replace the PFC inductor on page 134  Replace the transformer on page 130  Replace the output inductor on page 127

34 810440 Service Parts and Procedures Powermax65/85 SYNC

Machine interface and RS-485 serial interface upgrade kits

Service Parts

Item Part number Description

1 228539 Kit: Serial interface receptacle with internal cables and RS-485 serial interface PCB

2 228697 Kit: Machine interface receptacle with internal cables and voltage divider PCB for

Powermax65/85 SYNC (does not include cover for receptacle)

3 128650 Remote start pendant for machine torch, 7.6 m (25 foot)

3 128651 Remote start pendant for machine torch, 15 m (50 foot)

3 128652 Remote start pendant for machine torch, 23 m (75 foot)

3 428755 Remote start pendant for machine torch, 46 m (150 foot)

428975 Kit: Replacement switch for remote start pendant (not shown)

4 127204 Cover for machine interface receptacle

The remote start pendant connects to the machine interface receptacle.



EDGE®Connect CNC: To connect Hypertherm’s EDGE Connect CNC



with a Powermax65/85/105 SYNC, refer to the EDGE Connect Installation and Setup Manual (809340).

EDGE®Pro CNC: To connect Hypertherm’s EDGE Pro CNC with a



Powermax65/85/105 SYNC, refer to the Phoenix Software V9 Series Installation and Setup Manual (806410).

Technical documentation is available at www.hypertherm.com/docs.



Powermax65/85 SYNC Service Parts and Procedures 810440 35

Service Parts

External cables for machine interface receptacle and RS-485 serial interface receptacle

Hypertherm offers a variety of external cables that connect to the machine interface receptacle and the RS-485 serial interface receptacle. For setup information refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

Machine interface cables

Item Part number Description

1 023206 External machine interface cable*, 4 spade connectors, 7.6 m (25 foot)

1 023279 External machine interface cable*, 4 spade connectors, 15 m (50 foot)

2 228350 Kit: External machine interface cable

2 228351 Kit: External machine interface cable

3 223354 External machine interface cable

3 223355 External machine interface cable

3 223048 External machine interface cable

3 223356 External machine interface cable

3 123896 External machine interface cable

4 223733 External machine interface cable

ratio (for example, PlasmaCAM

4 223734 External machine interface cable

ratio (for example, PlasmaCAM

* Communicates start, stop, and arc transfer signals. Uses an external voltage divider PCB.

** Communicates start, stop, arc transfer, and divided arc voltage signals. Uses the internal voltage divider PCB.

†

Communicates start, stop, and divided arc voltage signals. Uses the internal voltage divider PCB.

**, 6 spade connectors, 7.6 m (25 foot)

**, 6 spade connectors, 15 m (50 foot)

**, D-sub connector with screws, 3.0 m (10 foot)

**, D-sub connector with screws, 6.0 m (20 foot)

**, D-sub connector with screws, 7.6 m (25 foot)

**, D-sub connector with screws, 10.7 m (35 foot)

**, D-sub connector with screws, 15 m (50 foot)

†

for mechanized cutting systems with a 21.1:1 voltage

systems), 6-pin DIN connector, 4.6 m (15 foot)

†

for mechanized cutting systems with a 21.1:1 voltage

systems), 6-pin DIN connector, 6.0 m (20 foot)

36 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Parts

RS-485 serial interface cables

The RS-485 serial interface cables communicate information for controlling operating mode, amperage, and gas pressure and control mode.

Item Part number Description

1 223236 External RS-485 cable, unterminated, 7.6 m (25 foot)

1 223237 External RS-485 cable, unterminated, 15 m (50 foot)

2 223239 External RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 7.6 m (25 foot)

2 223240 External RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 15 m (50 foot)

Powermax65/85 SYNC Service Parts and Procedures 810440 37

Service Parts

FineCut

30 A – 45 A: 428928

105 A: 428937

85 A: 428935 65 A: 428931 45 A: 428927

105 A: 428936

85 A: 428934 65 A: 428930 45 A: 428925

30 A – 45 A: 428926

105 A: 428938

45 A – 85 A: 428932

105 A: 428939

45 A – 85 A: 428933

428895

210692

105 A

95 A

85 A 65 A

55 A

45 A

30 A

105 A

FineCut

30 A – 45 A: 428928

85 A: 428935 65 A: 428931 45 A: 428927

85 A: 428934 65 A: 428930 45 A: 428925

30 A – 45 A: 428926

45 A – 85 A: 428932

45 A – 85 A: 428933

428895

210691

65 A

60 A

55 A 45 A

35 A

25 A

20 A

65 A

85 A

75 A

65 A 55 A

45 A

35 A

25 A

85 A

Powermax6 5/85 SYNC

Powermax105 SYNC

Powermax65/85/105 SYNC labels

Part number Description

528018 Kit: Powermax65 SYNC labels, CSA

528020 Kit: Powermax85 SYNC labels, CSA

528022 Kit: Powermax105 SYNC labels, CSA

528019 Kit: Powermax65 SYNC labels, CE/CCC

528021 Kit: Powermax85 SYNC labels, CE/CCC

528023 Kit: Powermax105 SYNC labels, CE/CCC

The label kits include:

 Warning label  Interface decals for the front panel and rear panel  Product decals  Cartridge label

Cartridge labels

38 810440 Service Parts and Procedures Powermax65/85 SYNC

CSA warning label

WARNING: This product can expose you to chemicals including

lead and lead compounds, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.p65warnings.ca.gov.

AVERTISSEMENT : Ce produit peut vous exposer à des produits chimiques, dont

le plomb et des composés de plomb, reconnus par l’État de la Californie comme cause de cancer et d’anomalie congénitale ou d’autres anomalies de l’appareil reproducteur. Pour obtenir de plus amples renseignements, consultez le www.p65warnings.ca.gov.

Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied Processes” from American Welding Society (http://www.aws.org) and OSHA Safety and Health Standards, 29 CFR 1910 (http://www.osha.gov).

WARNING

1. Cutting sparks can cause explosion or ﬁre.

1.1 Do not cut near ﬂammables.

1.2 Have a ﬁre extinguisher nearby and ready to use.

1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.

2.1 Turn off power before disassembling torch.

2.2 Do not grip the workpiece near the cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.

3.1 Wear insulating gloves. Replace gloves when wet or damaged.

3.2 Protect from shock by insulating yourself from work and ground.

3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Do not operate in closed spaces. Remove fumes with ventilation.

6. Become trained. Only qualiﬁed personnel should

operate this equipment. Use torches speciﬁed in the manual. Keep non-qualiﬁed personnel and children away.

5. Arc rays can burn eyes and injure skin.

5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of ﬁlter.

7. Do not remove, destroy, or cover this label.

Replace if it is missing, damaged, or worn.

Plasma cutting can be injurious to operator and persons in the work area. Consult manual before operating. Failure to follow all these safety instructions can result in death.

AVERTISSEMENT

Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le non respect des ces instructions de sécurité peut entraîner la mort.

1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.

1.1 Ne pas couper près des matières inﬂammables.

1.2 Un extincteur doit être à proximité et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.

2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce.

2.1 Couper l’alimentation avant de démonter la torche.

2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.

2.3 Se protéger entièrement le corps.

3. Tension dangereuse. Risque de choc électrique ou de brûlure.

3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.

3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.

3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Les fumées plasma peuvent être dangereuses.

4.1 Ne pas inhaler les fumées.

4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.

4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.

5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un ﬁltre de nuance appropriée.

6. Suivre une formation. Seul le personnel qualiﬁé a

le droit de faire fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualiﬁé et les enfants doivent se tenir à l’écart.

7. Ne pas enlever, détruire ni couvrir cette étiquette.

La remplacer si elle est absente, endommagée ou usée.

(

110673 Rev F)

This warning label is affixed to some plasma power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described.

Service Parts

Powermax65/85 SYNC Service Parts and Procedures 810440 39

Service Parts

www.hypertherm.com/weeewww.hypertherm.com/weee

Descriptions of warning label icons

This warning label is affixed to some plasma power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The descriptions at right are numbered the same as the symbols on the label.

1. Cutting sparks can cause explosion or fire.

1.1 Do not cut near flammables.

1.2 Have a fire extinguisher nearby and ready to use.

1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.

2.1 Turn off electrical power before disassembling torch.

2.2 Do not grip the workpiece near the cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.

3.1 Wear insulating gloves. Replace gloves when wet or damaged.

3.2 Protect from shock by insulating yourself from work and ground.

3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local exhaust to remove fumes.

4.3 Do not operate in closed spaces. Remove fumes with ventilation.

5. Arc rays can burn eyes and injure skin.

5.1 Wear correct and approved protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.

6. Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.

7. Do not remove, destroy, or cover this label. Replace it if it is missing, damaged, or worn.

40 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Parts

Parts necessary for safety

Genuine Hypertherm parts are factory-recommended parts for your Hypertherm system. Any damage caused by the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty. Parts that are necessary for safety are parts that must be replaced with only genuine Hypertherm parts to maintain the warranty and system certifications.

Part number Description Page

228680 Kit: Strain relief for Powermax65/85 SYNC power cords (all models) page 18

228691 Kit: Powermax65/85 SYNC power cord with strain relief, CSA models, 3 m

(10 foot)

528015 Kit: Powermax65 SYNC power cord with strain relief, CE/CCC models, 3 m

(10 foot)

528016 Kit: Powermax85 SYNC power cord with strain relief, CE/CCC models, 3 m

(10 foot)

228644 Kit: Powermax65 SYNC power switch CSA page 20

228655 Kit: Powermax85 SYNC power switch CSA page 20

228671 Kit: Powermax65/85 SYNC power switch CE/CCC page 20

428991 Kit: Powermax65/85 SYNC Fan assembly page 23

528029 Kit: Powermax65 SYNC power PCB CSA page 26

528030 Kit: Powermax65 SYNC power PCB CE/CCC page 26

528031 Kit: Powermax85 SYNC power PCB CSA page 26

528032 Kit: Powermax85 SYNC power PCB CE/CCC page 26

528028 Kit: DSP PCB page 27

228683 Kit: Powermax65 SYNC bulk capacitor CSA page 27

228684 Kit: Powermax65 SYNC bulk capacitor CE / CCC page 27

228681 Kit: Powermax85 SYNC bulk capacitor CSA page 27

page 18

228682 Kit: Powermax85 SYNC bulk capacitor CE / CCC page 27

228661 Kit: Powermax65 SYNC PFC inductor CSA page 33

228670 Kit: Powermax65 SYNC PFC inductor CE / CCC page 33

228668 Kit: Powermax85 SYNC PFC inductor CSA page 33

228664 Kit: Powermax85 SYNC PFC inductor CE / CCC page 33

228663 Kit: Powermax65 SYNC transformer CSA page 33

228669 Kit: Powermax65 SYNC transformer CE / CCC page 33

228667 Kit: Powermax85 SYNC transformer CSA page 33

228654 Kit: Powermax85 SYNC transformer CE / CCC page 34

528036 Kit: Powermax65 SYNC output inductor page 34

528037 Kit: Powermax85 SYNC output inductor page 34

Powermax65/85 SYNC Service Parts and Procedures 810440 41

Service Parts

Recommended spare parts

Hypertherm recommends that service centers keep the following spare parts available for repairs because these parts are parts necessary for safety or are usually exposed to continuous wear. Parts that are necessary for safety are parts that must be replaced with only genuine Hypertherm parts to maintain the warranty and system certifications. You may need to revise or expand this list for your customers, based on the conditions and work environments in your region.

Part number Description Page

428141 Kit: Replacement screws (16) for plasma power supply cover page 14

428143 Kit: Adjustment knob only page 14

223125 65 A work lead with hand clamp, 7.6 m (25 foot) page 15

223200 65 A work lead with ring terminal, 7.6 m (25 foot) page 15

223035 85 A work lead with hand clamp, 7.6 m (25 foot) page 16

223209 85 A work lead with ring terminal, 7.6 m (25 foot) page 16

228695 Kit: Air filter element and O-ring (compatible with both filter bowl types) page 17

428352 Kit: Air filter bowl, polycarbonate (comes with plasma power supply, includes the

O-ring but not the filter element)

027055 Silicone lubricant, 0.25 ounces page 17

228644 Kit: Powermax65 SYNC power switch CSA page 20

228655 Kit: Powermax85 SYNC power switch CSA page 20

228671 Kit: Powermax65/85 SYNC power switch CE/CCC page 20

428942 Kit: Air filter assembly (includes air filter, air filter bowl, air filter element, and

O-ring)

528017 Kit: 90° gas tube fitting page 22

528053 Kit: Solenoid valve (includes gas tubes and screws) page 22

528065 Kit: Powermax65/85/105 SYNC Gas tubes page 22

228694 Kit: Powermax65/85 SYNC Fan shroud page 23

428991 Kit: Powermax65/85 SYNC Fan assembly page 23

528026 Kit: Control PCB and adjustment knob page 24

428068 Kit: Ribbon cable for control PCB, 14 cm (5.5 inches) page 24

528029 Kit: Powermax65 SYNC power PCB CSA page 26

528030 Kit: Powermax65 SYNC power PCB CE/CCC page 26

page 17

page 21

528031 Kit: Powermax85 SYNC power PCB CSA page 26

528032 Kit: Powermax85 SYNC power PCB CE/CCC page 26

228683 Kit: Powermax65 SYNC bulk capacitor CSA page 27

228684 Kit: Powermax65 SYNC bulk capacitor CE / CCC page 27

228681 Kit: Powermax85 SYNC bulk capacitor CSA page 27

228682 Kit: Powermax85 SYNC bulk capacitor CE / CCC page 27

128836 Thermal grease, 0.125 ounce page 28

42 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Parts

Part number Description Page

228693 Kit: Snubber resistor, 5 , 120 W page 32

228661 Kit: Powermax65 SYNC PFC inductor CSA page 33

228670 Kit: Powermax65 SYNC PFC inductor CE / CCC page 33

228668 Kit: Powermax85 SYNC PFC inductor CSA page 33

228664 Kit: Powermax85 SYNC PFC inductor CE / CCC page 33

228663 Kit: Powermax65 SYNC transformer CSA page 33

228669 Kit: Powermax65 SYNC transformer CE / CCC page 33

228667 Kit: Powermax85 SYNC transformer CSA page 33

228654 Kit: Powermax85 SYNC transformer CE / CCC page 34

528036 Kit: Powermax65 SYNC output inductor page 34

528037 Kit: Powermax85 SYNC output inductor page 34

Powermax65/85 SYNC Service Parts and Procedures 810440 43

Service Parts

Find replacement parts by part number

Use this list to find the page number for a part number in Service Parts on page 13.

Part number .................................................................................................... Page

008337.....................................................................................................15, 16

023206............................................................................................................36

023279............................................................................................................36

027055............................................................................................................17

123896............................................................................................................36

127204............................................................................................................35

128650............................................................................................................35

128651............................................................................................................35

128652............................................................................................................35

128836............................................................................................................28

128883............................................................................................................31

223033.....................................................................................................15, 16

223034............................................................................................................16

223035............................................................................................................16

223048............................................................................................................36

223125............................................................................................................15

223126............................................................................................................15

223194............................................................................................................15

223200............................................................................................................15

223201............................................................................................................15

223209............................................................................................................16

223210............................................................................................................16

223211.....................................................................................................15, 16

223236............................................................................................................37

223237............................................................................................................37

223239............................................................................................................37

223240............................................................................................................37

223354............................................................................................................36

223355............................................................................................................36

223356............................................................................................................36

223733............................................................................................................36

223734............................................................................................................36

228350............................................................................................................36

228351............................................................................................................36

228539............................................................................................................35

228644............................................................................................................20

228654............................................................................................................34

44 810440 Service Parts and Procedures Powermax65/85 SYNC

228655............................................................................................................20

228661............................................................................................................33

228663............................................................................................................33

228664............................................................................................................33

228667............................................................................................................33

228668............................................................................................................33

228669............................................................................................................33

228670............................................................................................................33

228671............................................................................................................20

228680............................................................................................................18

228681............................................................................................................27

228682............................................................................................................27

228683............................................................................................................27

228684............................................................................................................27

228691............................................................................................................18

228693............................................................................................................32

228694............................................................................................................23

228695............................................................................................................17

228697............................................................................................................35

228705............................................................................................................26

228706............................................................................................................32

228709.....................................................................................................15, 16

228740............................................................................................................32

228741............................................................................................................29

228742............................................................................................................28

228803............................................................................................................28

228804............................................................................................................28

228805............................................................................................................31

428066............................................................................................................27

428068............................................................................................................24

428070............................................................................................................24

428141............................................................................................................14

428143............................................................................................................14

428352............................................................................................................17

428415............................................................................................................17

428685............................................................................................................17

428755............................................................................................................35

428921.....................................................................................................15, 16

428942............................................................................................................21

428975............................................................................................................35

428990............................................................................................................31

428991............................................................................................................23

Service Parts

Powermax65/85 SYNC Service Parts and Procedures 810440 45

Service Parts

528000............................................................................................................25

528001............................................................................................................19

528009............................................................................................................14

528010............................................................................................................14

528011............................................................................................................14

528012............................................................................................................14

528015............................................................................................................18

528016............................................................................................................18

528017............................................................................................................22

528018............................................................................................................38

528019............................................................................................................38

528020............................................................................................................38

528021............................................................................................................38

528022............................................................................................................38

528023............................................................................................................38

528024............................................................................................................24

528026............................................................................................................24

528028............................................................................................................27

528029............................................................................................................26

528030............................................................................................................26

528031............................................................................................................26

528032............................................................................................................26

528036............................................................................................................34

528037............................................................................................................34

528039............................................................................................................30

528040............................................................................................................30

528041............................................................................................................31

528042............................................................................................................30

528043............................................................................................................30

528046............................................................................................................31

528047............................................................................................................31

528053............................................................................................................22

528065............................................................................................................22

46 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels,

and Connectors

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety information.

NOTICE

Static electricity can cause damage to printed circuit boards (PCBs). Use correct precautions when you touch PCBs.

Keep PCBs in antistatic containers. Put on a grounded wrist strap when you touch PCBs.

Powermax65/85 SYNC Service Parts and Procedures 810440 47

Service Procedures for the Cover, Panels, and Connectors

Tools necessary for this section

 Assorted Phillips  Assorted Phillips  Adjustable wrench  Grounded wrist strap (or similar grounding accessory)

, TORX®, and blade screwdrivers

offset screwdrivers

More tools necessary for some procedures

 Cable ties are necessary for Replace the rear panel on page 60.  Cable cutters are necessary for Replace the work lead connector on page 67.

48 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels, and Connectors

Replace the plasma power supply cover and component barrier

For kit contents, refer to Plasma power supply interior, power PCB side on page 26.

Remove the plasma power supply cover and component barrier

WARNING

STORED ENERGY HAZARD

You can get a serious electric shock from the uncontrolled release of stored energy in capacitors. Electric shock can seriously injure or kill you.

Before you remove the plasma power supply cover, disconnect electrical input power and wait 1 minute to allow stored energy to discharge.

1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and disconnect the gas supply.

2. Remove the 16 screws from the plasma power supply cover.

3. Remove the plasma power supply cover.

Powermax65/85 SYNC Service Parts and Procedures 810440 49

Service Procedures for the Cover, Panels, and Connectors

4. Remove the component barrier from the power-PCB side of the plasma power supply.

50 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels, and Connectors

Install the component barrier and plasma power supply cover

WARNING

SHOCK HAZARD

You can get a serious electric shock if you touch exposed plasma power supply components. Electric shock can seriously injure or kill you.

You must install the component barrier and the plasma power supply cover. Never operate the plasma power supply unless the component barrier and the plasma power supply cover are in position.

1. Push in the sides of the component barrier so that the component barrier bends out slightly down the center.

2. Put the sides of the component barrier inside the plasma power supply frame .

Powermax65/85 SYNC Service Parts and Procedures 810440 51

Service Procedures for the Cover, Panels, and Connectors

3. Fold the top of the component barrier onto the top edge of the power PCB, inside the plasma power supply frame and under the end panel bracket.

4. Make sure that all of the wires that are connected to the power PCB are behind the component barrier.

5. Put the cover on the plasma power supply. Do not pinch any wires.

6. Install the 16 screws on the plasma power supply cover. Tighten the screws to 1.7 N·m (15 lbf·in).

52 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the end panel bracket

Remove the end panel bracket

1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Lift the end panel bracket off of the plasma power supply.

Service Procedures for the Cover, Panels, and Connectors

Powermax65/85 SYNC Service Parts and Procedures 810440 53

Service Procedures for the Cover, Panels, and Connectors

Install the end panel bracket

1. Put the end panel bracket on the top of the plasma power supply.

2. Install the plasma power supply cover and the component barrier. Refer to page 51.

54 810440 Service Parts and Procedures Powermax65/85 SYNC

Loosen and attach the front panel

Loosen the front panel

Some repairs are easier to make if you first loosen the front panel from the plasma power supply. To replace an old front panel with a new one, complete this procedure, then continue with step 3 in

Replace the front panel on page 59.

1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Remove the end panel bracket. Refer to page 53.

4. Put the fan side of the plasma power supply on a clean, dry, and flat surface.

5. Remove the screws that attach the front panel to the bottom of the

plasma power supply.

Service Procedures for the Cover, Panels, and Connectors

6. Move the bottom of the front panel off of the bottom of the plasma power supply. Use a blade screwdriver to carefully pry the front panel away from the bottom of the plasma power supply.

7. Put the plasma power supply in an upright position.

Powermax65/85 SYNC Service Parts and Procedures 810440 55

Service Procedures for the Cover, Panels, and Connectors

Attach the front panel

1. Put the fan side of the plasma power supply on a clean, dry, and flat surface.

2. Push the front panel onto the bottom of the plasma power supply.

3. Install the screws that attach the front panel to the bottom of the

plasma power supply. Tighten the screws to 2.3 Nm (20 lbfin).

4. Put the plasma power supply upright position.

5. Install the end panel bracket. Refer to page 54.

56 810440 Service Parts and Procedures Powermax65/85 SYNC

Loosen and attach the rear panel

Loosen the rear panel

Some repairs are easier to make if you first loosen the rear panel from the plasma power supply. To replace an old rear panel with a new one, complete this procedure, then continue with step 3 in

Replace the rear panel on page 60.

1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Remove the end panel bracket. Refer to page 53.

4. Push-to-disconnect the gas tube from the air filter.

5. Put the fan side of the plasma power supply on a clean,

dry, and flat surface.

Service Procedures for the Cover, Panels, and Connectors

6. Remove the screws that attach the rear panel to the bottom of the plasma power supply.

7. Move the bottom of the rear panel off of the bottom of the plasma power supply. Use a blade screwdriver to carefully pry the rear panel away from the bottom of the plasma power supply.

8. Put the plasma power supply in an upright position.

Powermax65/85 SYNC Service Parts and Procedures 810440 57

Service Procedures for the Cover, Panels, and Connectors

Attach the rear panel of the plasma power supply

1. Put the fan side of the plasma power supply on a clean, dry, and flat surface.

2. Push the rear panel onto the bottom of the plasma power supply.

3. Install the screws that attach the rear panel to the bottom of the

plasma power supply. Tighten the screws to 2.3 N·m (20 lbf·in).

4. Put the plasma power supply in an upright position.

5. Push-to-connect the gas tube to the air filter.

6. Install the end panel bracket. Refer to page 54.

58 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the front panel

111

For kit contents, refer to Front panel on page 25.

Remove the front panel

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Loosen the front panel. Refer to page 55.

3. Remove the 4 mounting screws from the torch

quick-disconnect receptacle housing.

4. Remove the torch quick-disconnect receptacle housing from the front panel.

5. Remove the work lead receptacle. Refer to page 69.

Service Procedures for the Cover, Panels, and Connectors

6. Remove the control PCB and disconnect the ribbon cable. Refer to page 96.

7. Remove the front panel from the plasma power supply.

Install the front panel

1. Push the front panel onto the body of the plasma power supply.

2. Install the control PCB and ribbon cable. Refer to page 97.

3. Install the work lead receptacle. Refer to page 70.

4. Attach the torch quick-disconnect receptacle to the inside of

the front panel with the 4 mounting screws. Tighten the screws to 1.7N·m (15lbf·in) .

5. Attach the front panel. Refer to page 56.

6. Install the plasma power supply cover and the component

barrier. Refer to page 51.

Powermax65/85 SYNC Service Parts and Procedures 810440 59

Service Procedures for the Cover, Panels, and Connectors

Replace the rear panel

For kit contents, refer to Rear panel on page 19.

Remove the rear panel

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Loosen the rear panel. Refer to page 57.

3. Remove the air filter assembly and gas inlet fitting. Refer to page 83.

4. If a machine interface receptacle is installed, remove the 2 screws from the machine interface

receptacle.

5. If an RS-485 serial interface receptacle is installed, do the following:

a. Remove the RS-485 serial interface cable connector from J1 on the RS-485 PCB.

b. Cut the cable tie that holds the cable.

60 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels, and Connectors

c. Remove the 2 mounting screws from the RS-485 serial interface receptacle.

d. Remove the RS-485 serial interface receptacle and cable from the rear panel.

6. Remove the power switch. Refer to page 75.

7. Remove the power cord:

For the procedure to replace the power cord and strain relief, refer to the



Power Cord and Strain Relief Replacement Field Service Bulletin (807020). Download the file at www.hypertherm.com/docs.

a. Remove the screw that attaches the ground wire to the heatsink. b. On the outside of the plasma power supply, remove the strain relief retention nut from the

strain relief. Move the retention nut away from the plasma power supply.

c. Remove the power cord.

 CSA: From the outside of the plasma power supply, pull the power cord and power

wires through the strain relief in the rear panel.

 CCC/CE: From the inside of the plasma power supply, pull the power wires and the

power cord through the strain relief in the rear panel.

CCC/CE models have ferrite cores on the power wires and the ground



wire. To maintain CCC/CE certification, install a CCC/CE power cord.

8. Remove the rear panel from the plasma power supply.

Powermax65/85 SYNC Service Parts and Procedures 810440 61

Service Procedures for the Cover, Panels, and Connectors

123

9. Remove the strain relief from the rear panel:

a. On the inside of the plasma power supply, remove the nut . For some models, also remove

the washer.

b. On the outside of the plasma power supply, remove the strain relief . For some models,

also remove the strain relief adapter .

62 810440 Service Parts and Procedures Powermax65/85 SYNC

Install the rear panel

12345

CSA

CCC/CE

1. Install the strain relief into the new rear panel:

a. On the outside of the plasma power supply, put the strain relief in the hole in the rear panel

of the plasma power supply. If your model has a strain relief adapter, first put the strain relief in the adapter.

b. On the inside of the plasma power supply, install the nut on the strain relief. If your model

has a washer, first put the washer on the strain relief. Tighten the nut with your hand.

2. Put the power cord in the strain relief:

 CSA: From the outside of the plasma power supply, put the power wires and ground wire

through the retention nut . Then put the power wires and ground wire through the strain relief .

 CCC/CE: From the inside of the plasma power supply, put the wires at the line-disconnect

end of the power cord through the strain relief . From the outside of the plasma power supply, pull the power cord through the strain relief. Then put the wires at the line-disconnect end of the power cord through the retention nut .

Service Procedures for the Cover, Panels, and Connectors



CCC/CE models have ferrite cores on the power wires and the ground wire. To maintain CCC/CE certification, install a CCC/CE power cord.

3. Attach the ground wire to the heatsink with the screw you removed previously. Tighten the screw to 4 N·m (35 lbf·in).

Powermax65/85 SYNC Service Parts and Procedures 810440 63

Service Procedures for the Cover, Panels, and Connectors

4. Push the 3 power wires into the inside edge of the rear panel using the guide posts . Make sure that the routing of the wires is correct.

5. From the outside of the rear panel, tighten the strain relief retention nut on the strain relief with your hand plus a quarter turn with a wrench.

6. Put fan side of the plasma power supply on a clean, dry, and flat surface.

7. Push the rear panel onto the body of the plasma power supply.

8. Put the plasma power supply in an upright position.

9. Install the power switch. Refer to page 76.

10. If you have an RS-485 serial interface receptacle, do the

following:

a. Put the RS-485 serial interface cable through the hole in

the rear panel.

b. Attach the RS-485 serial interface receptacle to the rear panel with the 2 mounting screws.

Tighten the screws to 0.8 N·m (7 lbf·in).

64 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels, and Connectors

c. Put the RS-485 serial interface cable behind the gas tubes and below the solenoid valve.

NNOTICE

Do not put the RS-485 serial interface cable below the fan. This can cause the wires to be pinched by the fan. If any wires get pinched by the fan, this can damage the wires and prevent the fan from operating correctly.

d. Bundle the RS-485 serial interface cable with the cables that are already in the plasma

power supply with a new cable tie.

e. Put the RS-485 serial interface cable through the upper grommet on the center panel.

f. Connect the RS-485 serial interface cable connector to J1 on the RS-485 PCB.

Powermax65/85 SYNC Service Parts and Procedures 810440 65

Service Procedures for the Cover, Panels, and Connectors

11 . If you have a machine interface receptacle, install the 2 mounting screws that attach the

machine interface receptacle to the rear panel. Tighten the screws to 1.1 Nm (10 lbfin).

12. Install the air filter assembly and gas inlet fitting. Refer to page 84.

13. Attach the rear panel. Refer to page 58.

14. Install the plasma power supply cover and the component barrier. Refer to page 51.

66 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the work lead connector

For kit contents, refer to Work leads on page 15.

Remove the work lead connector

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Use cable cutters to cut the work lead cable close to the rubber boot .

Install the work lead connector

1. Put the new rubber boot over the work lead cable.

Service Procedures for the Cover, Panels, and Connectors

2. Move the rubber boot back along the work lead cable.

3. Strip 13 mm (0.5 inches) off the end of the work lead cable.

4. Put the stripped end of the work lead cable into the new work lead connector.

5. Tighten the set screw to 11.3 Nm (100 lbfin).

Powermax65/85 SYNC Service Parts and Procedures 810440 67

Service Procedures for the Cover, Panels, and Connectors

6. Align the tabs in the rubber boot with the slots in the work lead connector.

CAUTION

INCORRECTLY INSTALLED WORK LEAD CONNECTORS CAN OVERHEAT

To prevent damage and risk of burns, make sure that the face of the work lead connector is flush with the face of the rubber boot.

7. Align the face of the rubber boot with the face of the work lead connector. If the face of the work lead connector is below the face of the rubber boot, the work lead can overheat which can cause damage and risk of burns.

68 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the work lead receptacle

234

For kit contents, refer to Plasma power supply interior, front on page 24.

Remove the work lead receptacle

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Remove the bolt from the work lead receptacle.

4. Remove the ring terminal from the work lead receptacle.

5. Remove the nut and washer from the work lead

receptacle.

Service Procedures for the Cover, Panels, and Connectors

6. Remove the work lead receptacle. Push the work lead receptacle in the direction of the front panel.

Powermax65/85 SYNC Service Parts and Procedures 810440 69

Service Procedures for the Cover, Panels, and Connectors

Install the work lead receptacle

1. Push the new work lead receptacle into the hole in the front panel. Position the receptacle so that the key way points up.

2. From inside the plasma power supply, put the washer on the work lead receptacle.

3. Install the nut onto the work lead receptacle. Tighten the nut to 9 Nm (80 lbfin).

4. Put the ring terminal on the work lead receptacle.

5. Install the bolt on the work lead receptacle. Tighten the

bolt to 13.6 Nm (120 lbfin).

6. Install the plasma power supply cover and the component barrier. Refer to page 51.

70 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels, and Connectors

RED

ORG

RED

B R

WORK

LEAD

TP7

TP9

TP8

Replace the torch quick-disconnect receptacle

For kit contents, refer to Plasma power supply interior, front on page 24.

Remove the torch quick-disconnect receptacle

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Loosen the front panel. Refer to page 55.

4. Remove the torch interface cable connector from

J20 on the power PCB.

5. From the fan side, pull the torch interface cable through the grommet.

6. Remove the nozzle wires from the power PCB.

7. Pull the wires through the protective sheath .

Powermax65/85 SYNC Service Parts and Procedures 810440 71

Service Procedures for the Cover, Panels, and Connectors

8. Push-to-disconnect the 90° gas inlet fitting from the torch quick-disconnect receptacle.

9. Remove the following components from the torch quick-disconnect receptacle:

 Retention nut  Ring terminal  Washer

10. Push the torch quick-disconnect receptacle out through the torch quick-disconnect receptacle housing.

11 . Remove the 4 screws from the torch quick-disconnect

receptacle housing.

12. Remove the torch quick-disconnect receptacle housing from the front panel.

72 810440 Service Parts and Procedures Powermax65/85 SYNC

Install the torch quick-disconnect receptacle

1. Use the 4 new screws to install the new torch quick-disconnect receptacle into the front panel. Tighten the screws to 1.7 Nm (15 lbfin).

2. From the front panel, put the small end of the new torch quick-disconnect receptacle into the center hole of the receptacle housing. Align the hexagonal flats on the receptacle with the hexagonal flats on the receptacle housing.

3. Push the receptacle in until the front is flush with the plastic receptacle housing .

Service Procedures for the Cover, Panels, and Connectors

4. Push the washer onto the hub of the torch quick-disconnect receptacle until the washer makes a click.

5. Put the ring terminal on the torch quick-disconnect receptacle.

6. Put the new retention nut onto the torch quick-disconnect receptacle. Tighten the retention nut to

14.7 Nm (130 lbfin).

7. Push-to-connect the 90° gas inlet fitting .

8. Put the nozzle wires through the protective sheath in

the center panel.

Powermax65/85 SYNC Service Parts and Procedures 810440 73

Service Procedures for the Cover, Panels, and Connectors

RED

ORG

RED

B R

WORK

LEAD

TP9

TP8

111

9. Put the torch interface cable through the upper grommet on the center panel.

10. From the power PCB side, attach the nozzle wires

to the power PCB. Tighten the screw to 2.3 Nm (20 lbfin).

11 . Connect the torch interface cable connector to

J20 on the power PCB.

12. Attach the front panel. Refer to page 56.

13. Install the plasma power supply cover and the

component barrier. Refer to page 51.

74 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the power switch

123

6 BAR (85 PSI) MIN 9 BAR (135 PSI) MAX

456

For kit contents, refer to Plasma power supply interior, rear on page 20.

Remove the power switch

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Loosen the rear panel. Refer to page 57.

3. Use an offset Phillips screwdriver to loosen the set screws that

attach the 3 power wires to the top of the power switch.

4. Pull the 3 power wires from the power switch.

5. Make a note of which AC input wires are attached to T1, T2, and

T3.

Service Procedures for the Cover, Panels, and Connectors

6. Use an offset Phillips screwdriver to loosen the set screws that attach the 3 AC input wires to the bottom of the power switch.

7. Pull the 3 power wires from the power switch.

8. Loosen the set screws on the auxiliary switch.

9. Pull the 2 wires from the auxiliary switch.

10. Remove the power switch handle screw .

11 . Pull the power switch handle straight off the post.

12. Use a blade screwdriver to pry up the edge of the

label .

13. Peel off the label.

14. Remove the 4 power switch mounting screws .

15. Remove the power switch from the plasma power supply.

Powermax65/85 SYNC Service Parts and Procedures 810440 75

Service Procedures for the Cover, Panels, and Connectors

6 BAR (85 PSI) MIN 9 BAR (135 PSI) MAX

2 3

123

Install the power switch

1. Put the power switch into the plasma power supply.

2. Push the power switch post through the hole in the rear panel.

3. Attach the power switch to the rear panel with the

4 mounting screws . Tighten the screws to 1.7 Nm (15 lbfin).

4. If the optional RS-485 receptacle is not installed:

a. Peel the protective cover off the new label. b. Carefully align the hole in the label with the correct

hole in the rear panel.

c. Push the label onto the rear panel.

5. If the optional RS-485 receptacle is installed:

a. Bend the new label at the perforation and tear the label in half. Discard the right half . b. Peel the protective cover off the left half of the new label. c. Carefully align the hole in the label with the correct hole in the rear panel. d. Push the label onto the rear panel.

6. Put the power switch handle onto the post.

7. Install the screw into the power switch handle. Tighten the screw to 0.8 Nm (7 lbfin).

76 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Cover, Panels, and Connectors

8. Put the auxiliary wires in the auxiliary switch. Tighten the screws to 1.1 Nm (10 lbfin).

9. Put the AC input wires into the bottom of the power switch. Tighten the set screws to 2.3 Nm (20 lbfin) for CSA models or 0.8 Nm (7 lbfin) for CE/CCC models.

10. Put the 3 power wires into the top of the power switch. Tighten the set screws to 2.3 Nm (20 lbfin) for CSA models or

0.8 Nm (7 lbfin) for CE/CCC models.

Table 1

Color

Power Wire Position CSA CE/CCC

L1 Black Brown

L2 White Black

L3 Red Grey

11 . Attach the rear panel. Refer to page 58.

12. Install the plasma power supply cover and the component barrier. Refer to page 51.

Powermax65/85 SYNC Service Parts and Procedures 810440 77

Service Procedures for the Cover, Panels, and Connectors

78 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the Gas Line

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

Refer to the Safety and Compliance Manual (80669C) for more safety information.

NOTICE

Static electricity can cause damage to printed circuit boards (PCBs). Use correct precautions when you touch PCBs.

Keep PCBs in antistatic containers. Put on a grounded wrist strap when you touch PCBs.

Powermax65/85 SYNC Service Parts and Procedures 810440 79

Service Procedures for the Gas Line

Tools necessary for this section

 Assorted Phillips  Assorted TORX  Adjustable wrench  Grounded wrist strap (or similar grounding accessory)

, TORX®, and blade screwdrivers

offset screwdrivers

More tools necessary for some procedures

 Cable ties are necessary for Replace the fan and fan shroud on page 85 and Replace the

solenoid valve on page 88.

80 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the air filter bowl and filter element

123

For kit contents, refer to Plasma power supply exterior, rear on page 17.

Remove the air filter bowl and filter element

1. Set the power switch on the plasma power supply to OFF (O).

2. Disconnect the power cord from electrical power.

3. Disconnect the gas supply from the rear of the plasma power supply.

4. Hold the filter bowl with your right hand. With the index finger of your left hand, push down the latch and turn the filter bowl approximately 45 degrees to the right.

Service Procedures for the Gas Line

5. Pull the filter bowl straight down to remove.

6. Gently turn and pull the filter element out of the filter bowl. Be careful not to damage the

O-ring at the top of the bowl.

Powermax65/85 SYNC Service Parts and Procedures 810440 81

Service Procedures for the Gas Line

Replace the air filter bowl, O-ring, and filter element

1. To replace the filter element, twist and pull the plastic fittings away from the filter element, approximately a 1/4 turn. Set the fittings aside. Discard the used filter element.

2. Put the new air filter element in the plastic fittings. Twist the plastic fittings until they lock together, approximately a 1/4 turn.

3. If the air filter bowl will not be replaced:

 Clean the bowl and O-ring of any oil, dirt, or other contamination. Apply a thin layer of

silicone lubricant on the O-ring.

 To replace the O-ring, discard the used O-ring. Put the thick O-ring at the top of the filter

bowl.

4. To replace the air filter bowl, discard the old air filter bowl.

5. Put the filter element inside the air filter bowl. Push down on the top plastic fitting until you hear

a click.

82 810440 Service Parts and Procedures Powermax65/85 SYNC

Install the air filter bowl and filter element

1. Vertically align the filter bowl and push it up into the receptacle in the rear panel.

2. Turn the filter bowl 45 degrees to the left until you hear a click.

Replace the air filter assembly

Service Procedures for the Gas Line

For kit contents, refer to Plasma power supply interior, fan side on page 21.

This kit contains an extra gas tube. This procedure uses the shortest gas tube in the kit.

Remove the air filter assembly

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Loosen the rear panel. Refer to page 57.

4. Remove the air filter bowl and air filter element. Refer to

page 81.

5. Push-to-disconnect both ends of the gas tube .

6. From the outside of the rear panel, remove the gas

fitting from the air filter assembly.

7. Remove the 3 screws from the rear panel.

8. Remove the air filter assembly from the plasma power

supply.

Powermax65/85 SYNC Service Parts and Procedures 810440 83

Service Procedures for the Gas Line

Install the air filter assembly

1. Remove the new air filter bowl and air filter element from the new air filter assembly.

2. Put the new air filter assembly into the plasma power supply.

3. Install the 3 screws on the rear panel. Tighten the

screws to 1.7 Nm (15 lbf·in).

4. Apply a small amount of thread sealant to the threads of the gas fitting.

 Too much thread sealant can contaminate the gas

line.

NOTICE

PTFE TAPE CAN CAUSE CLOGGED VALVES, REGULATORS, AND TORCHES

Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male thread ends.

5. Install the gas fitting onto the air filter assembly.

 CSA models: Tighten the 1/4 NPT quick-disconnect

nipple to 10.2 N·m (90 lbf·in).

 CE/CCC models: Tighten the G-1/4 BSPP adapter to

12.4 N·m (110 lbf·in).

6. Use the shortest gas tube in the kit. Push-to-connect the new gas tube into the new air filter assembly and solenoid valve.

7. Attach the ground wires with the ground screw . Tighten the screw to 2.8 Nm (25 lbfin).

8. Install the new air filter bowl and air filter element. Refer to page 83.

9. Attach the rear panel. Refer to page 58.

10. Install the component barrier and the plasma power supply cover. Refer to page 51.

84 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the fan and fan shroud

J2 J3

J4 J5

CSA

CE/CCC

For kit contents, refer to Plasma power supply interior, fan side on page 21.

Remove the fan and fan shroud

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Remove the end panel bracket. Refer to page 53.

4. Pull the fan shroud straight off of the fan.

5. Cut the cable tie that holds the fan wires.

6. Disconnect the fan wire connector from J3 (CSA) or J5 (CE/CCC) near the top of the power

PCB.

Service Procedures for the Gas Line

7. From the fan side, pull the fan wire through the grommet.

Powermax65/85 SYNC Service Parts and Procedures 810440 85

Service Procedures for the Gas Line

2 2

8. Use an offset TORX screwdriver to remove the 4 screws from fan.

9. Remove the old fan.

86 810440 Service Parts and Procedures Powermax65/85 SYNC

Install the fan and fan shroud

1 1

J2 J3

J4 J5

CSA

CE/CCC

1. Attach the new fan to the center panel with the 4 supplied screws .Tighten the screws to

1.1Nm (10inlbf).

Service Procedures for the Gas Line

2. Put the fan wire through the lower left grommet .

3. Connect the fan wire connector to J3 (CSA) or J5 (CE/CCC) near the top of the power PCB

4. Bundle the fan and solenoid valve wires with a new cable tie.

5. Align the plastic posts on the fan shroud with the related holes in the fan.

6. Push the fan shroud straight onto the fan.

7. Install the end panel bracket. Refer to page 54.

8. Install the component barrier and the plasma power supply cover. Refer to page 51.

Powermax65/85 SYNC Service Parts and Procedures 810440 87

Service Procedures for the Gas Line

J2 J3

J4 J5

CSA

CE/CCC

Replace the solenoid valve

For kit contents, refer to Plasma power supply interior, fan side on page 21.

Remove the solenoid valve

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Remove the end panel bracket. Refer to page 53.

4. Cut the cable tie that holds the solenoid valve wires.

5. Disconnect the solenoid valve wire connector from J4 (CSA) or J6 (CE/CCC) near the top of

the power PCB.

6. From the fan side, pull the solenoid valve wires through the grommet .

88 810440 Service Parts and Procedures Powermax65/85 SYNC

7. Remove the mounting screw from the bracket.

345

123

8. Push-to-disconnect the short gas tube and long gas tube from the solenoid valve .

9. Remove the solenoid valve and bracket.

10. Push-to-disconnect the short gas tube from the air filter assembly .

11 . Push-to-disconnect the long gas tube from elbow fitting .

Install the solenoid valve

1. Push-to-connect the shortest gas tube supplied into the air filter assembly .

2. Push-to-connect the middle length gas tube supplied into the elbow fitting .

3. If necessary, snap the new bracket onto the new solenoid valve.

4. Hold the solenoid valve and bracket in position, and push-to-connect the short gas tube and

long gas tube to the solenoid valve .

Service Procedures for the Gas Line

5. Attach the new solenoid valve to the center panel with the supplied screw . Tighten the screw to 2.2Nm (20lbfin).

6. Put the solenoid valve wires through the lower left grommet .

Powermax65/85 SYNC Service Parts and Procedures 810440 89

Service Procedures for the Gas Line

J2 J3

J4 J5

CSA

CE/CCC

7. Connect the solenoid valve wire connector to J4 (CSA) or J6 (CE/CCC) near the top of the power PCB.

8. Bundle the fan and solenoid valve wires with a new cable tie.

9. Install the end panel bracket. Refer to page 54.

10. Install the component barrier and the plasma power supply cover. Refer to page 51.

90 810440 Service Parts and Procedures Powermax65/85 SYNC

Replace the gas tubes

For kit contents, refer to Plasma power supply interior, fan side on page 21.

This kit contains an extra gas tube.

NOTICE

Do not make kinks or bend the gas tubes. This will damage the gas tubes.

Remove the gas tubes

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

Service Procedures for the Gas Line

3. Remove the end panel bracket. Refer to page 53.

4. Push-to-disconnect both ends of the short gas

tube .

5. Push-to-disconnect both ends of the long gas tube .

Install the gas tubes

1. Use the 44.5 mm (1.75 inch) gas tube in the kit. Push-to-connect both ends of the gas tube .

2. Use the 196.9 mm (7.75 inch) gas tube in the kit. Push-to-connect both ends of the gas tube .

3. Install the end panel bracket. Refer to page 54.

4. Install the component barrier and the plasma power

supply cover. Refer to page 51.

Powermax65/85 SYNC Service Parts and Procedures 810440 91

Service Procedures for the Gas Line

Replace the 90° gas tube fitting

For kit contents, refer to Plasma power supply interior, fan side on page 21.

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Push-to-disconnect the long gas tube from the 90° degree gas inlet fitting.

4. Push-to-disconnect the 90° gas inlet fitting from the torch quick-disconnect receptacle .

5. Push-to-connect the new 90° gas inlet fitting to the torch quick-disconnect receptacle.

6. Push-to-connect the long gas tube into the new 90° gas inlet fitting.

92 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the PCBs and

Related Components

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before doing installation or maintenance. The line-disconnect switch must REMAIN in the OFF position until all

installation or maintenance steps are complete. See the Safety and Compliance Manual (80669C) for more safety

information.

NOTICE

Static electricity can cause damage to printed circuit boards (PCBs). Use correct precautions when you touch PCBs.

Keep PCBs in antistatic containers. Put on a grounded wrist strap when you touch PCBs.

Powermax65/85 SYNC Service Parts and Procedures 810440 93

Service Procedures for the PCBs and Related Components

Tools necessary for this section

 Assorted Phillips  Assorted offset screwdrivers  Assorted hexagonal socket wrenches  Needle nose pliers  Grounded wrist strap (or similar grounding accessory)  Anti-static container to store printed circuit boards (PCBs)

, TORX®, and blade screwdrivers

More tools necessary to for some procedures

The following tools are necessary for Replace the heatsink components on page 105:

 Plastic scraper  Isopropyl alcohol  Paper towels  Lint-free cloth

94 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the PCBs and Related Components

Replace the DSP PCB

For kit contents, refer to Plasma power supply interior, front on page 24.

For the procedure to replace the DSP PCB, refer to the DSP PCB Replacement and Power Supply Data Backup Field Service Bulletin (810950). Download the file at www.hypertherm.com/docs.

NOTICE

POSSIBLE LOSS OF DATA

You can lose system-level cut data if you do not save that data before you install the new DSP PCB. Use the procedure in the 810950 Field Service Bulletin to save the system-level cut data from the old

DSP PCB to the new DSP PCB.

NOTICE

SYSTEM CANNOT CUT

The 2-pin jumper (108855) in this kit is necessary to save system data to the new DSP PCB. But it prevents the torch from firing a plasma arc if you keep it on the DSP PCB.

Make sure that you remove the 2-pin jumper from the new DSP PCB before you try to cut.

Powermax65/85 SYNC Service Parts and Procedures 810440 95

Service Procedures for the PCBs and Related Components

MTG

Replace the control PCB and the ribbon cable

For kit contents, refer to Plasma power supply interior, front on page 24. The control PCB and the ribbon cable are sold as different kits. The control PCB does not come with a ribbon cable.

Remove the control PCB and the ribbon cable

1. Set the power switch on the plasma power supply to OFF (O), disconnect the power cord, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Loosen the front panel. Refer to page 55.

4. Pull the adjustment knob off of its post on the front panel. If necessary, use a blade

screwdriver to carefully pry the knob off of the post.

5. Remove the 3 mounting screws from the control PCB . Use an offset TORX screwdriver. The screws have the label MTG.

6. From the power PCB side of the plasma power supply, remove the control PCB from the front panel.

7. Disconnect the ribbon cable from J6 on the control PCB.

MTG

96 810440 Service Parts and Procedures Powermax65/85 SYNC

8. Is it necessary to replace the ribbon cable?

MTG

 If yes, go to the next step.  If no, continue with Install the control PCB and the ribbon cable.

9. Remove the left mounting screw from the DSP PCB .

10. Disconnect the ribbon cable from J6 on the DSP PCB.

Install the control PCB and the ribbon cable

1. Connect the ribbon cable to the J6 connector on the new control PCB .

2. From the power PCB side of the plasma power supply, put the control PCB into position in the

front panel as follows:

a. Tilt the bottom of the control PCB towards the front panel until it is on the plastic tabs in the

panel.

b. Push the post on the control PCB through the hole in the front panel.

3. Attach the control PCB to the front panel

with the 3 mounting screws. Tighten the screws to 0.6 N·m (5 lbf·in).

Service Procedures for the PCBs and Related Components

MTG

4. Push the adjustment knob onto the post in the front panel.

5. Attach the front panel. Refer to page 56.

6. Did you install a new ribbon cable?

 If yes, go to the next step.  If no, continue with step 9.

7. Connect the ribbon cable to J6 on the DSB PCB .

8. Install the left mounting screw in the DSP PCB. Tighten the screw to 1.1 N·m (10 lbf·in).

9. Install the component barrier and the plasma power supply cover. Refer to page 51.

Powermax65/85 SYNC Service Parts and Procedures 810440 97

Service Procedures for the PCBs and Related Components

Replace the power PCB

For kit contents, refer to Plasma power supply interior, power PCB side on page 26.

Refer to page 100 through page 100 for an image of your power PCB.

Remove the power PCB

1. Set the plasma power supply switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.

2. Remove the plasma power supply cover and the component barrier. Refer to page 49.

3. Remove the end panel bracket. Refer to page 53.

4. Get a photograph of the power PCB so that you have a record of how all the screws and wires

are attached.

5. Remove the DSP PCB, as follows:

a. If you are using a serial connection, remove the DSP connector from J7 at the top of the

DSP PCB.

b. Remove the 2 mounting screws from the DSP PCB. c. Be careful not to bend the pins as you pull the DSP PCB away from the power PCB. d. Disconnect the ribbon cable from J6 on the DSP PCB. e. Set aside the DSP PCB in an anti-static bag.

98 810440 Service Parts and Procedures Powermax65/85 SYNC

Service Procedures for the PCBs and Related Components

J2 J3

J4 J5

CSA

CE/CCC

6. Disconnect the 4 wire connectors near the top of the power PCB.

For step 7 through step 15, refer to Figure 1 and Figure 2.

7. Remove the 3 µF capacitors from near the center of the power PCB. The number of capacitors is different for each system. Set aside the capacitors and the screws.

8. Disconnect the gate drive wire connectors .

9. CSA models: Disconnect the PFC temperature sensor wire connector .

10. CE/CCC models: Disconnect the MOV assembly from the right side of the power PCB. Set

aside the MOV assembly and the screws.

11 . Remove all of the remaining screws that attach the power PCB to the heatsink components and

to the center panel. Make sure that you identify where the screws go so that you know where to install them on the new power PCB.

12. Disconnect the J12 and J20 connectors from the left side of the power PCB.

13. If you are using a machine interface connection, disconnect the J21 and J32 (CSA) or J33

(CE/CCC) connectors from the left side of the power PCB.

14. Pull the right edge of the power PCB forward, and push the gate drive wires and PFC temperature sensor wire through the openings in the PCB.

15. Carefully remove the power PCB and set it aside in an anti-static bag.

Powermax65/85 SYNC Service Parts and Procedures 810440 99

Service Procedures for the PCBs and Related Components

RED

J32

RED J21

ORG J20

J12

B R

WORK

LEAD

BLK

J13

J16J17J18J19

J26

J29

TP12

J28

TP10

TP11

J4 J2 J1J3

2 3

RED

J33

RED J21

ORG

J20

J12

B R

J13

J19

TP13

TP11

TP12

J6 J5 J4 J3

WORK

LEAD

J27

J29

J18

J23

J24

J30

Figure 1 – Powermax65/85 SYNC CSA power PCB

Figure 2 – Powermax65/85 SYNC CE/CCC power PCB

100 810440 Service Parts and Procedures Powermax65/85 SYNC

Hypertherm Manual Family Service Manual (SM)

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Before You Begin

Service Parts

Plasma power supply exterior, front

Work leads

Powermax65 SYNC

Powermax85 SYNC

Plasma power supply exterior, rear

Power cord and strain relief

Rear panel

Plasma power supply interior, rear

Plasma power supply interior, fan side

Fan and fan shroud

Plasma power supply interior, front

Front panel

Plasma power supply interior, power PCB side

Capacitors and DSP PCB

Plasma power supply interior, heatsink

65 A/85 A heatsink diode bridges

65 A/85 A heatsink IGBTs and thermal sensor

IGBT tester

65 A/85 A heatsink resistors

Power supply interior, magnetics

Machine interface and RS-485 serial interface upgrade kits

External cables for machine interface receptacle and RS-485 serial interface receptacle

Machine interface cables

RS-485 serial interface cables

Powermax65/85/105 SYNC labels

Cartridge labels

CSA warning label

Descriptions of warning label icons

Parts necessary for safety

Recommended spare parts

Find replacement parts by part number

Tools necessary for this section

More tools necessary for some procedures

Replace the plasma power supply cover and component barrier

Remove the plasma power supply cover and component barrier

Install the component barrier and plasma power supply cover

Replace the end panel bracket

Remove the end panel bracket

Install the end panel bracket

Loosen and attach the front panel

Loosen the front panel

Attach the front panel

Loosen and attach the rear panel

Loosen the rear panel

Attach the rear panel of the plasma power supply

Replace the front panel

Remove the front panel

Install the front panel

Replace the rear panel

Remove the rear panel

Install the rear panel

Replace the work lead connector

Remove the work lead connector

Install the work lead connector

Replace the work lead receptacle

Remove the work lead receptacle

Install the work lead receptacle

Replace the torch quick-disconnect receptacle

Remove the torch quick-disconnect receptacle

Install the torch quick-disconnect receptacle

Replace the power switch

Remove the power switch

Install the power switch

Service Procedures for the Gas Line

Tools necessary for this section

More tools necessary for some procedures

Replace the air filter bowl and filter element

Remove the air filter bowl and filter element

Replace the air filter bowl, O-ring, and filter element

Install the air filter bowl and filter element

Replace the air filter assembly

Remove the air filter assembly

Install the air filter assembly