Hypertherm Powermax45 XP Field Service Bulletin

Powermax45 XP® Raw Arc Voltage Kit

Kit de tension d’arc brute Powermax45 XP

Field Service Bulletin

Bulletin de service sur le terrain

809520 | Revision 1 | December 2016

| Révision 1 | Decembre 2016

Hypertherm Inc.

Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office Email)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service Email)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)

[e-mail] (RMA email)

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
[e-mail] (Technical Service Email)

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)

[e-mail] (Technical Service Email)

Hypertherm (Singapore) Pte Ltd.

82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing Email)
[e-mail] (Technical Service Email)

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
[e-mail] (Main Office Email)
[e-mail] (Technical Service Email)

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)

[e-mail]
(Technical Service Email)

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)

[e-mail]
(Technical Service Email)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service Email)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing Email)
[e-mail]
(Technical Service Email)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office Email)
[e-mail]
(Technical Service Email)

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
[e-mail] (Main Office Email)
[e-mail]
(Technical Service Email)

1/28/16

© 2016 Hypertherm Inc. All rights reserved. Tous droits réservés.
Powermax and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and/or other countries. All other trademarks

are the property of their respective holders.
One of Hypertherm’s long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and our customers’,

success. We are always striving to become better environmental stewards; it is a process we care deeply about.
Powermax et Hypertherm sont des marques d’Hypertherm Inc. qui peuvent être déposées aux États-Unis et/ou dans d’autres pays. Toutes les autres

marques de commerce sont la propriété de leurs détenteurs respectifs.
Une des valeurs fondamentales d’Hypertherm depuis toujours est l’accent mis sur la minimisation de notre impact sur l’environnement. Cet objectif est

essentiel pour notre réussite et celle de nos clients. Nous nous efforçons de devenir de meilleurs gestionnaires environnementaux, c’est une chose qui
nous tient à cœur.

Introduction

Purpose

This field service bulletin explains how to install a customer-supplied machine interface cable that
does not use the internal 50:1 voltage divider on the Powermax45 XP.

Raw Arc Voltage Kit

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

All work requiring removal of the power supply cover must be performed
by a qualified technician.

See the safety information provided with your product for more safety
precautions.

Notice: Installation of the system at the installed site is subject to the approval of the Local

Inspection Authorities (LIA). Without approval of the LIA, modification of the factory installed
wiring voids the safety test marks (for example, cCSAus, CCC, CE, GOST-TR, UkrSEPRO,
RCM, EAC) applied to the product in the Hypertherm factory, and the safety certificates
provided by Hypertherm become invalid after modification.

Tools and materials needed

 Wire strippers
 Wire terminal crimper
 Assorted Phillips
 Electric drill with a 15 mm or 19/32 inch drill bit
 0.75 mm

OLFLEX

 M3 (#5) insulated ring terminals, quantity 2

2

or 18 AWG, 2 wire, non-shielded cable similar to

®

190 (manufacturer’s part number 601802)

428689 Kit contents

Part number Description Quantity

®

and TORX® screwdrivers

008279 Strain relief 1

075529 M3 x 10 mm machine screw with lock washer 2

Powermax45 XP Field Service Bulletin 809520 3

Raw Arc Voltage Kit

1

234

3

2

4

1

3

1

2

Install the interface cable

Connecting a cable to the power board to bypass the voltage divider board and access raw arc
voltage must be done by trained service personnel.

SHOCK HAZARD, ENERGY HAZARD, AND FIRE HAZARD

Connecting directly to the plasma circuit for access to raw arc voltage
increases the risk of shock hazard, energy hazard, and fire hazard in the
event of a single fault. The output voltage and the output current of the
circuit are specified on the data plate.

Remove cover and component barrier

1. Turn OFF the power. Disconnect the power cord and gas supply.

WARNING

2. Remove the two screws from the power supply handle . Remove the two screws from the
bottom of the front and rear panels. Tilt the tops of the front and rear panels away from the
unit to pull the handle out .

4 809520 Field Service Bulletin Powermax45 XP

3. Slide the cover off.

Raw Arc Voltage Kit

4. Remove the two plastic pins that secure the component barrier to the main power board. Slide
the component barrier off.

Powermax45 XP Field Service Bulletin 809520 5

Raw Arc Voltage Kit

48.3 cm (19 inches)

Prepare the interface cable

1. Use 2 conductor, non-shielded 18 AWG wires to connect to the power supply. Measure the
distance needed to connect from the CNC to the power supply. Add an additional 51.5 cm
(20.25 inches) to make the connection inside the power supply.

2. Cut back the outer jacket 48.3 cm (19 inches) from one end of the cable. Make sure you do not
cut into the insulation on the two 18 AWG wires.

Do not strip the wire ends until after they have been routed through the



power supply.

Install the strain relief

1. Pull the rear panel slightly away from the unit leaving enough space to drill a hole while avoiding
any contact with internal components or wires when drilling.

2. Use a 15 mm (19/32 inch) drill to drill out the interface cable entry point on the panel. Clean the
area of any chips from drilling.

6 809520 Field Service Bulletin Powermax45 XP