Hypertherm POWERMAX 45 Manuale di riferimento

Field Service Bulletin

Bulletin de service sur le terrain

806200 – Revision 4 – July 2014

Révision 4 – Juillet 2014

Powermax45®

Raw Arc Voltage Kit

Kit de tension d’arc brute

Powermax45

Hypertherm Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

[email protected] (Main Office Email)

800-643-9878 Tel (Technical Service)

[email protected] (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)

877-371-2876 Fax (Return Materials Authorization)

[email protected] (RMA email)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D-63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane

Media Centre

Annexe Block #A01-01

Singapore 349567, Republic of Singapore

65 6841 2489 Tel

65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 301, South Building

495 ShangZhong Road

Shanghai, 200231

PR China

86-21-60740003 Tel

86-21-60740393 Fax

Hypertherm Europe B.V.

Vaartveld 9

4704 SE

Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (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

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia

Guarulhos, SP - Brasil

CEP 07115-030

55 11 2409 2636 Tel

55 11 2408 0462 Fax

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

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D,

1514 Woo-dong, Haeundae-gu, Busan

Korea, 612-889

82 51 747 0358 Tel

82 51 701 0358 Fax

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.

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 commerciales sont la propriété de leurs détenteurs respectifs.

Powermax45 Field Service Bulletin 806200 3

Powermax45 Raw Arc Voltage Kit

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.

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, C-Tick, Kvalitet, 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 crimpers

Assorted Phillips®and TORX®screwdrivers

Electric drill with a 15 mm or 19/32 inch drill bit

0.75 mm2or 18 AWG, 2 wire, non-shielded cable similar to OLFLEX®190 (601802)

M4 (#8) insulated ring terminals

M5 (#10) insulated ring terminals

228352 Kit contents

WARNING!

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance. See the

Safety and Compliance Manual (80669C) for more safety precautions.

Part number Description Quantity

008279 Strain relief 1

4Powermax45 Field Service Bulletin 806200

Powermax45 Raw Arc Voltage Kit

Accessing raw arc voltage

Connecting a cable to the Powermax45 power board to bypass the voltage divider and access raw arc voltage must

be done by trained service personnel.

To access raw arc voltage on a Powermax45, you will need the strain relief in kit number 228352 and an 0.75 mm2

(18 AWG), 2 wire, non-shielded cable similar to OLFLEX 190 (601802) in the length needed to go between the power

supply and the CNC or other equipment plus an additional 45.72 cm (18 inches) to connect inside the power supply.

1. On the end of the cable that will be attached to the power supply, strip the outer jacket 11.43 cm (4.5 inches). Cut

6.35 cm (2.5 inches) off of wire 2 so that wire 1 is 11.43 cm (4.5 inches) long and wire 2 is 5.08 cm (2 inches) long.

Then strip 1.27 cm (0.5 inches) of wire insulation off of each wire.

2. Crimp an M4 (#8) insulated ring on the end of wire 1 (negative lead) and an M5 (#10) insulated ring on the end

of wire 2 (positive lead).

3. Remove the 2 screws from the handle on the top of the power supply. Tip the end panels back slightly so that you

can get the edges of the handle out from underneath them. Lift the cover off the power supply. Remove the Mylar®

barrier that protects the power board.

4. Separate the rear panel from the Powermax45 by removing the screw from the bottom and backing the panel away

from the base so that there is enough room to drill out the access point without risk of hitting the interior components.

WARNING!

HIGH VOLTAGE AND CURRENT

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.

Powermax45 Field Service Bulletin 806200 5

Powermax45 Raw Arc Voltage Kit

5. Use a drill with a 15 mm (19/32 inch) drill bit to drill out the access point on the rear panel.

6. Route the cable through the strain relief so that 45.72 cm (18 inches) of insulated wire is on the side of the strain

relief that will go inside the power supply.

7. Thread the 45.72 cm (18 inches) of wire through the hole you drilled in the rear panel and fit the strain relief into the

hole. If necessary, drill out any remaining rough spots so that the strain relief fits snugly.

8. Tighten the strain relief nut on the inside of the rear panel to hold the strain relief in place.

Access point

Rear panel

12345

Cable direction

1Strain relief retention nut (outside power supply)

2Strain relief

3Rear panel

4Strain relief nut (inside power supply)

5Wire 1 (-)

6M4 (#8) ring

7Wire 2 (+)

8M5 (#10) ring

6Powermax45 Field Service Bulletin 806200

Powermax45 Raw Arc Voltage Kit

9. Find the grommet closest to the rear panel and at the bottom of the center panel. Route the 2 wires through the

grommet to the power board side of the power supply.

10. Route the wires along the base of the unit and behind the cables connected to the power board.

11 . Remove the work lead connector screw at J21 and the white wire connector screw at J19 (J18 for 400 V CE and

480 V CSA power supplies).

12. Connect wire 1 to J19 (J18 for 400 V CE and 480 V CSA power supplies). Orient the wires such that the ring

connector for wire 1 is closest to the power board, and the connector for the white wire is closest to the head of the

screw. Turn the ring connector for wire 1 upside down so that the slight bend in the ring connector base creates a

little space between the wire and the board. Tighten the screw to 23.0 kg∙cm (20 inch∙pounds).

Grommet in center panel

Rear panel pulled slightly

away from the base

Powermax45 Field Service Bulletin 806200 7

Powermax45 Raw Arc Voltage Kit

13. Connect wire 2 to J21. This time, put the connector for the work lead closest to the power board, and put the ring

connector for wire 2 closest to the head of the screw. Torque the screw to 23.0 kg∙cm (20 inch∙pounds).

14. Replace the rear panel and secure it with the screw. Replace the Mylar barrier in front of the power board.

Replace the cover.

15. Tighten the strain relief retention nut onto the strain relief on the outside of the power supply.

16. Connect the other end of the cable to the equipment according to the manufacturer’s instructions. Remember to

observe polarity.

Notice: The output of the internal voltage divider board is designed to prevent shock, energy and fire hazards, and

is intended to satisfy most codes and standards for external wiring outside the electrical enclosure. All external

wiring practices for an unprotected raw arc voltage should be reviewed and approved by the Local

Inspection Authorities (LIA) at the time of installation prior to operation and use.

Raw arc voltage wiring terminals and connections should not be exposed to accidental contact

under normal and single fault conditions.

External wiring from an unprotected (that is, no voltage divider used in the power source) raw arc

voltage routed inside conduit between electrical enclosures will normally satisfy all electrical codes

and standards worldwide. Failure to address the hazards associated with live contact,

accessibility and single fault failures to this unprotected output can result in death

or fire.

A voltage divider board inside the CNC protects only the CNC and does NOT protect the external interconnecting

wiring between the power source and the CNC. Overcurrent protection may be required to protect the user and/or

machine in fault conditions.

External wiring outside the electrical enclosure should be suitable for the installation and meet national and local

regulations (for example, NFPA 70 NEC, NFPA 79, Canadian Electrical Code, CSA/CAN E60974-1, IEC 60204-1,

BS 7671) or other codes and/or standards applicable to the installed site where the equipment will be operated.

TP 19

TP 18

TP 17

192 VDC 192 VDC

J19 or J18

(white wire)

J21 (work lead)

8Powermax45 Field Service Bulletin 806200

Powermax45 Raw Arc Voltage Kit

Powermax45 Bulletin de service sur le terrain 806200 9

Kit de tension d’arc brute Powermax45

Introduction

Objet

Le présent bulletin de service sur le terrain décrit comment installer un câble d’interface de machine fourni par le client

n’utilisant pas le diviseur de tension interne 50:1 sur le Powermax45.

Avis : l’installation du système sur le site doit être approuvée par le service d’inspection local (LIA). Sans

l’approbation de la LIA, la modification du câblage fait en usine annule le marquage des essais de sécurité

(comme par exemple le cCSAus, CCC, CE, GOST-TR, UkrSEPRO, C-Tick, Kvalitet, EAC) apposé au produit

à l’usine Hypertherm. Les certificats de sécurité fournis par Hypertherm seront également déclarés nuls et non

avenus après ladite modification.

Outils et matériel requis

Pince à dénuder

Pince à sertir

Tournevis Phillips®et TORX®assortis

Perceuse électriques avec mèche de 15 mm

0,75 mm2, câble non blindé, à 2 fils, similaire au OLFLEX®190 (601802)

Cosses rondes isolées M4 (nº 8)

Cosses rondes isolées M5 (nº 10)

Contenu du kit 228352

AVERTISSEMENT !

UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL

Avant tout entretien, débrancher l’alimentation électrique. Se reporter

au Manuel de sécurité et de conformité (80669C) pour des mesures

de sécurité supplémentaires.

Numéro de référence Description Quantité

008279 Serre-câble 1

10 Powermax45 Bulletin de service sur le terrain 806200

Kit de tension d’arc brute Powermax45

Accès à la tension de l’arc brute

Le branchement d’un câble au panneau d’alimentation du Powermax45 afin de contourner le diviseur de tension

et accéder à la tension d’arc brute doit être effectué par un technicien de maintenance qualifié.

Pour accéder à la tension d’arc brute d'un Powermax45, il faut utiliser le serre-câble du kit numéro 228352 et un câble

non blindé à deux fils de calibre 0,75 mm2de type OLFLEX 190 (601802) d’une longueur suffisante pour relier la source

de courant et la CNC ou les autres équipements, en prévoyant une longueur supplémentaire de 45,72 cm pour le

connecter à l’intérieur de la source de courant.

1. Sur l’extrémité du câble devant être branchée à la source de courant, dénuder la gaine extérieure du fil sur une

longueur de 11,43 cm. Raccourcir de 6,35 cm la longueur du fil 2 de sorte à ce que le fil 1 mesure 11,43 cm

et le fil 2 mesure 5,08 cm de long. Dénuder ensuite 1,27 cm d’isolant sur chaque fil.

2. Sertir une cosse ronde isolée M4 (nº 8) à l’extrémité du fil 1 (fil négatif) et une cosse ronde isolée M5 (nº 10)

à l’extrémité du fil 2 (fil positif).

3. Déposer les deux vis de la poignée en haut de la source de courant. Basculer légèrement les panneaux d’extrémité

de façon à en extraire les bords de la poignée d’en dessous. Retirer le couvercle de la source de courant en le levant.

Déposer la barrière Mylar®qui protège le circuit imprimé d’alimentation.

4. Retirer le panneau arrière du Powermax45 en retirant la vis du bas et en écartant le panneau d’extrémité

du socle de manière à laisser suffisamment d’espace pour percer le point d’accès sans endommager

les composants internes.

AVERTISSEMENT !

HAUTE TENSION ET COURANT ÉLEVÉ

DANGER D’ÉLECTROCUTION, D’ÉNERGIE ET D’INCENDIE

Le raccordement direct au circuit plasma pour accéder à la tension de

l’arc brute augmente le danger d’électrocution, de problèmes d’énergie

et d’incendie s’il y a le moindre défaut. La tension de sortie et le courant

de sortie du circuit sont indiqués sur la plaque signalétique.

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