Hypertherm Powermax45 Service Manual - Manual (Page 110)

Component replaCement
6-6
powermax
45 Service Manual
8. If you are replacing the old strain relief with the new strain relief contained in the kit, slide the new strain relief onto
the new power cord and route the wires for the new power cord through the hole in the end panel. Slide the new
strain relief nut over the wires and screw it to the strain relief from the inside of the end panel. Hand tighten the nut
and then over-tighten slightly more.
If you are keeping the old strain relief in place, route the wires for the new power cord through the strain relief.
9. Screw the connector for the black wire onto the pin on the upper left side of the power switch with a torque
setting of 23.0 kg cm (20 inch-pounds).
10. Screw the connector for the white wire onto the pin on the upper right side of the power switch with a torque
setting of 23.0 kg cm (20 inch-pounds).
11. Tighten the green ground wire to the heat sink with a torque setting of 17.3 kg cm (15 inch-pounds).
12. Position the wires in the wire chase up the side of the end panel and out of the way of the power board.
13. Replace or reposition the end panel. Make sure that the screw hole in the ground clip aligns with the screw holes
in the end panel and the power supply.
14. Tighten the strain relief’s retention nut on the outside of the end panel to secure the new power cord.
15. Being careful not to pinch any of the wires, replace the Mylar barrier and slide the cover back onto the power
supply. Position the handle over the holes in the top of the cover, then use the 2 screws to secure the cover.
16. Reconnect the electrical power and the gas supply.
Replace the power cord (230 V Ce)
1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Use a #2 Phillips screwdriver to 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.
The 230 V CE power cord has a brown wire and a blue wire that connect to the power switch, and a green/yellow
ground wire that connects to the heat sink.
3. Remove the rear end panel or gently tilt it away from the power supply until you can access the screws that secure
the power cord wires to the back of the power switch.
NOTE: To remove the rear end panel, you must first remove the air fitting.
4. Remove the screws that secure the connectors for the blue and brown wires from the power switch to disconnect
them.
5. Remove the screw that holds the green/yellow wire to the heat sink.