Hypertherm Powermax45 Service Manual - Manual (Page 114)

Component replaCement
6-10
powermax
45 Service Manual
11. Press the connector for the brown wire into the hole on the top left side of the power switch (L1) and replace the
screw that secures it. Torque the screw to 11.5 kg cm (10 inch-pounds).
12. Press the connector for the black wire into the hole on the top middle of the power switch (L2) and replace the
screw that secures it. Torque the screw to 11.5 kg cm (10 inch-pounds).
13. Press the connector for the gray wire into the hole on the top right of the power switch (L3) and replace the screw
that secures it. Torque the screw to 11.5 kg cm (10 inch-pounds).
14. Tighten the green/yellow ground wire to the heat sink with a torque setting of 17.3 kg cm (15 inch-pounds).
15. Position the wires in the wire chase up the side of the end panel and out of the way of the power board.
16. 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.
17. Tighten the strain relief’s retention nut on the outside of the end panel to secure the new power cord.
18. If you are installing a plug on the new power cord, use a plug that meets national and local electrical codes. The
plug must be connected to the power cord by a licensed electrician.
19. 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.
20. Reconnect the electrical power and the gas supply.
Replace the power cord (480 V CSA)
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 480 V CSA power cord has 3 wires – black, white, and red – that connect to the power switch and a green
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 3 screws that secure the power cord wires to the power switch and gently pull the wires out of the
switch.
5. Remove the screw that holds the green ground wire to the heat sink.