Hypertherm Powermax 45 voltage divider mod
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- Опубликовано: 8 мар 2015
- I had to modify the Powermax 45 one way or another to use it with the PlasmaCAM. PlasmaCAM uses an oddball (21.1:1) voltage divider and can't use the built-in 50:1 divider of the Powermax 45. The bigger units have programmable dividers. I added in an external divider and wired it into the factory connector so I can use the machine interface connector with PlasmaCAM.
Thanks for the great video. I really only needed the part numbers but I appreciated getting the wiring tour! Nice work.
Thanks a lot for your help (From Mexico)
Happy to help!
This only works with the machine torch. The hand torch does not have trigger connections to the CPC port.
Hello I have a powermax 65 sync and a cnc table the requires a 1:1 voltage divider ratio, is it possible to achieve that ?
I looked at the docs for this unit and it doesn't look like they offer either a machine torch or machine interface on this model of plasma cutter. The manual is also missing any repair information that previous generations had. It looks like this is not intended to be a user-serviceable plasma cutter and they only intend for it to be used with hand torches. Adapting it to machine use may be difficult, you will definitely need to contact Hypertherm for any information on doing that. My personal opinion would be to stay away from the SYNC line of plasma cutters if you want a machine interface or less expensive consumables. The one-piece consumable looks expensive and has the potential to become another keurig type scenario where they prevent 3rd party consumables from being used because the consumable "talks" to the plasma cutter. While I buy Hypertherm consumables, I can buy all of the pieces separately and replace them separately. A drag or gouge shield might last multiple sets of consumables, or you might oopsie and need to replace the shield while the consumables are still good.
I have been trying to bypass an internal voltage divider on a Jasic cut 60/unimig razorcut, as my THC has its own divider and dividing the signal twice is making it too low,
I tried simply tapping a signal off the raw torch output, but i think that is causing issues with the high voltage of the pilot arc? does that seem plausible?
thanks for any help!
It's fundamentally a bad idea to run the pilot arc (high voltage) over a long distance. The reason the divider is in the plasma unit is to a) increase the impedance (lower the energy requirement and thus potential for interference) b) keep high voltage from being carried by unshielded conductors for a long distance. You should look into what it would take to modify the THC, not the plasma cutter.
@@eformance Ok thanks for that, modifying the THC has been suggest to me right enough,
The jasic divider is 20:1 and the THC one is 40:1, perhaps i could modify the THC one to be 20:1 also, which would mean the controller would be getting the 40:1 its expecting,
Am I correct in that theory or way off?!
Thanks very much again for your help!!
@@finlaybichan1275 The THC wants a lower voltage than the Jasic divider puts out. Say you've got 10,000 volts and divide that by 20, that is 500 volts to the THC. The THC has a 40:1 divider, if you gave it 10,000 volts it would see 250v on the output of the divider. To get your THC to see 250v without modifying the Jasic divider, you only need a 2:1 divider in the THC. A simple 2:1 divider can be had with just 2 10 kiloohm resistors replacing the existing divider. That will divide the 500v from the plasma cutter down to 250v that the THC expects. Here are a couple links to help you understand better:
en.wikipedia.org/wiki/Voltage_divider
learn.sparkfun.com/tutorials/voltage-dividers/all
@@eformance thats some great info, thanks very much for taking the time to reply!! a true gent!
Hello. We have a Hypertherm 105A and set with a ratio of 50:1, then in our THC voltage divider with the ratio of 100:1. How will we connect this to our voltage divider if we have different ratios? Thanks
If the plasma cutter is set to 50:1 and the THC expects 100:1, then the THC will get twice as much voltage as it expects. This could damage the THC, cause it to cut too low (crashing into the metal sometimes), or it may work but be wonky. The voltage increases as the arc length increases, so if it thinks the arc length is longer than it is, it can cut too low and your parts will have a lot of bevel on the backside.
@@eformance Thank you so much. But can we adjust the THC 100:1 ratio to 50:1? We are using HYD XPTHC-100III. Thanks again
@@crichfoodie It looks like the THC is fixed, but you can use 2 10 kilo-ohm resistors to create a 2:1 voltage divider, which will divide the 50:1 down to 100:1. Look here: learn.sparkfun.com/tutorials/voltage-dividers/all You could also contact the manufacturer of the THC and ask their advice.
@@eformance Thank you!!
my divider board only supports 100:1 ratio and there is no option for that please help
The PlasmaCAM comes with the divider cable, you can hook it up with their directions. I chose to modify the plasma cutter by using the end of the cable that came with the plasma table. I didn't use the internal divider, I just cut the cable in 2 and put the end section inside the plasma cutter.
@@eformance does that mean u are receiving raw voltage??
@@alimehboob8908 I suggest that you wire the 100:1 divider board directly to the arc voltage inside the plasma cutter. Work is + and electrode is -. If the divider board only has - coming out, then you connect the divider board to the electrode voltage and use the work clamp connection as the +. For a divider to work properly it must be connected to both voltages inside the plasma cutter.
@@eformancethanks for your replies. so 100:1 ratio won't matter anymore??
@@alimehboob8908 You need the 100:1 divider for your torch height control to work properly. The divider will have at least 3 connections, 1 for electrode voltage, 1 for the workpiece clamp, and 1 output that goes to the torch height control. The torch height control will need a wire from the workpiece clamp and from the voltage divider. The plasma cutter has 2 screws inside for the raw electrode voltage and for the workpiece clamp, this is where you need to connect the divider. The workpiece clamp is + and the output of the divider is -.
I need to splice into the trigger signal for my 45xp. Wish I understood. Im envious of your knowledge. All Chinese to me
I empathize with you, there's stuff that's greek to me too!
Is this the same for the 45 xp
I can't say for certain, but the 45XP has a machine interface so the procedure should be similar.