MAX40/40cs/

HT40C
CH50 Chopper
Replacement
Field Installation Bulletin
801580 - Rev. 1
CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C

In this bulletin:

Objective .............................................................................................. 2
Customer Required Tools ..................................................................... 2
Hypertherm Parts ................................................................................. 2
Single-Phase (1PH) Chopper SA - MAX40, MAX40cs, HT40C ........... 2
Three-Phase (3PH) Chopper SA - MAX40, MAX40cs, HT40C ............ 2
Single-Phase Chopper Removal Procedure ........................................ 4
Single-Phase Chopper Installation Procedure ..................................... 6
Three-Phase Chopper Removal Procedure ......................................... 8
Three-Phase Chopper Installation Procedure ...................................... 10

FIELD INSTALLATION BULLETIN Page 1

CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C
Objective

The objective of this field installation bulletin is to provide instruction for replacing the
#041106 EWS chopper module with the #029631 CH50 chopper module. The procedures
presented in this bulletin are applicable for the MAX40, MAX40cs, and the HT40C.

Customer Required Tools

• Regular and Phillips-head screwdrivers

• Vise grips
• Adjustable wrench

Hypertherm Parts

The format to list and call out Hypertherm parts is as follows:

Part No. Description

XXXXXX Bold heading indicates parent item or kit containing one or more items.
XXXXXX Indented item in normal type indicates a part
. contained under the parent item or kit.
XXXXXX Indented bold heading indicates a subassembly under the parent
item or kit that also contains one or more items.

Single-Phase (1PH) Chopper SA - MAX40, MAX40cs, HT40C

Part No. Description Qty.

128087 CH SA 1PH MAX40 40CS HT40C 1
004554 CH50 Stand-off #10-32 X 3.625 4
023571 Jumper CH50 (HT40c & MAX40) 1
075094 M/S:10-32 X 5/8 PH Pan 4
029676 CHP SA:MAX40/CS/HT40C 1PH 1
801580 FSB:CH50 Replacement

Three-Phase (3PH) Chopper SA - MAX40, MAX40cs, HT40C

Part No. Description Qty.

128100 CH SA 3PH MAX40 40CS HT40C 1
004554 CH50 Stand-off #10-32 X 3.625 4
023571 Jumper CH50 (HT40c & MAX40) 1
075094 M/S:10-32 X 5/8 PH Pan 4
029678 CHP SA:MAX40/CS/HT40C 3PH 1
801580 FSB:CH50 Replacement

Page 2 FIELD INSTALLATION BULLETIN

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CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C

WARNING!

Extremely dangerous voltages are present in the MAX40, MAX40cs,

and HT40C power supplies. Be certain that all power to the power
supply is disconnected before attempting any field installation work as
described below.

FIELD INSTALLATION BULLETIN Page 3

CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C
Single-Phase Chopper Removal Procedure

To remove the #041106 EWS chopper and install the #029676 CH50 chopper assembly,
refer to Figures 1, 2 and 3 and proceed as follows:

1. Turn off main power to power supply.

2. Remove the seven screws from the front panel cover, and remove the front panel
to expose the #041106 EWS chopper assembly.

3. Remove the cables marked AD and BC on the large transformer (T2) located on the
base of the power supply. See Figure 1 below for location of terminal connections
for AD and BC on the single-phase transformer.

Front of
Power Supply
BC

AD

Figure 1 Single-phase transformer

4. Unplug the 12-pin connector from the top of the chopper module.

5. Unscrew and remove cables marked 48, 49, 39 from the chopper module.

6. From the three large capacitors, unscrew and remove the 1.5KΩ resistor and wires
that are attached to the resistor.

7. Unscrew and remove the long bar labeled +48 that attaches the chopper module to
the top capacitor.

8. Unscrew and remove the short copper bar that attaches the chopper module to the
top capacitor.

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 CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C

Remove screw Remove screw

Remove 12-pin
connector Remove short
copper bar

Unplug
terminals
(HT40C,
MAX40 only)
+ 48

Remove long bar

12
11

Remove
resistor and
wires

Remove screws

48 49 39

Remove cables 48, 49 and 39 from chopper

Figure 2 #041106 EWS Single-Phase Chopper to Remove

FIELD INSTALLATION BULLETIN Page 5

CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C
9. On the HT40C and MAX40, unplug mating terminals marked 11 and 12 from the
sensor that is attached to the chopper frame.

10. Remove the four screws (or nuts) that secure the chopper module to the power
supply frame, and remove the chopper module.

11. Unscrew the four standoffs that held the chopper to the power supply frame.

Single-Phase Chopper Installation Procedure

1. Take the four 3 5/8" standoffs that came with the kit, and attach them to the power
supply frame in the same locations where the original four standoffs were.

2. Mount and secure the #029676 CH50 chopper assembly to the standoffs using the
four 10-32 machine screws that came with the kit.

3. Attach the 12-pin connector to the top of the chopper module. Be certain that the
connector is properly mated with the pins on the module.

4. Attach the long wires from the chopper labeled 1 and 2 to the large transformer
(T2) as follows (Refer to Figure 1):

• Attach 1 to where AD was attached (terminal closest to front of power supply).

• Attach 2 to where BC was attached (terminal farthest from front of power

supply).

5. Attach the cables labeled 48, 49, and 39 to the chopper as follows (Refer to
Figure 3):

• 39 attaches to the screw terminal labeled OUT.

• 49 attaches to the screw terminal labeled - CAPS.

• 48 attaches to the screw terminal labeled + CAPS.

6. On the HT40C and the MAX40, jumper terminals 11 and 12 together with the
supplied jumper wire (# 023571).

7. Replace and secure the power supply cover.

Installation of the single-phase chopper module is now complete.

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CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C

14 13

5
1

+ CAPS
- CAPS
OUT

1 2 3
39 49 48

Cables to attach

Figure 3 #029631 CH50 Chopper to Install

FIELD INSTALLATION BULLETIN Page 7

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CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C
Three-Phase Chopper Removal Procedure

To remove the #041106 EWS chopper and install the #029678 CH50 chopper assembly,
refer to Figures 3, 4 and 5 and proceed as follows:

1. Turn off main power to power supply.

2. Remove the seven screws from the front panel cover, and remove the front panel
to expose the #041106 EWS chopper assembly.

3. Remove the cables marked 1,2 3,4 and 5,6 on the large transformer (T2) located on
the base of the power supply. See Figure 4 below for location of terminal
connections for 1,2 3,4 and 5,6 on the three-phase transformer.

1,2

3,4

5,6

Figure 4 Front View of Three-Phase Transformer

4. Unplug the 12-pin connector from the top of the chopper module.

5. Unscrew and remove cables marked 48, 49, 39 from the chopper module.

6. Unscrew and remove the long bar labeled +48 that attaches the chopper module to
the large capacitor.

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 CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C

Remove screw Remove screw

Remove 12-pin
connector

Unplug
terminals
(HT40C,
MAX40 only)

Remove short
copper bar
12 Remove long bar
11

+ 48

Remove screws 5KΩ Resistor

(Do not remove)

48 49 39

Remove cables 48, 49 and 39 from chopper

Figure 5 #041106 EWS Three-Phase Chopper to Remove

FIELD INSTALLATION BULLETIN Page 9

CHOPPER INSTALLATION - MAX40/MAX40cs/HT40C
7. Unscrew and remove the short copper bar that attaches the chopper module to the
large capacitor.

8. On the HT40C and MAX40, unplug mating terminals marked 11 and 12 from the
sensor that is attached to the chopper frame.

9. Remove the four screws (or nuts) that secure the chopper module to the power
supply frame, and remove the chopper module.

10. Unscrew the four standoffs that held the chopper to the power supply frame.

Three-Phase Chopper Installation Procedure

1. Take the four 3 5/8" standoffs that came with the kit, and attach them to the power
supply frame in the same locations where the original four standoffs were.

2. Mount and secure the #029676 CH50 chopper assembly to the standoffs using the
four 10-32 machine screws that came with the kit.

3. Attach the 12-pin connector to the top of the chopper module. Be certain that the
connector is properly mated with the pins on the module.

4. Attach the long wires from the chopper labeled 1 , 2 , and 3 to the large
transformer (T2) as follows (Refer to Figure 4):

• Attach 1 to where 1,2 was attached (top terminal point).

• Attach 2 to where 3,4 was attached (middle terminal point).

• Attach 3 to where 5,6 was attached (lower terminal point).

5. Attach the cables labeled 48, 49, and 39 to the chopper as follows (Refer to
Figure 3):

• 39 attaches to the screw terminal labeled OUT.

• 49 attaches to the screw terminal labeled - CAPS.

• 48 attaches to the screw terminal labeled + CAPS.

6. On the HT40C and the MAX40, jumper terminals 11 and 12 together with the
supplied jumper wire (# 023571).

7. Replace and secure the power supply cover.

Installation of the three-phase chopper module is now complete.

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