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Hypertherm Powermax 30, Service Manual

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MAINTENANCE

powermax30

Service Manual

3-5

Troubleshooting preparation

The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply
theory. In addition to being technically qualified, technicians must perform all testing with safety in mind.

If questions or problems arise during servicing, call the Hypertherm Technical Services team listed in the front of
this manual.

Test equipment

• Multimeter with a variety of jumper leads, including E-Z Hooks

®

.

Troubleshooting procedures and sequence

When performing the troubleshooting procedures,

• Read Section 1, 

Safety;

• Refer to Section 5 for the system’s electrical schematic;

• Refer to Section 4 to locate power supply components and

torch components.

After the problem has been located and repaired, refer to the 

Sequence of operation flow diagram in this section to

test the power supply for proper operation.

External inspection

1. Inspect the exterior of the power supply for damage to the cover and external components, such as the power

cord and plug.

2. Inspect the torch and the torch lead for damage.

Power OFF and disconnected

External inspection

Power ON

Internal inspection

Resistance checks

Troubleshooting guide

Troubleshooting tests

Summary of Contents for Powermax 30

Page 1: ...Plasma arc cutting system Service Manual 805170 Revision 2 ...

Page 2: ...2 January 2006 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2007 Hypertherm Inc All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries ...

Page 3: ...hai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 497...

Page 4: ...s f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and ot...

Page 5: ...iece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note the cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess...

Page 6: ...t Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or near the data plate Each certification test mark mean...

Page 7: ...ith coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products National and Local codes National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage ...

Page 8: ...re fatals 1a 3 L électricité statique peut endommager les cartes de circuits imprimés 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 5 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles de gaz comprimé peuven...

Page 9: ...CE Controls and indicators 3 2 Front controls and LEDs 3 2 Rear controls 3 2 Theory of operation 3 3 General 3 3 Functional description 3 3 Sequence of operation 3 4 Troubleshooting preparation 3 5 Test equipment 3 5 Troubleshooting procedures and sequence 3 5 External inspection 3 5 Internal inspection 3 6 Initial resistance check 3 7 Power supply overview 3 8 Troubleshooting guide 3 9 Control bo...

Page 10: ...28 Replace the fan 3 30 Replace the air filter element 3 31 Replace the air filter regulator 3 32 Replace the control board 3 33 Replace the power board 3 34 Replace the base 3 37 Section 4 PARTS Power supply parts 4 2 Exterior 4 2 Interior power board side 4 3 Interior fan side 4 4 T30v hand torch parts 4 5 Safety critical parts 4 6 Recommended spare parts 4 7 Section 5 WIRING DIAGRAMS Electrical...

Page 11: ...TABLE OF CONTENTS viii powermax30 Service Manual ...

Page 12: ...ity can damage circuit boards 1 3 Toxic fumes can cause injury or death 1 4 A plasma arc can cause injury and burns 1 5 Arc rays can burn eyes and skin 1 5 Grounding safety 1 5 Compressed gas equipment safety 1 6 Gas cylinders can explode if damaged 1 6 Noise can damage hearing 1 6 Pacemaker and hearing aid operation 1 6 A plasma arc can damage frozen pipes 1 6 Additional safety information 1 6 Wa...

Page 13: ...e the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres bef...

Page 14: ...AN KILL Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the work...

Page 15: ...where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations TOXIC FUMES CAN CAUSE INJURY OR DEATH The air quality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of c...

Page 16: ... clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or matches from your pockets before cutting Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect othe...

Page 17: ...drape the torch lead or work cable around your body Keep as far away from the power supply as possible PACEMAKER AND HEARING AID OPERATION ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standar...

Page 18: ... Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel...

Page 19: ... path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced ve...

Page 20: ... imprimés 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des brûlures 1a 5 Les rayons de l arc peuvent brûler les yeux et la peau 1a 5 Mise à la masse et à la terre 1a 5 Sécurité des bouteilles de gaz comprimé 1a 6 Les bouteilles de gaz comprimé peuvent exploser en cas de dommages 1a 6 Le bruit peut provoquer des problèmes aud...

Page 21: ... sont pas suivies correctement Prévention des incendies Avant de commencer s assurer que la zone de coupage ne présente aucun danger Conserver un extincteur à proximité Éloigner toute matière inflammable à une distance d au moins 10 m du poste de coupage Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles Ne jamais c...

Page 22: ...ructions du présent manuel et conformément aux codes électriques locaux et nationaux Inspecter fréquemment le cordon d alimentation primaire pour s assurer qu il n est ni endommagé ni fendu Remplacer immédiatement un cordon endommagé Un câble dénudé peut tuer Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés Ne pas saisir la pièce à couper ni les chutes lors du coupage Lai...

Page 23: ...ux normes et réglementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT Le niveau de qualité de l air dans tout lieu de travail dépend des variables propres au site comme Type de table humide sèche sous l eau Composition du matériau fini de la surface et composition des revêtements Volume de matériau enlevé Durée du coupage ou du gougeage Dimensions volume...

Page 24: ...iter que des étincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière Utiliser des éc...

Page 25: ... jamais exposer des bouteilles à une chaleur excessive aux étincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des clés ou d autres outils pour débloquer le robinet des bouteilles Les tuyaux gelés peuvent être endommagés ou éclater si l on essaie de les dégeler avec une torche plasma LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉ...

Page 26: ... saisir la pièce à couper de la trajectoire de coupage 2 3 Se protéger entièrement le corps 3 Tension dangereuse Risque de choc électrique ou de brûlure 3 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommagés 3 2 Se protéger contre les chocs en s isolant de la pièce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pièces sous tension 4 Le...

Page 27: ... être fatal Se protéger contre les risques de chocs électriques 3 1 Porter des gants isolants Ne pas porter de gants mouillés ou abîmés 3 2 S isoler de la surface de travail et du sol 3 3 Débrancher la prise ou la source de courant avant de manipuler l équipement 4 L inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé 4 1 Garder le visage à l écart des vapeurs 4 2 Ut...

Page 28: ...las de circuito 1b 3 Humos tóxicos pueden causar lesiones o muerte 1b 4 El arco de plasma puede causar lesiones y quemaduras 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel 1b 5 Seguridad de toma a tierra 1b 5 Seguridad de los equipos de gas comprimido 1b 6 Los cilindros de gas pueden explotar si están dañados 1b 6 El ruido puede deteriorar la audición 1b 6 Operación de...

Page 29: ... daños en el equipo Prevención ante el fuego Asegúrese de que el área sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables colocándolos a por lo menos 10 metros del área de corte Remoje los metales calientes o permita que se enfríen antes de que entren en contacto con materiales combustibles Nunca corte depósitos que contengan mater...

Page 30: ... Instale este equipo y conéctelo a tierra según el manual de instrucciones y de conformidad con los códigos locales y nacionales Inspeccione el cordón de alimentación primaria con frecuencia para asegurarse de que no esté dañado ni agrietado Si el cordón de alimentación primaria está dañado reemplácelo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha...

Page 31: ...n el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables específicas al sitio tales como Diseño de mesa mojada seca bajo agua La composición del material el acabado de la superficie y la composición de los recubrimientos Volumen que ...

Page 32: ... chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión Utilice pantallas o barreras protectoras para proteger a los demás...

Page 33: ...r excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro Se puede hacer daño a los tubos congelados o se los puede reventar si uno trata de descongelarlos con una antorcha por plasma EL RUIDO PUEDE DETERIORAR LA AUDICIÓN UN ARCO PLASMA PUEDE DAÑAR TUBOS CONGELADOS Los campos magnéticos producidos por las elevadas ...

Page 34: ... Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear...

Page 35: ...ques provocados por la antorcha o el cableado pueden ser fatales Protéjase del electrochoque 3 1 Colóquese guantes aislantes No utilice guantes dañados o mojados 3 2 Aíslese de la pieza de trabajo y de la tierra 3 3 Antes de trabajar en una máquina desconecte el enchufe de entrada o la potencia primaria 4 La inhalación de los humos provenientes del área de corte puede ser nociva para la salud 4 1 ...

Page 36: ...ax30 Service Manual 2 1 Section 2 SPECIFICATIONS In this section Power supply 2 2 Dimensions and weight 2 2 T30v torch ratings 2 3 Dimensions 2 3 Symbols and markings 2 4 mark 2 4 CE mark 2 4 IEC symbols 2 4 ...

Page 37: ...U2 83 V 100 I2 21 A U2 83 V Operating temperature 14 to 104 F 10 to 40 C Storage temperature 13 to 131 F 25 to 55 C Power factor 120 V 240 V 0 99 0 97 Input voltage U1 Input current I1 at 120 V 26 A rated output U2 MAX I2 MAX 200 240 V 15 5 13 A Gas type Air Nitrogen Gas quality Clean dry oil free 99 995 pure Minimum required gas inlet flow and pressure 3 5 scfm 65 psi 99 1 l min 5 5 bar Recommend...

Page 38: ... mm 3 10 79 mm 1 58 40 mm 1 00 25 mm T30v torch ratings Recommended cutting capacity 1 4 inch 6 mm at 30A 35 duty cycle Maximum cutting capacity 3 8 inch 10 mm at 30A 35 duty cycle Severance cutting capacity 1 2 inch 12 mm at 30A 35 duty cycle Weight 2 1 lbs 1 0 kg 2 00 50 mm ...

Page 39: ...s over heated Volt amp curve drooping characteristic Symbols and markings S mark The mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock CE mark The CE mark constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE mark located ...

Page 40: ...3 12 Use the Error and Reset LEDs to troubleshoot 3 13 System tests 3 14 Test 1 voltage input 3 15 Test 2 power board voltage checks 3 16 Test 3 VBUS and voltage balance 3 17 Test 4 solenoid valve 3 18 Test 5 torch stuck open TSO 3 19 Test 6 plasma start 3 20 Test 7 torch cap sensor 3 20 Test 8 fan 3 21 Test 9 pressure switch 3 21 Component replacement 3 22 Remove an endcap 3 22 Replace the torch ...

Page 41: ...s below 40 psi 2 8 bar Correct this condition before continuing Torch cap LED yellow When illuminated this LED indicates that the consumables are loose improperly installed or missing AC AC Front controls and LEDs Temperature LED yellow When illuminated this LED indicates that the power supply s temperature is outside the acceptable operating range Amperage adjustment knob Use this knob to set the...

Page 42: ...C boost converter consists of an insulated gate bipolar transistor IGBT Q1 choke and control circuit It provides a 375 VDC bus voltage when the input AC voltage is between 120 and 240 VAC The inverter consists of an IGBT Q2 the power transformer a current sense transformer and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit that is rectified b...

Page 43: ...ch lightly across the workpiece to make a cut The workpiece drops after the cut Release the plasma start trigger on the hand torch The gas solenoid valve V1 opens The gas flow starts The cutting arc starts Position the torch on the workpiece Pull the plasma start trigger on the torch The power circuits are ready Set the amps adjustment knob to the desired output current between 15 and 30 amps base...

Page 44: ... procedures and sequence When performing the troubleshooting procedures Read Section 1 Safety Refer to Section 5 for the system s electrical schematic Refer to Section 4 to locate power supply components and torch components After the problem has been located and repaired refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation External inspecti...

Page 45: ...tput circuit and may result in serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards Internal inspection 1 Set the ON OFF switch S1 to O OFF unplug the power cord and disconnect the g...

Page 46: ...hasing any major replacement component verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility Initial resistance check All resistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform the steps in Internal inspection before continuing in this section If resistance values are not close 25 to the values ...

Page 47: ...ce Manual Input diode bridges D24 D30 Output diode and pilot arc IGBT module D27 PFC IGBT Q1 Inverter IGBT Q2 Power supply overview Power switch S1 Work lead connection J22 Power board PCB2 Control board PCB1 Flyback circuit PE ground ...

Page 48: ...s supply line has a restriction or the air filter element is dirty The pressure switch is not reading at least 40 psi 2 8 bar on the gas supply line Ensure that the gas supply is connected correctly Check the gas supply line for restrictions or damage Check the air filter element and replace it if necessary Perform test 9 to verify that the pressure switch functions correctly The power ON LED and ...

Page 49: ... start signal was being sent The system was powered on while the torch trigger was being pulled The start circuit is stuck closed Release the torch trigger and turn OFF the power supply and then turn it ON again to reset the unit Perform test 6 to test the start signal All four LEDs flash when the system is powered on A major fault has occurred in the power supply Any of the fan solenoid valve con...

Page 50: ... bar Repair any restrictions in the supply line Perform test 3 to test the voltage balance on the power board Arc goes out while cutting or intermittently will not fire The arc lost contact with the workpiece The work lead or work lead connection may be faulty Check for loose connections at the work clamp and at the power supply Reposition the work lead on the workpiece Clean the cutting surface t...

Page 51: ...ct the work lead for damage Reposition it and clean the work surface to ensure good contact Check the amps adjustment knob setting If your input circuit is 120 V 20 A 120 V 30 A or 240 V 20 A turn the knob to the highest setting The pilot arc extinguishes when you move the plasma arc off the work piece while still pulling the torch s trigger The continuous pilot arc feature is not working The powe...

Page 52: ... and Transfer LEDs on the control board illuminate When a problem occurs with the system one or more of the fault LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or flash Use the control board Error and Reset LEDs to troubleshoot The Error and Reset LEDs provide information to use when troubleshooting a system failure If the LEDs on the ...

Page 53: ...section for detailed test procedures Number of error LED flashes Problem indicated Solution 1 Faulty control board Replace the control board 2 Faulty power board Replace the power board 3 Either a faulty power board or a faulty control board Perform test 3 If any of the values are incorrect replace the power board Perform test 2 If any of the values for pins 5 7 or 12 are incorrect remove the cont...

Page 54: ...F switch set to OFF The voltage should equal the line voltage of the incoming circuit for example 120 V or 240 V 4 If the AC voltage is incorrect check to see that you have power to the unit If you do have power check the power cord for damage 5 If the power source and power cord are functioning correctly disconnect the electrical power again and reconnect the wires 6 Reconnect the electrical powe...

Page 55: ...V 230 line voltage 21 VBUS DC bus voltage 2 28 VDC 375 VBUS 18 IPFC input current 0 1 VDC 20 IFB output current 0 1 VDC 22 ITF transfer current 0 1 VDC 5 3 3 VDC 3 3 VDC 5 7 5 VDC 5 VDC 5 12 24 V sense pin 2 2 VDC 16 Start signal 3 2 VDC closed 0 VDC open Note To test the values at pin 16 you must have the torch and power supply positioned such that you can safely pull and release the torch s trig...

Page 56: ...wer ON after you have connected the E Z Hooks The multimeter should read 375 VDC If you get a value other than 375 VDC multiply the reading by 0 00601 to convert it to millivolts Test pin 21 on J7 It should have the same value 3 Turn the power OFF and move the E Z Hooks to VBUS and 375 VDC 2 Turn the power ON after you have connected the multimeter This value should be 187 5 VDC or one half of wha...

Page 57: ...of J6 on the power board to ground You should hear the valve click Solenoid valve LED 2 There is an LED on the solenoid valve that illuminates red when the torch is fired It stays illuminated until postflow stops Fire the torch and watch for the LED to illuminate 3 If you do not hear the valve click or the LED does not illuminate replace the solenoid valve J6 PE ground ...

Page 58: ...N OFF switch to OFF O 2 Measure the resistance from the torch lead s white wire group and red wire to the positive and negative connections on the power supply The resistance should read as closed 3 If the resistance reads as open then the nozzle and electrode are not touching or one of the wires in the torch lead is broken Make sure that the torch plunger moves freely in the torch head If it does...

Page 59: ...Test 2 earlier in this section It should measure as 0 VDC for an open circuit or 3 2 VDC for a closed circuit If the values are not correct replace the power board Test 7 torch cap sensor Test the cap sensor switch and torch leads 1 Set the ON OFF switch to OFF O 2 Gently pull the front endcap away from the power supply Unplug J12 from the back side of the power board just below the torch start te...

Page 60: ...est 9 pressure switch Test the pressure switch to ensure that the system is receiving the proper gas pressure 1 Turn OFF the power 2 Check the resistance between pins 1 and 2 of J4 It should read approximately 4 7 kΩ if there is no gas pressure If the gas pressure is within system tolerances the circuit should read as closed J5 Ground to ground wire clip or to the heat sink ...

Page 61: ...s screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the endcaps back slightly so that you can get the edges of the handle out from underneath the endcaps Remove the handle and then lift the cover off the power supply DANGER ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that...

Page 62: ... Snap Snap Snap Snap Rib Rib Rib Rib Retaining screw Retaining screw Rear endcap Front endcap 4 Remove the retaining screw from the bottom of the endcap that you will remove 5 There are snaps on both sides of each endcap that hold the endcaps in place Insert needlenose pliers into the opening for one of the snaps and use the pliers to squeeze it together 6 Place a flat blade screwdriver against th...

Page 63: ...e base to re engage the snaps and then tighten the retaining screw On the rear endcap make sure that the hole in the ground clip is aligned with the screw holes in the endcap and the power supply before attempting to insert the retaining screw Replace the torch lead 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 fr...

Page 64: ...with a 3 pin connector at J12 Remove the connector by pulling it toward the front of the power supply J12 5 The white wire group and the red wire from the torch lead are secured to studs in the power supply s center panel on the fan side of the power supply Use a 5 16 inch 8 mm nut driver to remove the nuts from the studs and slide the ring terminals off the studs White wire group Red wire ...

Page 65: ...line for the new torch lead through the hole in the endcap and then through the nut for the strain relief 8 Tighten the torch lead s strain relief retaining nut onto the strain relief 9 Push the torch s gas supply hose approximately 65 inch 16 mm into the fitting on the bottom of the solenoid valve 10 Slide the ring terminal for the white wire group over the left stud labeled WHT on the center pan...

Page 66: ...cord CSA 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board The power cord has a black wire and a white wire that connect to the power switch and a green ground wire that connects to the ...

Page 67: ...n relief s retention nut 15 Replace or reposition the endcap Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply 16 Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cove...

Page 68: ...to the new power cord On the inside of the endcap screw the nut onto the strain relief 12 Press the connector for the brown wire onto the pin on the upper left side of the power switch 13 Press the connector for the blue wire onto the pin on the upper right side of the power switch 14 Tighten the green and yellow ground wire to the heatsink with a torque setting of 17 28 kg cm 15 inch pounds 15 Po...

Page 69: ...he power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply 3 Detach the connector from J5 on the power board You may have to lift the top edge of the Nomex barrier to see the connector 4 From the top of the power supply use needlenose pliers to compress and release the 4 corner clip...

Page 70: ... Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply 3 Remove the drain hose from the hole in the bottom of the power supply s base 4 Unscrew the nut that holds the air filter in the bracket Tip the bottom of the air filter away from the power s...

Page 71: ...on the new air filter in the bracket and replace the retainer nut 9 Route the drain hose through the hole in the base of the power supply 10 Press the black wire s connector onto the pin on the left side of the pressure sensor and the red wire s connector onto the pin on the right side of the pressure sensor 11 Connect the gas supply hose to the new filter If you are replacing the hose cut the new...

Page 72: ... the ribbon cable again and set aside the new control board 7 Remove the 3 retaining screws from the old control board and lift it out of the power supply 8 Screw the new control board into place with the 3 retaining screws and then attach the ribbon cable 9 Reposition the front endcap Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply 1...

Page 73: ...h the ribbon cable from the heatsink side of the power board See the illustration on the following page for the location of the ribbon cable and the components listed in the next steps 4 Remove the torch start and cap sensor connector at J12 on the heatsink side of the power board 5 Remove the connectors at J4 J5 and J6 on the heatsink side of the power board 6 Remove the wires for the transformer...

Page 74: ... red and the white wires that are routed underneath the board to the studs on the fan side of the unit The studs are labeled RED and WHT Ribbon cable Torch start and cap sensor J12 J4 J5 and J6 J18 J19 J20 J21 J13 J14 J15 Work lead connector J22 Retaining screw Retaining screw Retaining screw Heat sink assembly screw Heat sink assembly screw Heat sink assembly screw Heat sink assembly screw IGBT a...

Page 75: ...ct the 2 white wires to the ON OFF switch 22 Replace the 4 heatsink assembly screws and the 3 retaining screws Torque these screws to 15 inch pounds 17 28 kg cm 23 Replace the screw you removed from the snubber resistor in step 10 Torque it to 7 inch pounds 8 06 kg cm Note Torque settings greater than 7 inch pounds 8 06 kg cm may damage the resistor 24 Replace the 5 screws that attach the IGBTs to...

Page 76: ...n the front endcap aligns with the screw holes in the endcap and the power supply 9 Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 10 Reconnect the electrical power and the gas su...

Page 77: ...MAINTENANCE 3 38 powermax30 Service Manual ...

Page 78: ...vice Manual 4 1 Section 4 PARTS In this section Power supply parts 4 2 Exterior 4 2 Interior power board side 4 3 Interior fan side 4 4 T30v hand torch parts 4 5 Safety critical parts 4 6 Recommended spare parts 4 7 ...

Page 79: ...ic 1 228097 Kit Labels CE 1 228096 Kit Screws 49 1 228101 Kit Front panel 1 2 108616 Current adjustment knob 1 3 123868 Work lead assembly 1 4 229121 Kit Power supply cover with labels domestic 1 229122 Kit Power supply cover with labels CE 1 5 228100 Kit Rear panel 1 6 228099 Kit Powermax30 handle 1 15 30 25 20 1 2 3 4 5 6 ...

Page 80: ...tion Designator Qty 1 228093 Kit Control board PCB1 1 2 005605 Power rocker switch 1 3 228094 Kit Power board CSA PCB2 1 228102 Kit Power board CE PCB2 1 4 228139 Kit Base 1 5 228105 Kit Magnetic mounting base 1 228104 Kit Powermax30 insulator 1 228103 Kit Powermax30 wire group 1 1 2 3 4 5 ...

Page 81: ...on Designator Qty 1 005112 Kit Pressure sensor 1 2 228108 Kit Solenoid valve V1 1 3 228095 Kit Hoses 2 4 228142 Kit CSA power cord 1 phase 8 ft 1 5 228140 Kit CE power cord 1 phase 2 5 m 6 228106 Kit Filter regulator 1 011106 Air filter element 1 7 228107 Kit Fan M1 1 1 2 3 5 6 4 7 ...

Page 82: ...228109 Kit Cap off sensor replacement 1 4 228110 Kit T30v torch head repair kit 1 5 228111 Kit T30v torch handle replacement 1 6 075714 Screws 4 x 1 2 SLTD Torx PAN S B 5 7 002244 Safety trigger and spring replacement 1 8 228113 Kit T30v 15 ft 4 6 m torch lead replacement 1 Top assembly includes the following consumables 220478 Electrode 1 220479 Swirl ring 1 220483 Retaining cap 1 220480 Nozzle 1...

Page 83: ...ical parts that must be replaced only with Hypertherm parts to maintain the warranty and all system certifications including CE CSA GOST and CCC certification Part Item number Description 1 228094 Kit Power board CSA and subcomponents 228102 Kit Power board CE and subcomponents 2 228105 Kit 30 A magnetics 3 005112 Filter regulator pressure switch 4 228106 Kit Filter regulator 5 228107 Kit Fan 6 00...

Page 84: ...base 4 3 005112 Pressure sensor 4 4 228108 Kit Solenoid valve 4 4 228106 Kit Filter regulator 4 4 011106 Air filter element 4 4 228107 Kit Fan 4 4 058503 Torch o ring 4 5 228111 Kit T30v torch handle replacement 4 5 075714 T30v torch handle screws 5 required 4 5 002244 T30v torch trigger assembly with spring 4 5 027254 Replacement trigger spring T30v 4 5 128642 Kit Start switch replacement 4 5 228...

Page 85: ...PARTS 4 8 powermax30 Service Manual ...

Page 86: ...powermax30 Service Manual 5 1 Section 5 WIRING DIAGRAM In this section Electrical schematic 5 3 ...

Page 87: ...WIRING DIAGRAM 5 2 powermax30 Service Manual ...

Page 88: ...OUT1 19 IN1 1 OUT2 18 GND 17 GND 16 GND 15 GND 14 OUT3 13 OUT4 12 PRG 20 IN4 10 1 2 3 IN OUT GND IN15 15 IN9 9 IN8 8 IN7 7 IN13 13 IN12 12 IN11 11 IN10 10 IN6 6 IN16 16 IN3 3 IN2 2 IN1 1 IN5 5 IN14 14 IN4 4 IN17 17 IN18 18 IN19 19 TDO 40 SPI EN 32 TCK 42 TDI 43 VCC 44 TMS 41 OUT1 20 OUT2 21 OUT3 22 OUT4 23 OUT5 24 OUT6 25 OUT7 26 OUT8 27 I O 28 SPI IN 31 SPI CLK 30 SPI OUT 29 1 2 3 L 2 F 5 X 3 D 7...

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