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Hypertherm Powermax30 AIR, Service Manual

The Hypertherm Powermax30 AIR is a compact and versatile plasma cutting system. Unlock the full potential of this advanced tool by downloading the free Operator's Manual from manualshive.com. This comprehensive manual provides detailed instructions and tips to maximize your cutting experience.

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Powermax30 AIR

Service Manual

808850

159

6 – Power Supply Component Replacement

5.

Rotate the coil into the power supply until the top of the coil points up.

6.

Push-to-connect the other end of the heat exchange coil into the elbow fitting on the left side of the air filter.

7.

Make sure all the hose and tube connections on the air filter are secure.

8.

Complete the following procedures:

a.

See 

Install the fan

 on page 156.

b.

See 

Install the power supply cover

 on page 99.

c.

Reconnect the power cord, and set the power switch to ON (

I

).

CAUTION!

If there are leaks in the gas supply hoses or connections:

Cut speeds can decrease.

Cut quality can deteriorate.

Cutting thickness capability can decrease.

Parts life can shorten.

Summary of Contents for Powermax30 AIR

Page 1: ...Powermax30 AIR Plasma Arc Cutting System with Integrated Air Compressor Service Manual 808850 Revision 0 English ...

Page 2: ...________________________________________________________ Distributor __________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Maintenance notes ____________________________________________________________________________ _______________...

Page 3: ...Powermax30 AIR Service Manual 808850 Revision 0 English March 2015 Hypertherm Inc Hanover NH 03755 USA www hypertherm com ...

Page 4: ...41 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Serv...

Page 5: ...TION Before operating or maintaining any Hypertherm equipment read the Safety and Compliance Manual 80669C for important safety information You can find the Safety and Compliance Manual in the Downloads library at www hypertherm com ...

Page 6: ......

Page 7: ...t SC 13 Cutting cables SC 13 Equipotential bonding SC 13 Earthing of the workpiece SC 13 Screening and shielding SC 14 Warranty SC 15 Attention SC 15 General SC 15 Patent indemnity SC 15 Limitation of liability SC 15 National and local codes SC 15 Liability cap SC 15 Insurance SC 16 Transfer of rights SC 16 1 Specifications 17 Safety information 17 System description 17 Power supply dimensions 18 ...

Page 8: ...a cutting system 27 Prepare the electrical power 27 Voltage configurations 27 Requirements for grounding 29 Power cord considerations 29 CSA power cords and plugs 29 CE power cords 30 Install a plug on the power cord 30 Extension cord recommendations 31 Generator recommendations 31 3 Torch Setup 33 Introduction 33 Hand torch components 33 Consumable life 34 Consumable use 35 Using the cut charts 3...

Page 9: ...r rated power plugs 45 Cutting expanded metal 45 Step 4 Attach the ground clamp 46 Step 5 Power ON the system 46 Step 6 Check the indicator LEDs 47 Step 7 Make sure the system is ready and start cutting 47 What to expect during and after cutting 47 Postflow 47 Internal compressor and fan activity 47 Water under the power supply 47 Understand duty cycle limitations 48 System operation guidelines 49...

Page 10: ...6 Torch cap LED faults 68 Common cutting issues 69 Control board LEDs 71 Use the control board Rest and Error LEDs to troubleshoot 72 Reset LED 72 Error LED 73 System tests 73 Test 1 voltage input 78 Test 2 power board voltage checks 80 Test 3 VBUS and voltage balance on power board 82 Test 4 solenoid valve 84 Test 5 torch stuck open or torch stuck closed 85 Test 6 plasma start 87 Test 7 torch cap...

Page 11: ...place the solenoid valve 142 Replace the torch lead and strain relief 144 Replace the air filter assembly 148 Replace the air filter bowl and air filter element 151 Replace the fan 155 Replace the heat exchange coil 157 Replace the internal compressor 160 Replace the air inlet filter in the internal compressor 165 Replace the front panel 166 Replace the rear panel 169 Replace the base 173 Replace ...

Page 12: ...n side 207 Interior wires 208 Power supply base and magnetics 209 Hand torch parts 210 Hand torch consumables 211 Accessory parts 212 Safety critical parts 213 Recommended spare parts 215 Power supply labels 216 Consumables label 216 CSA warning label 217 CE warning label 218 9 Wiring Diagrams 219 Process flow for troubleshooting internal compressor and temperature fault LEDs 220 Timing chart for ...

Page 13: ...ding area may extend beyond the boundaries of the premises Methods of reducing emissions Mains supply Cutting equipment must be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently install...

Page 14: ... risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is provided in IEC 60974 9 Arc Welding Equipment Part 9 Installation and Use Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entir...

Page 15: ...l not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph and with Hypertherm s prior written consent The warranty set forth above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all impli...

Page 16: ...under only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Within thirty 30 days before any such transfer occurs you agree to notify in writing Hypertherm which reserves the right of approval Should you fail timely to notify Hypertherm and seek its approval ...

Page 17: ...mum portability and ease of use With it you can cut electrically conductive metals such as mild steel stainless steel or aluminum of thicknesses up to 10 mm 3 8 inches You can also pierce thicknesses up to 6 mm 1 4 inch The Powermax30 AIR ships in several different configurations based on region Typically all configurations include 1 complete set of consumables preinstalled on the Air T30 hand tor...

Page 18: ...mation You can order additional consumables and accessories such as a dust cover and circle cutting guides for example from any Hypertherm distributor See Parts on page 201 for a list of spare and optional parts Power supply dimensions System weights The following system weights include the hand torch with 4 6 m 15 foot torch lead a 4 6 m 15 foot work lead with ground clamp and a 3 0 m 10 foot pow...

Page 19: ...04 F Storage temperature 25 C to 55 C 13 F to 131 F Power factor 120 V 240 V 0 99 0 97 EMC classification CISPR 11 CE models only Class A Input voltage U1 Input current I1 at rated output U2 MAX I2 MAX See Voltage configurations on page 27 for more information 120 V 1 phase 50 60 Hz 28 7 A 200 V 240 V 1 phase 50 60 Hz 16 7 A 15 0 A Gas type Air Defined as a plot of output voltage versus output cur...

Page 20: ...rch dimensions Torch weight Air T30 torch with consumables only 0 3 kg 0 65 pounds Air T30 torch with consumables and 4 6 m 15 foot lead with strain relief 1 0 kg 2 25 pounds 25 mm 1 0 inch 51 mm 2 0 inches 230 mm 9 0 inches 45 mm 1 8 inches 86 mm 3 4 inches 75 ...

Page 21: ...m of 125 mm minute 5 inches minute When you operate this system at altitudes higher than 2 200 m 7 500 feet above sea level you may experience some reduction in cutting performance due to the adverse effect that altitude has on air compressors 120 V When you operate the system at the maximum recommended output of 20 A the cut capacities are 3 mm 10 gauge at 762 mm minute 30 inches minute 6 mm 1 4 ...

Page 22: ...d with your system In addition you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at www hypertherm com 1 Click Downloads library 2 Select a product from the Product type menu 3 Select Regulatory from the Category menu 4 Select Acoustical Noise Data Sheets from the Sub Category menu Direct current DC Alternating current AC Plasma torch cutting AC input ...

Page 23: ...te have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking Eurasian Customs Union CU mark CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirement...

Page 24: ...24 Powermax30 AIR Service Manual 808850 1 Specifications ...

Page 25: ... rear panel of the power supply 3 Before you set up and operate this system read the separate Safety and Compliance Manual 80669C included with your system for important safety information Claims Claims for damage during shipment If your unit was damaged during shipment file a claim with the carrier You can contact Hypertherm for a copy of the bill of lading If you need additional assistance call ...

Page 26: ...he specific components included with the system are subject to change over time 1 2 3 4 5 6 7 8 11 9 10 1 Operator Manual 2 Quick Setup Card 3 Registration card 4 Safety and Compliance Manual 5 Air T30 torch with lead 6 Consumable kit 7 Ground clamp and work lead 8 CE power cord no power plug included 9 CSA power cord with power plug adapters 10 Power supply 11 Carrying strap ...

Page 27: ...system s maximum output voltage varies based on the input voltage and the circuit s amperage Additional factors must be considered when you are operating the system at an input power of 120 V as tripped circuit breakers can result under some conditions For more information see System operation guidelines on page 49 and Troubleshooting guide on page 63 Voltage configurations The system automaticall...

Page 28: ...propriately sized slow blow time delay fuses or circuit breakers Input voltage 120 V Input current at rated output 19 A 83 V 1 6 kW 19 2 A Input current at arc stretch 37 5 A Voltage tolerance 10 10 Input voltage 120 V Input current at rated output 30 A 83 V 2 5 kW 28 7 A Input current at arc stretch 37 5 A Voltage tolerance 10 10 Input voltage 200 V 240 V Input current at rated output 28 A 83 V 2...

Page 29: ...iderations This system ships with a CSA or CE power cord configuration See Exterior rear on page 203 for part number information CSA power cords and plugs CSA configurations include the following plug and adapters The power cord is equipped with a NEMA twist lock style plug NEMA L6 20P appropriate for use on a 240 V 20 A circuit with a NEMA twist lock style outlet To operate the system on a lower ...

Page 30: ...rician Install a plug on the power cord 1 Strip back the cord insulation to separate wires 3 5 and 6 2 Remove each wire s insulation to allow good contact with the plug terminals 3 Make the connections 4 Reinstall the outer shell and cord grip and tighten the cord grip s screws until snug Do not overtighten 1 2 3 4 5 6 1 Cord grip 2 Outer shell 3 To line 1 terminal brown 4 230 V CE plug 5 To line ...

Page 31: ... with this system should produce 240 VAC Adjust the cutting current as needed based on the generator rating age and condition If a fault occurs while using a generator turn OFF the system and wait approximately 60 seconds before turning it ON again Turning the power switch quickly to OFF and ON again called a quick reset may not clear the fault Input voltage Phase Recommended cord gauge size Lengt...

Page 32: ...32 Powermax30 AIR Service Manual 808850 2 Power Supply Setup ...

Page 33: ...R includes the Air T30 hand torch This section explains how to set up and operate your torch To achieve optimal consumable life and cut quality follow the instructions in this manual Hand torch components 1 2 3 4 5 6 1 Handle 2 Deflector 3 Retaining cap 4 Safety catch 5 Trigger red 6 Screws 5 ...

Page 34: ...xcept for those listed in this section which are designed specifically for this system The use of any other consumables could adversely affect system performance Although largely dependent on the factors listed above as a general rule the consumables last approximately 1 to 2 hours of actual arc on time If the consumables life is shorter than expected or the cut quality is poor make sure that you ...

Page 35: ...ction which are designed specifically for this system The use of any other consumables could adversely affect system performance Using the cut charts Use the following cut charts to guide you in selecting the cutting current amperage based on the thickness and type of the metal you need to cut The maximum cut speeds listed in the cut charts are the fastest possible speeds to cut metal without rega...

Page 36: ...p Deflector The following consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch They cannot be used with any other Powermax system or torch Hypertherm does not recommend operating this system on a 120 V 15 A circuit 5 4 3 2 1 6 1 Torch 2 Electrode 3 Swirl ring 4 Nozzle 5 Retaining cap 6 Deflector ...

Page 37: ...5 1 155 7 570 9 400 11 280 13 215 16 125 1 Stainless steel 30 10 160 2 3 290 3 1 970 4 1 260 5 980 7 535 9 310 11 215 13 170 1 Aluminum 30 10 160 2 6 630 3 3 585 4 2 370 5 1 770 7 575 9 435 11 245 13 135 To cut material thicker than 6 mm 1 4 inch at 240 V start the torch at the edge of the workpiece Maximum cut speed is limited by the test table s maximum speed 10 160 mm minute or 400 inches minut...

Page 38: ...12 gauge 130 10 gauge 64 1 4 30 5 16 22 3 8 13 1 2 9 5 8 5 18 gauge Stainless steel 30 370 14 gauge 135 10 gauge 56 1 4 24 3 8 10 1 2 7 1 32 Aluminum 30 400 1 16 306 1 8 111 1 4 38 3 8 13 1 2 6 To cut material thicker than 6 mm 1 4 inch at 240 V start the torch at the edge of the workpiece Maximum cut speed is limited by the test table s maximum speed 10 160 mm minute or 400 inches minute ...

Page 39: ...c current A Maximum cut speed mm minute 1 Mild steel 20 6 540 2 2 420 3 1 245 4 680 6 400 8 235 10 90 1 Stainless steel 20 3 295 2 2 140 3 1 270 4 965 5 660 7 150 1 Aluminum 20 5 500 2 3 610 3 1 720 4 1 030 5 740 7 165 To cut material thicker than 3 mm 10 gauge at 120 V start the torch at the edge of the workpiece ...

Page 40: ...urrent A Maximum cut speed inches minute 18 gauge Mild steel 20 220 14 gauge 100 10 gauge 30 1 4 14 3 8 5 18 gauge Stainless steel 20 120 14 gauge 89 12 gauge 54 1 4 10 1 32 Aluminum 20 231 1 16 170 1 8 49 1 4 14 To cut material thicker than 3 mm 10 gauge at 120 V start the torch at the edge of the workpiece ...

Page 41: ...850 41 Section 4 Operation Controls and indicators Familiarize yourself with the controls and LED indicators on the system before you begin cutting Rear controls ON I OFF O power switch Activates the system and its control circuits O O ...

Page 42: ...ir compressor Torch cap LED yellow When illuminated this LED indicates that the consumables are loose improperly installed or missing Temperature LED yellow When illuminated this LED indicates that the system s temperature is outside the acceptable operating range Some fault conditions cause multiple LEDs to illuminate or blink at the same time For information on what these fault conditions are an...

Page 43: ...ng Nozzle Retaining cap Deflector Install the deflector by snapping it securely into place on the retaining cap Do not apply grease or other lubricants to the O rings on the electrode and swirl ring These consumables are designed specifically for the Powermax30 AIR power supply and Air T30 hand torch They cannot be used with any other Powermax system or torch WARNING INSTANT ON TORCHES PLASMA ARC ...

Page 44: ...ord See also For information on connecting the proper plug to the power cord see Power cord considerations on page 29 To understand what cutting capacity to expect based on input voltage see Consumable use on page 35 For information on electrical requirements for this system see Power Supply Setup on page 25 ...

Page 45: ...tem on a 120 V 15 A circuit Operating the system on a 240 V 20 A circuit Set the amperage between 15 30 A Decrease output current for lower rated power plugs If you are operating the system using a lower rated power plug or service turn down the output current to avoid tripping the circuit breaker For example to operate the system on a 230 V 16 A circuit set the amperage below 28 A See Voltage con...

Page 46: ...ece make good metal to metal contact Attach the ground clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields EMF and to achieve the best possible cut quality Do not attach the ground clamp to the portion of the workpiece that you are cutting away Step 5 Power ON the system Set the ON OFF switch to the ON I position O O ...

Page 47: ...cutting Postflow After you complete a cut and release the torch trigger air continues to flow from the torch in order to cool the consumables This is referred to as postflow The length of postflow depends on how long the torch fired a sustained arc Internal compressor and fan activity The internal compressor runs while you are cutting and it continues to run during postflow The fan inside the powe...

Page 48: ...ting the system at 30 A on 120 V input can result in frequent tripped circuit breakers When you exceed the duty cycle and the system overheats one of the following conditions occurs The temperature LED illuminates the arc shuts off and the cooling fan continues to run To resume cutting wait for the temperature LED to extinguish The internal compressor LED and the temperature LED both illuminate Al...

Page 49: ...the same circuit Be aware that extension cords can reduce the voltage to the machine from what is output by the circuit This reduction in power can impair cutting performance and increase the probability of tripping the circuit breaker Cutting a thicker workpiece requires a higher amperage setting It is preferable to operate on a higher rated circuit 240 V 30 A when cutting thicker metal See Volta...

Page 50: ...Y AND BURNS Plasma arc ignites immediately when you pull the torch trigger The plasma arc cuts quickly through gloves and skin Keep hands clothes and objects away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN Always wear proper protective equipment...

Page 51: ...workpiece so that the nozzle is at a 90 angle to the cutting surface and watch the arc as it cuts along the line Pulling the torch toward you along the cut is easier than pushing it or moving from side to side For straight line cuts use a straight edge as a guide To cut circles use a template or a radius cutter attachment a circle cutting guide See Accessory parts on page 212 for the Hypertherm pl...

Page 52: ...e to prolong consumable life 1 With the ground clamp attached to the workpiece hold the torch perpendicular 90 to the workpiece and on the edge 2 Pull the torch trigger to start the arc You may need to pause at the edge until the arc has cut completely through the workpiece 3 Drag the torch lightly across the workpiece to proceed with the cut Maintain a steady even pace ...

Page 53: ...e Hold the torch perpendicular 90 to the workpiece with the torch tip just above the workpiece Rolling pierce Hold the torch at an approximate 30 45 angle to the workpiece with the torch tip within 1 5 mm 1 16 inch of it before firing the torch 3 Straight pierce Pull the torch trigger to start the arc Rolling pierce Pull the torch trigger to start the arc while still at an angle to the workpiece t...

Page 54: ...e consumables or in the air supply within the system Minimizing dross Dross is the molten metal that solidifies on the workpiece Some amount of dross is always present when cutting with air plasma However you can control the amount and type of dross by adjusting your system correctly for your application Low speed dross forms when the torch s cutting speed is too slow and the arc shoots ahead It f...

Page 55: ...verter The compressor driver board supplies 15 VDC to power the internal air compressor The PFC 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 ...

Page 56: ...urrent between 15 A and 30 A based on the input voltage and circuit size The power circuits are ready Position the torch on the workpiece Pull the plasma start trigger on the torch The fan and the internal compressor turn on The gas solenoid valve V1 opens The gas flow starts The cutting arc starts Drag the torch lightly across the workpiece to make a cut The workpiece drops after the cut Release ...

Page 57: ... service or maintenance work is complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts Do not touch the tip of the nozzle when the system is powered ON I If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or dea...

Page 58: ...30 AIR schematic on page 222 for the system s electrical schematic Power Supply Component Replacement on page 97 or Torch Component Replacement on page 185 for replacement procedures Parts on page 201 for power supply components and torch components After the problem has been located and repaired refer to Sequence of operation on page 56 to test the power supply for proper operation Power OFF O an...

Page 59: ...s damaged components and so on Fan side Check for leaks and loose connections at each pneumatic air connection point on the internal compressor air filter and solenoid valve 5 Repair or replace components as necessary 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 ab...

Page 60: ... 25 However this range is intended only for reference Resistance values can vary widely depending on the type of multimeter and the polarity used to measure the readings 4 Remove the consumables from the torch If you do not remove the consumables the resistance values will not read correctly 5 Check the output resistance for the values shown in the following table J16 and J17 are labeled on the co...

Page 61: ... 1 6 If you do not find any problems during the visual inspection or the initial resistance check and the power supply is still not operating correctly see Troubleshooting guide on page 63 WORK LEAD BLK AC AC R w TORCH START BLK BLK B TORCH START J22 WORK LEAD BLK J16 red J17 white ...

Page 62: ...de of power supply WORK LEAD BLK AC AC R w TORCH START BLK BLK B TORCH START 1 2 4 5 6 7 8 9 10 3 1 Output diode and pilot arc IGBT module D27 2 Work lead connection J22 3 Input diode bridges D24 D30 4 PE ground 5 Power board PCB2 6 Power switch S1 7 PFC IGBT Q1 8 Flyback circuit 9 Inverter IGBT Q2 10 Control board PCB1 ...

Page 63: ...ate Possible causes Possible solutions The system has no incoming voltage or an improper incoming voltage The power cord power switch or power board is faulty Make sure the electrical power is connected to an appropriately sized circuit Make sure the system did not trip the circuit breaker Perform Test 1 voltage input on page 78 The power ON LED illuminates but no fault LEDs illuminate and no gas ...

Page 64: ...oltage input on page 78 All four LEDs blink when the system is powered ON Possible causes Possible solutions A major fault has occurred in the power supply For example the fan solenoid valve control board or power board may be faulty The error LED on the control board should be blinking The number of times it blinks between pauses indicates which components to test See Control board LEDs on page 7...

Page 65: ...are operating the system on a 120 VAC input circuit and the cutting current is set above 20 A You are operating the system on a 120 V 15 A circuit You are operating the system on a 120 VAC input circuit and are frequently stretching the arc while cutting You are using an extension cord that is too long The maximum length for an extension cord on a 120 VAC input circuit is 16 m 53 feet The maximum ...

Page 66: ...ot prevent you from firing the torch before the 4 minutes elapses However if you begin cutting before the compressor has time to fully cool down the same fault is likely to occur again If the fault LEDs persist continue with the following troubleshooting steps in the order listed Environmental conditions or worn consumables are adversely affecting the power supply s performance 2 Make sure the lou...

Page 67: ...ard and the power board to determine which component needs to be replaced Perform Test 9 internal compressor compressor driver board and power board on page 91 The internal compressor LED and the temperature LED blink alternately when the machine is powered ON Possible causes Possible solutions The system was powered on with the torch trigger being pulled The start circuit is stuck closed Release ...

Page 68: ... trigger is pulled The torch plunger is stuck The torch or torch lead has a broken or short circuited wire Inspect the torch lead If it is twisted or kinked straighten it out and try to fire the torch again Make sure the consumables are installed correctly See Step 1 Install the consumables on page 43 Inspect the consumables for wear and replace if necessary Always replace the nozzle and electrode...

Page 69: ...d at the power supply and repair if necessary Reposition the work lead on the workpiece Clean the cutting surface to make a better connection with the work lead The pilot arc extinguishes when you move the plasma arc off the workpiece while still pulling the torch trigger The consumables are worn or damaged The system is connected to a generator and is running on low input voltage for example less...

Page 70: ... use a heavy conductor cord of the shortest possible length See Extension cord recommendations on page 31 The circuit breaker trips frequently while you are cutting The amperage adjustment knob is set too high for the input circuit The wrong consumables are being used The input circuit is not delivering sufficient power to the power supply The operator is stretching the arc by holding the torch to...

Page 71: ...ture LEDs on the front of the power supply illuminate If all four LEDs on the front of the power supply are blinking the Error LED also blinks The number of blinks between pauses indicates which component may have failed Transfer This LED illuminates when there is proper arc transfer between the torch and the workpiece and blinks during continuous pilot arc operation such as when cutting expanded ...

Page 72: ...the number of times the Error LED blinks Then look at Table 5 on page 73 to determine the corrective action Reset LED When the control board s Reset LED illuminates the voltages on the power board may be incorrect Perform the following tests at J7 on the power board See Test 2 power board voltage checks on page 80 Test pin 5 to ground for 3 3 VDC 10 Test pin 7 to ground for 5 VDC 10 Test pin 12 to...

Page 73: ...age balance on power board on page 82 If any of the values are incorrect replace the power board Perform Test 2 power board voltage checks on page 80 If any of the values for pins 5 7 or 12 are incorrect remove the control board and test again If the values are correct replace the control board If the values for pins 5 7 or 12 are correct when you perform Test 2 power board voltage checks on page ...

Page 74: ...econds after disconnecting the input power Allow bus voltages to dissipate before performing any tests WORK LEAD BLK AC AC R w TORCH START BLK BLK B TORCH START 1 2 4 3 2 2 1 2 11 12 13 5 6 7 8 9 10 1 Retaining screw 2 2 Heatsink assembly screw 4 3 Torch start and cap sensor J12 4 J13 5 J14 6 J15 7 Work lead connector J22 8 J21 9 J20 10 J19 11 J18 12 Input diode bridge screws 2 13 IGBT screws 3 ...

Page 75: ...power board 1 2 6 9 1 5 5 5 2 7 8 3 4 10 11 13 14 12 1 Input diode bridges 2 Capacitors 3 J17 white 4 J16 red 5 IGBTs 6 J12 torch start cap sensor switch connector 7 Snubber resistor 8 Ribbon cable connector J7 from control board 9 J9 10 J6 11 J5 12 375 VDC bus voltage to compressor driver board 13 J2 14 J1 ...

Page 76: ...76 Powermax30 AIR Service Manual 808850 5 Troubleshooting and System Tests Figure 8 Back of the compressor driver board 3 2 1 1 Compressor driver board 2 MOSFET 3 Diode ...

Page 77: ...Powermax30 AIR Service Manual 808850 77 5 Troubleshooting and System Tests Figure 9 Component side of the compressor driver board 1 2 3 4 5 1 1 1 Retaining screw 3 2 Diagnostic LED D5 3 J3 4 J1 5 J2 ...

Page 78: ...00 4 Partially pull the power switch s top two wires out from the tabs and attach the multimeter test leads to the tabs to check the AC voltage See Figure 10 on page 79 5 Once you have the test leads in place leave the power switch set to OFF O and reconnect the electrical power The voltage should equal the line voltage of the incoming circuit for example 120 V or 240 V All values can be 15 WARNIN...

Page 79: ...itch 8 Reconnect the electrical power and set the power switch to ON I 9 Measure the AC voltage from J1 to J2 labeled AC on the back of the power board This value should be the same as the incoming line voltage If it is not check the power switch and replace if necessary See Replace the power switch on page 116 Figure 11 10 If the power ON LED is still illuminated perform Test 2 power board voltag...

Page 80: ...he J7 pins listed in Table 6 on page 81 to make sure the power board PCB2 is functioning correctly If any of the values are incorrect replace the power board See Replace the power board on page 126 Figure 12 To test the values at pin 16 you must position the torch and power supply so that you can safely pull and release the torch trigger For ground locations see Figure 5 on page 73 WARNING ELECTRI...

Page 81: ...e rear panel or to the heatsink See Figure 5 on page 73 J7 pin number to ground Test Expected value 19 VACR rectified AC line voltage 0 86 V at 120 line voltage 1 87 V at 230 line voltage 21 VBUS DC bus voltage 2 28 VDC at 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 10 7 5 VDC 5 VDC 10 12 24 V sense pin 2 2 VDC 10 16 Start ...

Page 82: ... Reconnect the electrical power 5 For each of the following 3 steps carefully connect the test hooks to the edges of the holes in the power board so that the hook makes contact with the ring on the back side of the power board CAUTION Do not use VBUS W as ground Doing so could destroy the power supply Instead ground to either the ground wire clip on the rear panel or to the heatsink See Figure 5 o...

Page 83: ... values match it is a normal reading 7 Measure the voltage from W to B a Turn the power OFF O b Move the test hooks to W and B c Turn the power ON I d This value should be 187 5 VDC or one half of the value found in step 6 8 Measure the voltage from R to B a Turn the power OFF O b Move the test hooks to R and B c Turn the power ON I d This value should be 187 5 VDC or one half of the value found i...

Page 84: ...ect the electrical power 5 Place a jumper from pin 1 of J6 red wire on the power board to ground See Figure 5 on page 73 for grounding options Figure 14 6 Turn the power ON I The valve should click 7 Measure the voltage between pin 1 of J6 and ground 8 If you do not hear the valve click and the voltage check reads 24 VDC replace the solenoid valve See Replace the solenoid valve on page 142 WARNING...

Page 85: ...e power switch to OFF O and disconnect the power cord from the power source 2 Remove the power supply handle and cover See Remove the power supply cover on page 98 3 Remove the component barrier See Remove the component barrier on page 100 4 Measure the resistance between the torch lead s white wire group and red wire The resistance should read very low a closed circuit If the resistance reads as ...

Page 86: ...ng the nozzle and electrode are in contact or a short circuit occurred in one of the wires in the torch lead Continue with step 6 If no the solenoid valve may be faulty Perform Test 4 solenoid valve on page 84 6 Does the torch plunger move freely in the torch head If yes replace the torch lead See Replace the torch lead on page 197 If no replace the torch body See Replace the torch body on page 19...

Page 87: ...rical power and turn the power ON I 5 Quickly tap the torch trigger to force gas flow without firing an arc and watch the Start LED on the control board The Start LED should illuminate whenever the trigger is pulled See Control board LEDs on page 71 for the location of the Start LED 6 Turn OFF O the power WARNING While testing do not touch the nozzle at the end of the torch Dangerous voltages can ...

Page 88: ...if necessary See Replace the start switch on page 195 or Replace the torch lead and strain relief on page 144 9 Turn ON I the power 10 Measure pin 16 of J7 to ground See Test 2 power board voltage checks on page 80 a With the trigger pulled it should measure as 0 VDC for an open circuit b With the trigger released it should measure 3 2 VDC for a closed circuit 11 Are the values correct If yes repl...

Page 89: ...the tab on the connector toward the plug and pulling the plug out Figure 17 6 Measure the resistance from the blue wire pin 1 to the orange wire pin 2 It should measure less than 10 Ω If it measures high resistance the cap sensor switch circuit is open 7 Make sure the torch plunger moves smoothly If it does not replace the torch body See Replace the torch body on page 193 8 Make sure the consumabl...

Page 90: ...ck wire see Figure 18 5 Reconnect the electrical power and set the power switch to ON I 6 If the fan does not operate replace the fan See Replace the fan on page 155 Figure 18 Because of protection features on the fan driver chip this test can trigger a fault You can disregard this fault if it occurs as a result of a fan test The purpose of the fan test is to verify that the fan is operating prope...

Page 91: ...nd cover See Remove the power supply cover on page 98 3 Remove the component barrier See Remove the component barrier on page 100 Test 9a Check the diagnostic LED D5 on the compressor driver board 4 Reconnect the power cord and set the power switch to ON I 5 Quickly tap the torch trigger to force gas flow without firing an arc then watch the green diagnostic LED D5 on the compressor driver board D...

Page 92: ...u can see the gas shut off override button See Figure 19 12 Connect the internal compressor to an external 12 VDC power source for example a car battery 13 Hold down the gas shut off override button on top of the solenoid valve then quickly tap the torch trigger Is the compressor running and is air blowing from the torch a If yes check the compressor driver board Continue with the next step b If n...

Page 93: ...the power switch to OFF O 17 Remove the white cap from the top of the J3 connector on the compressor driver board See Figure 20 on page 94 You may need to unplug the J3 connector in order to remove the white cap If you do plug the connector back in before continuing with the next step WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages ...

Page 94: ...If no check the power board Skip to step 23 20 Set the power switch to ON I 21 Quickly tap the torch trigger then check the compressor enable voltage on the J1 connector on the compressor driver board Is compressor enable voltage present 3 VDC a If yes replace the compressor driver board See Replace the compressor driver board on page 121 b If no check the twisted pair wires that connect the compr...

Page 95: ... voltage at J9 on the power board 3 VDC Figure 21 28 Are VBUS and compressor enable voltage present on the power board a If VBUS and compressor enable voltage are both present on the power board replace the compressor driver board See Replace the compressor driver board on page 121 b If neither VBUS nor compressor enable voltage are present on the power board replace the power board See Replace th...

Page 96: ...96 Powermax30 AIR Service Manual 808850 5 Troubleshooting and System Tests ...

Page 97: ...ce All work requiring removal of the power supply cover must be performed by a qualified technician See the Safety and Compliance Manual 80669C for more safety precautions CAUTION Static electricity can damage circuit boards Use proper precautions when handling printed circuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards ...

Page 98: ...is almost out tilt the screwdriver slightly to help pull the screw out of the recessed hole 3 Slightly tip the front and rear panels away from the power supply so that you can get the edges of the handle out from underneath them Remove the handle and set it and the two screws aside 4 Continue to tilt the panels outward to release the fan side of the cover from its track Then lift the cover off the...

Page 99: ...with the power supply 3 Realign the rear panel with the power supply making sure that the hole in the ground clip aligns with the screw holes in both the panel and the power supply 4 Position the handle over the holes in the top of the cover and position the ends of the handle underneath the edges of the panels You may find it easier to install the screw near the rear panel before installing the s...

Page 100: ...ower switch to OFF O and disconnect the power cord from the power source 2 Remove the power supply cover See Remove the power supply cover on page 98 3 Remove the component barrier from the power board side of the power supply The barrier is flexible and can be bent slightly for removal Figure 24 Kit number Description 428395 Kit Component barrier ...

Page 101: ...of the power board 2 As you slide the barrier into place tuck the sides and the bottom edge of the barrier behind the plastic notches that run along the inside of the front panel rear panel and plastic base The barrier will not fit in the same track as the power supply cover 3 Put the power supply cover back in place See Install the power supply cover on page 99 Figure 25 1 2 3 4 1 2 3 4 ...

Page 102: ...on page 98 3 Loosen the strain relief nuts on the torch lead and work lead 4 Lay the power supply on its side 5 Remove the retaining screw from the bottom of the front panel Figure 26 6 Insert a blade screwdriver into the opening for one of the snaps While pushing up on the tab inside the snap pull the corner of the front panel away from the power supply until it detaches from the base 7 Repeat th...

Page 103: ...place 2 Tighten the retaining screw to 23 0 kg cm 20 inch pounds See Figure 26 on page 102 3 Reconnect the control board s ribbon cable to the power board at J7 Make sure the latches are folded up to hold the connector in place 4 Tighten the strain relief nuts on the torch lead and work lead 5 Put the power supply cover back in place See Install the power supply cover on page 99 6 6 7 8 7 ...

Page 104: ...acing an old rear panel with a new one see Replace the rear panel on page 169 Detach the rear panel 1 Set the power switch to OFF O and disconnect the power cord from the power source 2 Remove the power supply cover See Remove the power supply cover on page 98 3 Loosen the power cord s strain relief nut 4 Lay the power supply on its side 5 Remove the retaining screw from the bottom of the rear pan...

Page 105: ... up on the tab inside the snap pull the corner of the rear panel away from the power supply until it detaches from the base 7 Repeat the previous step on the other corner of the panel 8 Disconnect the ground wire from the ground wire clip near the top of the rear panel See Figure 29 9 Gently pull the panel away from the power supply Figure 29 4 4 5 6 7 5 6 7 ...

Page 106: ...rew to 23 0 kg cm 20 inch pounds See Figure 28 on page 104 4 Align the rear panel so the rectangular box on the inside of the panel slides over the heatsink in the power supply The power board and the wires from the power cord are hidden in Figure 30 in order to show the heatsink and the inside of the rear panel Figure 30 5 Reconnect the ground wire to the ground wire clip 6 Tighten the strain rel...

Page 107: ...and disconnect the power cord from the power source b See Remove the power supply cover on page 98 c See Remove the component barrier on page 100 d See Detach the rear panel on page 104 Kit number Description 228210 Kit CSA power cord with NEMA twist lock style 240 V 20 A plug 1 phase 3 0 m 10 feet strain relief not included 428390 Kit CE power cord 1 phase 3 0 m 10 feet plug and strain relief not...

Page 108: ...hite wires from the top of the power switch Figure 31 Single phase CSA power cord wires 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 heatsink Designator Wire color L live Black N neutral White PE ground Green AC AC N L PE ...

Page 109: ...0 AIR Service Manual 808850 109 6 Power Supply Component Replacement 3 Remove the screw that holds the ground wire to the heatsink A notch in the power board provides access to the screw See Figure 32 Figure 32 ...

Page 110: ...ower supply pull the wires through the strain relief and through the hole in the rear panel to remove the power cord 6 Are you replacing the strain relief If yes use an adjustable wrench to unscrew the retention nut on the inside of the power supply Remove the strain relief from the rear panel If no continue with Install the power cord and strain relief on page 114 Figure 33 1 2 3 4 1 2 3 4 Outsid...

Page 111: ...supply cover on page 98 c See Remove the component barrier on page 100 d See Detach the rear panel on page 104 CE power cords have a brown wire and a blue wire that connect to the power switch and a green yellow ground wire that connects to the heatsink 2 Remove the blue and brown wires from the power switch Figure 34 Single phase CE power cord wires Designator Wire color L live Brown N neutral Bl...

Page 112: ...rmax30 AIR Service Manual 808850 6 Power Supply Component Replacement 3 Remove the screw that holds the green yellow ground wire to the heatsink A notch in the power board provides access to the screw Figure 35 ...

Page 113: ... wires through the strain relief and the hole in the rear panel See Figure 36 You cannot remove the wires from outside the power supply because of the ferrite core installed on the wires 7 Are you replacing the strain relief If yes use an adjustable wrench to unscrew the retention nut on the inside of the power supply Remove the strain relief from the rear panel If no continue with Install the pow...

Page 114: ...m of the rear panel 3 Press the connector for the black wire onto the pin on the upper left side of the power switch 4 Press the connector for the white wire onto the pin on the upper right side of the power switch 5 Tighten the green ground wire to the heatsink Tighten the screw to 23 0 kg cm 20 inch pounds 6 Position the black and white wires in the wire chase up the side of the rear panel and o...

Page 115: ...ove the ferrite core from the power cord wires 3 Press the connector for the brown wire onto the pin on the upper left side of the power switch 4 Press the connector for the blue wire onto the pin on the upper right side of the power switch 5 Tighten the green yellow ground wire to the heatsink Tighten to screw to 23 0 kg cm 20 inch pounds 6 Position the brown and blue wires in the wire chase up t...

Page 116: ...isconnect the 4 wires from the back of the power switch 3 Using a small blade screwdriver press up one of the tabs on the bottom of the power switch and push that corner of the switch out of the rear panel 4 Press up the other tab on the bottom of the power switch and push that corner of the switch out of the panel Make sure the first tab does not snap back into place as you release the second tab...

Page 117: ...e right AC wire connects to the bottom right pin on the power switch See Figure 38 and Figure 39 Figure 38 3 Press the connector for the black CSA or brown CE wire onto the upper left pin on the power switch 4 Press the connector for the white CSA or blue CE wire onto the upper right pin on the power switch Figure 39 5 Complete the following procedures a See Install the component barrier on page 1...

Page 118: ...ling it a Attach the control board s ribbon cable to the power board at J7 b Reconnect the power cord to the power source and turn the system ON I c Make sure the Start LED on the control board is the only LED illuminated Also the fault LEDs on the front panel should be extinguished See Control board LEDs on page 71 Kit number Description 428404 Kit Control board 141365 CAUTION Static electricity ...

Page 119: ... the power source disconnect the ribbon cable and set the new control board aside 5 Remove the amperage adjustment knob from the front of the power supply by pulling it away from the front panel It does not have a set screw 6 Remove the 3 retaining screws from the control board Lift the board out of the front panel Figure 41 1 2 3 1 3 4 1 3 4 ...

Page 120: ...ect the ribbon cable to the power board at J7 and fold the latches up to hold the connector in place 9 Press the amperage adjustment knob onto the post on the front panel of the power supply 10 Complete the following procedures a See Reattach the front panel on page 103 b See Install the component barrier on page 101 c See Install the power supply cover on page 99 d Reconnect the power cord and se...

Page 121: ...s that secure the clips covering the MOSFET and diode Remove the clips and set them aside 4 Use a right angle TORX screwdriver to loosen the retaining screw near the bottom of the compressor driver board just above the heatsink Do not remove the screw A quarter turn to a half turn on the screw should loosen it enough for you to remove the compressor driver board Kit number Description 428401 Kit C...

Page 122: ...wdriver so that it is parallel to the top edge of the diode and next to the diode s curved metal prongs Slowly twist the screwdriver so that it pushes against the diode Continue twisting until the diode breaks free from the thermal strip Figure 43 7 Repeat the previous step to detach the MOSFET from its thermal strip 8 Make sure the MOSFET and diode are fully detached from the heatsink Lift the co...

Page 123: ...Component Replacement 9 Peel both thermal protection strips off the heatsink If the ends of the strips are tucked down between the heatsink and center panel firmly grip both corners of the strip and pull up to remove it from the power supply Figure 44 10 10 ...

Page 124: ...re the thermal strip evenly to the heatsink where the diode sits Make sure the strip meets the groove in the heatsink where the clip will be attached If there are any creases or air bubbles in the thermal strip remove it and apply a new one The kit contains additional strips Figure 45 3 Repeat the previous step to apply a thermal strip to the heatsink where the MOSFET sits 4 Make sure the thermal ...

Page 125: ... the heatsink Tighten the screw to 17 3 kg cm 15 inch pounds 8 Peel a circular piece of polyimide tape off its backing sheet Adhere it evenly to the top of the MOSFET Make sure the tape covers the MOSFET completely 9 Install the clips that cover the MOSFET and diode Tighten the screws to 17 3 kg cm 15 inch pounds Make sure the screw for the diode s clip goes straight down into the heatsink Do not ...

Page 126: ...ee Remove the component barrier on page 100 d See Detach the front panel on page 102 2 Make sure the J7 connector from the control board is removed from the power board See Figure 48 on page 127 3 Remove the TORCH START connector J12 on the component side of the power board by pushing the tab on the connector toward the plug and pulling the plug out Figure 47 Kit number Description 428402 Kit Powe...

Page 127: ...J9 on the component side of the power board 5 Remove the J3 connector from the compressor driver board Figure 48 1 2 4 7 8 9 1 3 3 3 2 5 6 10 1 Input diode bridges 2 Capacitors 3 IGBTs 4 J12 TORCH START connector 5 Snubber resistor 6 J7 ribbon cable connector 7 J9 8 J6 9 J5 10 J3 connects to compressor driver board ...

Page 128: ...ring terminal from J22 8 Remove the 2 retaining screws 9 Remove the 3 screws that attach the IGBTs to the heatsink and the 2 screws that attach the input diode bridges to the heatsink Holes in the power board provide access to the 2 input diode bridge screws 10 Remove the 4 heatsink assembly screws Figure 49 WORK LEAD BLK AC AC R w TORCH START BLK BLK B TORCH START 1 2 4 3 2 2 1 2 11 12 13 5 6 7 8...

Page 129: ... 13 Use an 8 mm 5 16 inch nut driver to remove the nuts that attach the red and the white wires to the studs on the fan side of the power supply The studs are labeled RED and WHT 14 Pull the red and white wires through the grommet in the center panel of the power supply Figure 51 15 From the power board side of the power supply push the wires that you disconnected down and out of the way 16 Pull t...

Page 130: ...lcohol to remove any residual thermal grease 2 Apply a 0 051 mm 0 002 inch layer of thermal grease about the thickness of a sheet of paper on all the IGBTs and the input diode bridges 3 Apply thermal grease to the bottom of the snubber resistor as follows a Avoid getting any thermal grease on the prongs of the snubber resistor b Start from the end closest to the power board and drag away from the ...

Page 131: ...53 7 Push the power board straight in Figure 53 8 Reconnect the 2 white wires to the power switch Connect the left AC wire to the bottom left pin on the power switch Connect the right AC wire to the bottom right pin on the power switch 9 Replace the 4 heatsink assembly screws Tighten the screws to 17 3 kg cm 15 inch pounds 10 Replace the 3 screws that attach the IGBTs to the heatsink and the 2 scr...

Page 132: ...s at J5 J6 and J9 See Figure 48 on page 127 15 Reconnect the J3 connector to the compressor driver board 16 Reconnect the ribbon cable from the control board to the power board at J7 Make sure the latches fold up over the connector 17 On the fan side of the power supply reconnect the ring terminals for the red and white wires to the studs labeled RED and WHT Tighten the nuts to 23 0 kg cm 20 inch ...

Page 133: ... hose runs from the solenoid valve to the torch lead You can also replace the plastic 90 fitting that connects the gas supply hose from the solenoid valve to the gas supply fitting from the torch lead The gas supply hoses in this system use push to connect fittings How to use push to connect fittings Kit number Description 428373 Kit Drain hose 2 gas supply hoses elbow fitting Push to Connect To c...

Page 134: ... other end of the drain hose from the fitting on the bottom of the air filter bowl 4 Remove the gas supply hose that connects to the air filter and the solenoid valve a Push to release the gas supply hose from the fitting on the air filter See How to use push to connect fittings on page 133 b Push to release the gas supply hose from the fitting on the solenoid valve 5 Remove the gas supply hose an...

Page 135: ...idden in Figure 54 to better show the hoses and fittings 1 2 6 3 4 5 7 1 Drain hose 2 Gas hose from air filter to solenoid valve 3 90 fitting on air filter right side 4 90 fitting on solenoid valve left side 5 Gas hose from solenoid valve to torch lead 6 90 fitting for torch lead 7 90 fitting on solenoid valve right side ...

Page 136: ... the longer gas supply hose to the solenoid valve and the plastic 90 fitting a Push to connect one end of the new hose into the fitting on the solenoid valve b Push to connect the other end of the new hose into the top of the plastic 90 fitting for the torch lead c Push to connect the plastic 90 fitting onto the torch lead s brass gas supply fitting inside the front panel of the power supply 5 Che...

Page 137: ... board See Figure 56 on page 138 3 Remove the J1 connector from the compressor driver board 4 Connect one end of the new twisted pair wires to J9 on the power board 5 Route the wires through the notch at the top of the center panel The notch is labeled AUX BOARD on the fan side of the power supply 6 Route the wires along the top of the center panel Use the notches provided as shown in Figure 56 7 ...

Page 138: ...Power Supply Component Replacement 8 Complete the following procedures a See Install the component barrier on page 101 b See Install the power supply cover on page 99 c Reconnect the power cord and set the power switch to ON I Figure 56 1 2 3 4 ...

Page 139: ...ector from the ground clip on the rear panel See Figure 57 3 Remove the ground wire s ring terminal from the screw that attaches it to the standoff in the center panel 4 Tighten the new ground wire s ring terminal to the standoff in the center panel Tighten the screw to 17 3 kg cm 15 inch pounds 5 Press the connector on the other end of the wire onto the rear panel s ground clip 6 Complete the fol...

Page 140: ...ring terminal on the other end of the ground wire from the screw that attaches it to the metal base plate of the magnetics assembly The wire runs through the grommet in the center panel 4 Tighten the new ground wire s ring terminal to the heatsink Tighten the screw to 23 0 kg cm 20 inch pounds 5 Route the new ground wire through the grommet in the center panel See Figure 58 6 Use the screw to atta...

Page 141: ...30 AIR Service Manual 808850 141 6 Power Supply Component Replacement Figure 58 1 3 2 1 Ground wire attached to heatsink 2 Ground wire attached to magnetics assembly s metal base plate 3 Grommet in center panel ...

Page 142: ...arrier to see the connector 3 Remove the valve s wires from the notch at the top of the center panel 4 Pull back the 2 clips from the center panel that hold the solenoid valve in place and work the solenoid valve free from the clips 5 Push to release the gas supply hose from the fitting on the left side of the solenoid valve See How to use push to connect fittings on page 133 6 Push to release the...

Page 143: ...between the 2 clips from the center panel It should snap into place 5 Connect the solenoid valve s wire connector to J6 on the power board Route the red and black wires through the notch in the center panel that is labeled VALVE 6 Check for leaks at each fitting on the solenoid valve assembly 7 Complete the following procedures a See Install the power supply cover on page 99 b Reconnect the power ...

Page 144: ... Complete the following procedures a Set the power switch to OFF O and disconnect the power cord from the power source b See Remove the power supply cover on page 98 c See Detach the front panel on page 102 2 Locate the 3 pin connector at the TORCH START slot J12 on the power board on the side facing the heatsink where the orange blue and purple wires from the torch lead connect Figure 60 Kit numb...

Page 145: ...nside the front panel of the power supply See How to use push to connect fittings on page 133 5 Locate the studs that attach the white wire group and the red wire from the torch lead to the power supply s center panel on the fan side of the power supply 6 Use an 8 mm 5 16 inch nut driver to remove the nuts from the studs and slide the ring terminals off the studs 7 Loosen the strain relief nut on ...

Page 146: ...d cable not the whole torch assembly refer to Replace the torch lead on page 197 for details on how to connect the new lead to the torch 1 Are you installing a new strain relief If yes slide the new strain relief and strain relief nut over the new torch lead and up to the hole in the front panel If no continue with the next step 2 Route the wires for the new torch lead through the hole in the fron...

Page 147: ... stud to 23 0 kg cm 20 inch pounds 7 Push to connect the plastic 90 fitting onto the new torch lead s brass gas supply fitting 8 Route the orange blue and purple wire group over the center panel Position the wires in the notch in the panel that is labeled TORCH 9 Press the connector into the TORCH START slot J12 on the power board See Figure 61 on page 145 10 Tighten the torch lead s strain relief...

Page 148: ... Remove any water that spills inside the power supply before operating the system again 3 Push to release the gas supply hose from the fitting on the right side of the air filter See How to use push to connect fittings on page 133 4 Push to release the copper heat exchange coil from the fitting on the left side of the air filter If you need better access to the air filter remove the fan plenum Use...

Page 149: ...lter See How to use push to connect fittings on page 133 3 Push to connect the gas supply hose into the fitting on the right side of the air filter 4 Make sure the top of the air filter is level If the top of the filter is angled up to the left or to the right check both fittings to make sure the hose and coil are properly seated 5 Make sure the fitting at the bottom of the air filter bowl points ...

Page 150: ...ilter assembly 9 Complete the following procedures a See Install the power supply cover on page 99 b Reconnect the power cord and set the power switch to ON I CAUTION If there are leaks in the gas supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Consumables life can be shortened ...

Page 151: ...wl It is normal to see water in the drain hose and in the air filter bowl Remove any water that spills inside the power supply before operating the system again If you need better access to the air filter remove the fan plenum Use a pair of needlenose pliers to compress and release the plenum s top 2 corner clips first before working the bottom 2 clips free from the fan casing 3 Hold the top of th...

Page 152: ...them Set the 2 plastic fittings aside Figure 67 Install the air filter element and air filter bowl 1 Are you replacing the whole filter bowl assembly or only the air filter element Air filter element continue with the next step Filter bowl assembly start with step 5 on page 153 2 Enclose the new air filter element in the plastic fittings Gently twist the plastic fittings until they lock together a...

Page 153: ... the wires from the fan Screw the filter bowl into the air filter Tighten the filter bowl to finger tight Be careful not to trap the fan s wires behind the filter bowl when you install the bowl 6 Connect the drain hose to the fitting at the bottom of the filter bowl 7 Make sure the other end of the drain hose is pressed securely in the hole in the base of the power supply Figure 68 8 Put the fan p...

Page 154: ...int on the air filter assembly 10 Complete the following procedures a See Install the power supply cover on page 99 b Reconnect the power cord and set the power switch to ON I CAUTION If there are leaks in the gas supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Parts life can shorten ...

Page 155: ...ack wires from the notch at the top of the center panel 4 Carefully pull the fan plenum straight off the fan casing to release the 4 clips at each corner of the plenum See Figure 69 If necessary use needlenose pliers to compress and release the plenum s top 2 corner clips first before working the bottom 2 clips free from the fan casing 5 Remove the retaining screw from each corner of the fan Slide...

Page 156: ...e installed tighten them to 11 5 kg cm 10 inch pounds 4 Orient the new fan plenum so that the wider end is at the bottom and snap it onto the fan See Figure 70 5 Route the fan s red and black wires through the notch in the top of the center panel that is labeled FAN The notch is above the air filter 6 Attach the connector for the red and black wires to J5 on the power board Figure 70 7 Complete th...

Page 157: ...oil points towards the bottom of the power supply 4 Push to release the heat exchange coil from the exhaust fitting on the internal compressor If you have trouble disconnecting the coil from the internal compressor try pushing the coil further into the fitting to straighten and reset it Then remove it using push to release 5 Use an 11 mm 7 16 inch wrench to remove the elbow fitting from the left s...

Page 158: ...mpressor If yes use an 11 mm 7 16 inch wrench to install the fitting Tighten until snug plus 1 turn Thread sealant is already applied to the threads of the exhaust fitting Do not apply additional thread sealant If no continue with the next step 3 Orient the new heat exchange coil on its side with the top end pointed towards the bottom of the power supply as shown in Figure 72 4 Push to connect the...

Page 159: ...of the air filter 7 Make sure all the hose and tube connections on the air filter are secure 8 Complete the following procedures a See Install the fan on page 156 b See Install the power supply cover on page 99 c Reconnect the power cord and set the power switch to ON I CAUTION If there are leaks in the gas supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thi...

Page 160: ...drain hose from the hole in the bottom of the power supply s base It is normal to see water in the drain hose and in the air filter bowl Remove any water that spills inside the power supply before operating the system again 3 Remove the J2 connector from the compressor driver board Remove the J2 wires from the notches in the center panel Kit number Description 428377 Kit Internal compressor includ...

Page 161: ...er Supply Component Replacement 4 Use an 8 mm 5 16 inch wrench to remove the hex nuts from the 3 retaining screws that secure the internal compressor to the base of the power supply 5 Remove the metal washer from each retaining screw Figure 73 2 2 ...

Page 162: ... is free of the 2 retaining screws 7 Rotate the internal compressor 90 counterclockwise so that it is outside the power supply See Figure 74 8 Lift the internal compressor until it is free of the third retaining screw the one in the middle of the power supply Remove the internal compressor from the power supply Figure 74 9 Check the 3 retaining screws in the power supply If brass sleeves were left...

Page 163: ... Figure 75 If yes replace the missing brass sleeve with one from the old compressor If no continue with the next step Figure 75 2 Orient the internal compressor so it is perpendicular to the power supply Slide the internal compressor s bracket over the retaining screw in the middle of the power supply s base as shown in Figure 76 Figure 76 Check for missing brass sleeves before installing the comp...

Page 164: ... cm 20 inch pounds 6 Plug the internal compressor s wire connector into J2 on the compressor driver board Route the wires through the notches at the top of the center panel labeled RED and BLK Position the wires in the wire chase up the side of the rear panel 7 Press the air filter s drain hose into the hole in the base of the power supply 8 Complete the following procedures a See Install the heat...

Page 165: ... the internal compressor 3 Unscrew the filter assembly from the internal compressor Install the air inlet filter in the internal compressor 1 Screw the new air inlet filter assembly onto the internal compressor Tighten the filter assembly only to finger tight 2 Complete the following procedures a See Install the power supply cover on page 99 b Reconnect the power cord and set the power switch to O...

Page 166: ...the power supply see Detach the front panel on page 102 and Reattach the front panel on page 103 1 Complete the following procedures a Set the power switch to OFF O and disconnect the power cord from the power source b See Remove the power supply cover on page 98 c See Remove the component barrier on page 100 2 Lay the power supply on its side 3 Remove the retaining screw from the bottom of the fr...

Page 167: ...pply until it detaches from the base 5 Repeat the previous step on the other corner of the panel 6 Disconnect the control board s ribbon cable from the power board by folding the latches back In Figure 78 the center panel is hidden in the image on the left Figure 78 7 Remove the amperage adjustment knob from the front of the power supply by pulling it away from the front panel It does not have a s...

Page 168: ... and strain relief on page 146 2 Install the work lead See Remove and install the work lead on page 180 3 Push the new front panel into the power supply base until it snaps into place 4 Tighten the retaining screw to 23 0 kg cm 20 inch pounds 5 Attach the control board to the new front panel with the 3 retaining screws 6 Connect the control panel ribbon cable to the power board at J7 and fold the ...

Page 169: ...that the serial number on the existing rear panel matches the one on the new rear panel Contact Hypertherm if the serial numbers do not match The serial number can be found on the data plate 2 Complete the following procedures a Set the power switch to OFF O and disconnect the power cord from the power source b See Remove the power supply cover on page 98 c See Remove the component barrier on page...

Page 170: ...from the back of the power switch 9 Using a small blade screwdriver press up one of the tabs on the bottom of the power switch and push that corner of the switch out of the rear panel 10 Press up the other tab on the bottom of the power switch and push that corner of the switch out of the panel Make sure the first tab does not snap back into place as you release the second tab 11 Repeat the previo...

Page 171: ...the screw holes in the rear panel and the power supply s center panel 4 Tighten the retaining screw to 23 0 kg cm 20 inch pounds 5 Align the rear panel so the rectangular box on the inside of the panel slides over the heatsink in the power supply The power board and the wires from the power cord are hidden in Figure 82 in order to show the heatsink and the inside of the rear panel 6 Press the powe...

Page 172: ...ire onto the upper left pin on the power switch 9 Press the connector for the white CSA or blue CE wire onto the upper right pin on the power switch Figure 84 10 Reconnect the ground wire to the ground wire clip on the rear panel 11 Tighten the strain relief nut on the power cord on the outside of the power supply 12 Complete the following procedures a See Install the component barrier on page 101...

Page 173: ...wer supply make sure the air filter s drain hose is disconnected from the hole in the bottom of the base It is normal to see water in the drain hose and in the air filter bowl Remove any water that spills inside the power supply before operating the system again 3 Lay the power supply on its side with the fan side facing up See Figure 85 4 Remove the 6 screws that attach the plastic base to the co...

Page 174: ...the wires do not get pinched 3 Press the plastic base into the power supply until it snaps into place 4 Attach the plastic base to the bottom components using the 6 screws 5 Complete the following procedures a See Install the internal compressor on page 163 b See Install the heat exchange coil on page 158 c See Install the fan on page 156 d See Reattach the rear panel on page 106 e See Reattach th...

Page 175: ...onent barrier on page 100 d See Detach the front panel on page 102 e See Detach the rear panel on page 104 f See Remove the fan on page 155 g See Remove the heat exchange coil on page 157 h See Remove the internal compressor on page 160 2 On the power board side of the power supply remove the wires for the transformers and inductors See Figure 86 a Remove J13 J14 and J15 located on the front panel...

Page 176: ...ir filter s drain hose is disconnected from the hole in the bottom of the base It is normal to see water in the drain hose and in the air filter bowl Remove any water that spills inside the power supply before operating the system again 5 Use an 8 mm 5 16 inch nut driver to remove the nut that attaches the ring terminal for the output inductor s white wire to the stud labeled WHT Figure 87 1 1 2 3...

Page 177: ...ire or other similar item with a 0 23 cm 0 092 inch diameter in each of the 6 holes on the power board side of the base Press each one in until the clips release and you can pull the base and the attached magnetics away from the center panel 8 Remove the 6 screws that hold the magnetics metal mounting plate in place Remove the plate and the magnetics Figure 88 4 5 4 5 ...

Page 178: ...er panel so that the wires do not get pinched 4 Press the plastic base and the magnetics into the bottom of the power supply until the assembly snaps into place 5 On the fan side of the power supply attach the ring terminal for the output inductor s white wire to the stud labeled WHT using an 8 mm 5 16 inch nut driver Tighten the nut to 23 0 kg cm 20 inch pounds See Figure 87 on page 176 Also put ...

Page 179: ...ew to 23 0 kg cm 20 inch pounds Figure 89 8 Complete the following procedures a See Install the internal compressor on page 163 b See Install the heat exchange coil on page 158 c See Install the fan on page 156 d See Reattach the rear panel on page 106 e See Reattach the front panel on page 103 f See Install the component barrier on page 101 g See Install the power supply cover on page 99 h Reconn...

Page 180: ...e power cord from the power source b See Remove the power supply cover on page 98 c See Remove the component barrier on page 100 d See Detach the front panel on page 102 2 Loosen the strain relief nut on the work lead 3 Remove and set aside the screw and washer from J22 on the power board labeled WORK LEAD Figure 90 Kit number Description 428388 Kit Work lead 4 6 m 15 feet with ground clamp 228561...

Page 181: ... the retaining nut 7 Attach the work lead to the power board at J22 using the screw and washer that you removed in step 3 Tighten the screw to 23 0 kg cm 20 inch pounds 8 On the inside of the front panel tighten the retaining nut onto the strain relief Figure 91 9 Complete the following procedures a See Reattach the front panel on page 103 b See Install the component barrier on page 101 c See Inst...

Page 182: ...ement clamp slide down the black plastic sleeve on the handle of the clamp where you want to connect the work lead You can attach the work lead to either of the clamp s handles 7 Thread the work lead through the plastic sleeve you moved in the previous step and then through the slots inside the handle 8 Line up the hole in the ring terminal with the hole in the handle of the ground clamp 9 Insert ...

Page 183: ...Powermax30 AIR Service Manual 808850 183 6 Power Supply Component Replacement Figure 92 2 3 4 1 ...

Page 184: ...184 Powermax30 AIR Service Manual 808850 6 Power Supply Component Replacement ...

Page 185: ...e Manual 808850 185 Section 7 Torch Component Replacement WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance See the Safety and Compliance Manual 80669C for more safety precautions ...

Page 186: ...10 11 12 13 14 2 6 9 8 15 1 Right side of the handle 2 Cap sensor switch 3 Start switch 4 Plunger screw 5 Plunger 6 Consumables 7 Torch body 8 Torch power wire 9 Left side of the handle 10 Screws 5 11 Trigger assembly 12 Trigger spring 13 Gas hose fitting s flange 14 Strain relief 15 Cap sensor wire connector ...

Page 187: ...nd disconnect the power cord from the power source 2 Remove the consumables from the torch 3 Place the torch on a flat surface with the left side of the handle facing up The left side of the handle is the side with the screws 4 Remove the screws from the torch handle Set the screws aside 5 Being careful to keep the trigger spring from launching out of the handle carefully pry the left side of the ...

Page 188: ...e holding the spring in place slide the trigger and spring up and out of the handle Set them aside 7 The torch body fits snugly into the right side of the handle While holding the torch body in place gently press the right side of the handle away from the torch body to remove it Figure 95 ...

Page 189: ... mounting post See Figure 96 and Figure 97 Figure 96 9 Slide the start switch off the 2 mounting posts Figure 97 1 2 3 4 5 6 1 Cap sensor switch s post hole 2 Cap sensor switch s mounting post 3 Trigger s pivot hole 4 Start switch s mounting posts 5 Slot for the gas hose fitting s flange 6 Strain relief slot ...

Page 190: ... cap sensor switch connector in place See Figure 97 on page 189 and Figure 98 Figure 98 5 Press the torch body into the torch handle with the gas hose fitting s flange aligned with the slot in the handle Make sure the flange does not pinch any wires 6 Align the strain relief with the strain relief slot in the handle See Figure 98 for the location of the strain relief slot 7 Compress the trigger sp...

Page 191: ...itch to OFF O and disconnect the power cord from the power source 2 Remove the consumables from the torch 3 Place the torch on a flat surface with the left side of the handle facing up 4 Remove the screws from the torch handle Set the screws aside 5 Being careful to keep the trigger spring from launching out of the handle carefully pry the left side of the handle away from the torch Kit Descriptio...

Page 192: ...Slide the trigger and spring into place 8 Being careful that the handle does not pinch the wires align the left half of the handle with the right half Make sure the trigger pivots are both located in the trigger pivot holes See Figure 98 on page 190 9 Install the handle screws 10 Pull the trigger to make sure it is positioned correctly in the torch handle 11 Install the consumables 12 Reconnect th...

Page 193: ...age 187 2 Remove the screw that attaches the torch power wire to the torch body Set the nut and screw aside 3 Peel off the tape that attaches the torch power wire to the torch body Figure 100 4 Use two wrenches to loosen the gas fitting that attaches the torch body to the torch lead Kit Description 428394 Kit Air T30 torch body includes O ring CAUTION Always use two wrenches to properly loosen and...

Page 194: ...rip of electrical tape to attach the torch power wire to the torch body s gas tube Apply the tape so that it will be above the post hole shown in Figure 102 when the torch body is in the handle Make sure the wire runs alongside the gas tube as shown in Figure 102 The tape holds the power wire in place and prevents the wire from getting pinched Do not pull the wire too tight when you attach it to t...

Page 195: ...Remove the handle on page 187 2 Disconnect the old start switch by pushing on the tab and pulling the start switch away from the connector 3 Connect the new start switch by pushing the mating plug into the socket 4 Complete the following procedures a Install all of the torch components that you removed See Install the handle on page 190 b Reconnect the power cord and set the power switch to ON I K...

Page 196: ...187 2 Disconnect the old cap sensor switch by pressing the tab on the connector and pulling the connector apart 3 Connect the new cap sensor switch to the torch lead by pushing the mating plug on the torch lead wires into the socket 4 Complete the following procedures a Install all of the torch components that you removed See Install the handle on page 190 b Reconnect the power cord and set the po...

Page 197: ...F O and disconnect the power cord from the power source b Remove all components from the torch See Remove the handle on page 187 2 Disconnect the cap sensor switch and start switch Figure 103 3 Remove the screw that attaches the torch power wire to the torch body Set the nut and screw aside 4 Peel off the tape that attaches the torch power wire to the torch body Figure 104 Kit Description 428176 K...

Page 198: ...tion order It is important that the screw be installed as shown 8 Use a small strip of electrical tape to attach the torch power wire to the torch body s gas tube Apply the tape so that it will be above the post hole shown in Figure 106 when the torch body is in the handle Make sure the wire runs alongside the gas tube as shown in Figure 106 The tape holds the power wire in place and prevents the ...

Page 199: ...ect the cap sensor switch and start switch Figure 107 10 Complete the following procedures a Install all of the torch components that you removed See Install the handle on page 190 b Reconnect the power cord and set the power switch to ON I Cap sensor switch Tab Tab Start switch ...

Page 200: ...200 Powermax30 AIR Service Manual 808850 7 Torch Component Replacement ...

Page 201: ... accessories and replacement parts for your power supply and hand torch You can find procedures explaining how to install these kits in Power Supply Component Replacement on page 97 Torch Component Replacement on page 185 For instructions on installing the consumables in the hand torch see Step 1 Install the consumables on page 43 ...

Page 202: ...28267 Kit Power supply handle includes screws and shoulder strap clips 2 428396 Kit Power supply cover with labels CSA 2 428398 Kit Power supply cover with labels CSA Built in America 2 428397 Kit Power supply cover with labels CE 3 428226 Kit Current adjustment knob 4 428389 Kit Front panel does not include current adjustment knob 5 428388 Kit Work lead 4 6 m 15 feet with ground clamp 6 228561 Ki...

Page 203: ...on 120 V 15 A plug adapter 3 228210 Kit CSA power cord with NEMA twist lock style 240 V 20 A plug 1 phase 3 0 m 10 feet strain relief not included 4 428390 Kit CE power cord 1 phase 3 0 m 10 feet plug and strain relief not included 5 228143 Kit Power cord strain relief 6 428391 Kit Rear panel includes data plate and consumables label 1 2 3 4 5 NEMA 6 50P NEMA 5 15P NEMA L6 20P 6 ...

Page 204: ...it Power board CE 141357 PCB2 3 428401 Kit Compressor driver board includes thermal strips and polyimide tape 141298 PCB3 428406 Kit Replacement clips not shown Replacement clip and screws for snubber resistor on power board Replacement clips and screws for MOSFET and diode on compressor driver board 428411 Kit Replacement hex nut standoffs 5 for mounting power board to heatsink not shown 1 3 2 ...

Page 205: ...wermax30 AIR Service Manual 808850 205 8 Parts Interior control board and power switch Item Kit number Description Designator 1 428404 Kit Control board 141365 PCB1 2 428235 Kit Power switch S1 AC AC 2 1 ...

Page 206: ...206 Powermax30 AIR Service Manual 808850 8 Parts Interior fan assembly Item Kit number Description Designator 1 428236 Kit Fan assembly with plenum M1 1 ...

Page 207: ...oil includes elbow fitting for air filter and exhaust fitting for internal compressor 4 428375 Kit Air filter assembly includes gas hose drain tube and elbow fittings 5 428378 Kit Air filter element 6 428380 Kit Air filter bowl includes air filter element O ring and drain hose 7 428374 Kit Solenoid valve includes gas hoses and elbow fittings V1 8 9 428373 Kit Drain hose 2 gas supply hoses elbow fi...

Page 208: ... Wire group 1 Power board J9 to compressor driver board J1 twisted pair wires red and black 2 Ground clip wire from rear panel to center panel green 3 Ground wire from heatsink to magnetics assembly green 4 428413 Kit Replacement hex nut standoff 5 for attaching ground clip wire to center panel 2 1 3 4 ...

Page 209: ...e and magnetics Item Kit number Description 1 428399 Kit Plastic base includes rubber bumpers or feet 428392 Kit Replacement bumpers feet for bottom of plastic base 4 not shown 2 428400 Kit Magnetics assembly 3 428407 Kit Replacement grommet for center panel 5 1 2 3 ...

Page 210: ...gs 5 for torch body 5 428156 Kit Torch trigger and spring 6 428182 Kit Replacement springs 5 for torch trigger 7 428381 Kit Air T30 torch handle includes handle screws 8 428181 Kit Air T30 torch replacement screws for handle 9 428176 Kit Air T30 torch lead 4 6 m 15 feet with strain relief The torch assembly includes one set of consumables Electrode 420132 Swirl ring 420133 Nozzle 420134 Retaining ...

Page 211: ...rder a package of 5 nozzles Use 420132 to order a package of 5 electrodes Use 428350 to order a kit of 2 nozzles and 2 electrodes These consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch They cannot be used with any other Powermax system or torch Individual consumables Kit electrode 2 nozzle 2 420133 420132 420134 420135 Electrode Swirl ring N...

Page 212: ... Deluxe plasma circle cutting guide 127144 Dust cover 024548 Leather torch lead cover brown 7 6 m 25 feet 024877 Leather torch lead cover black with Hypertherm logo 7 6 m 25 feet 127217 Shoulder strap 127169 Leather cutting gloves 127416 Protective glasses shade 5 lens 128836 Thermal grease 1 8 ounce 027055 Silicone lubricant 1 4 ounce ...

Page 213: ...red by the Hypertherm warranty In addition the following parts are safety critical parts that must be replaced only with genuine Hypertherm parts to maintain the warranty and system certifications including CE and CSA certification Item Kit number Description 1 428402 Kit Power board CSA and subcomponents 1 428403 Kit Power board CE and subcomponents 2 428401 Kit Compressor driver board 3 428235 K...

Page 214: ...5 Kit Air filter assembly includes gas hose drain tube and elbow fittings 7 228143 Kit Power cord strain relief 8 428400 Kit Magnetics assembly 9 228210 Kit CSA power cord with NEMA twist lock style 240 V 20 A plug 1 phase 3 0 m 10 feet 10 428390 Kit CE power cord 1 phase 3 0 m 10 feet plug not included Item Kit number Description ...

Page 215: ... Control board page 205 428235 Kit Power switch page 205 428377 Kit Internal air compressor page 207 428376 Kit Heat exchange coil page 207 428375 Kit Air filter assembly includes gas hose drain tube and elbow fittings page 207 428378 Kit Air filter element page 207 428374 Kit Solenoid valve includes gas hoses and elbow fittings page 207 428179 Kit Replacement O rings for torch body page 210 42838...

Page 216: ...es label and warning labels Consumables label The consumables label is affixed to the power supply s rear panel It shows the correct consumables to use with this system and torch and how to install them Kit number Description 428408 Kit Powermax30 AIR labels CSA 428410 Kit Powermax30 AIR labels CSA Built in America 428409 Kit Powermax30 AIR labels CE 210347 Rev A 420135 420134 420133 420132 420399...

Page 217: ...ons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death PN 110673 Rev D AVERTISSEMENT Le coupage plasma peut être préjudiciable pour l opérateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de sécurité peut entraîner la mort 1 Les étincell...

Page 218: ...ete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves 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...

Page 219: ... Manual 808850 219 Section 9 Wiring Diagrams This section contains the following diagrams Process flow for troubleshooting internal compressor and temperature fault LEDs Timing chart for torch start Powermax30 AIR schematic ...

Page 220: ...JJHU RQ RPSUHVVRU ZRUNV KHFN 9 86 DW RQ 9 86 SUHVHQW RQ KHFN 9 1 DW RQ after tapping torch trigger 9 1 SUHVHQW RQ LVFRQQHFW IURP KHFN 9 86 DW RQ DJDLQ 9 86 SUHVHQW RQ KHFN FRPSUHVVRU RQ H WHUQDO 9 SRZHU VRXUFH LVFRQQHFW DQG IURP WR LVRODWH 3 5 KHFN 9 86 RQ 3 5 KHFN 9 1 DW RQ 3 5 after tapping torch trigger 9 86 DQG 9 1 SUHVHQW RQ 3 5 1R HV 1R HV HV 1R HV 1R 1R HV 1R 1R HV HV KHFN 9 1 DW RQ 3 5 aft...

Page 221: ...er when work lead current 0 4 A Cutting steady state Torch trigger released Idle Start signal torch trigger ON OFF control board Start LED ON OFF Internal compressor ON OFF Pilot arc IGBT ON OFF Gas solenoid ON OFF Inverter output ON OFF Control board Transfer LED ON OFF system is cutting Postflow 5 20 seconds Postflow 5 20 seconds User set current Pilot arc current 15 A Transfer threshold 1 6 A ...

Page 222: ...Powermax30 AIR Service Manual 808850 222 9 Wiring Diagrams Powermax30 AIR schematic 013393 Rev A SHEET 1 of 2 ...

Page 223: ...Powermax30 AIR Service Manual 808850 223 9 Wiring Diagrams 013393 Rev A SHEET 2 of 2 ...

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