Hypertherm Powermax30 AIR Operator'S Manual Download Page 89

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MAINTENANCE AND PARTS

powermax30

Operator Manual

5-15

L
Black wire

N
White wire

Replace the power cord (CSA)

1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.

2. Remove the cover from the power supply and remove the Nomex barrier from in front of the

power board.

3. Remove the rear endcap.

4. 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.

Carefully pull the connector for the white wire away from the power switch to disconnect it. You
can use needlenose pliers or a straight screwdriver to ease it out, if necessary.

5. Remove the black wire the same way.

Single phase

Black

White

Green

PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-15

Summary of Contents for Powermax30 AIR

Page 1: ...Plasma arc cutting system Operator Manual 805160 Revision 2 COV_OM_805160 qxp COV_OM_805160 10 7 09 12 40 PM Page 1 ...

Page 2: ...____________________________________________ ________________________________________________________ ________________________________________________________ Maintenance notes ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ________________________________________...

Page 3: ...A www hypertherm com email info hypertherm com Copyright 2009 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 powermax30 PMX30_OM_TP qxp PMX30_OM_TP 10 7 09 12 42 PM Page 1 ...

Page 4: ...re 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit A 5th Floor Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 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...

Page 5: ...in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of ...

Page 6: ...workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where n...

Page 7: ...y packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above is exclusive and is in lieu...

Page 8: ...n Hypertherm products are shipped to one country for export to another country the product must be configured and certified properly for the end use site Higher level systems When a system integrator adds additional equipment such as cutting tables motor drives motion controllers or robots to a Hypertherm plasma cutting system the combined system may be considered a higher level system A higher le...

Page 9: ... Précaution 1a 2 Le coupage peut provoquer un incendie ou une explosion 1a 2 Les chocs électriques peuvent être fatals 1a 3 Le coupage peut produire des vapeurs toxiques 1a 3 L arc plasma peut provoquer des blessures ou des brûlures 1a 4 Les rayons de l arc peuvent brûler les yeux et la peau 1a 4 Mise à la masse et à la terre 1a 4 Sécurité des bouteilles de gaz comprimé 1a 5 Les bouteilles de gaz ...

Page 10: ...2 Power supply ratings 2 3 Torch dimensions 2 4 T30v torch ratings 2 4 Symbols and markings 2 5 mark 2 5 CE mark 2 5 IEC symbols 2 5 Section 3 Setup Unpack the Powermax30 3 2 Claims 3 2 Contents 3 2 Position the power supply 3 3 Voltage configurations 3 3 Requirements for grounding 3 3 Power cord considerations 3 4 Power cord and plugs for CSA power supplies 3 4 Power cord for CE power supplies 3 ...

Page 11: ...ting 5 4 Repairs 5 7 Remove and replace the cover and Nomex barrier 5 7 Remove an endcap 5 9 Disconnect the torch lead 5 11 Replace the work lead 5 13 Replace the power cord CSA 5 15 Replace the power cord CE 5 17 Replace the air filter element 5 19 Replacement and accessory parts 5 20 Power cords and adapters 5 20 Accessory parts 5 20 T30v hand torch assembly 5 21 Consumables 5 21 Filter regulato...

Page 12: ...TABLE OF CONTENTS viii powermax30 Operator Manual PMX30_OM_FM qxp PMX30_OM_FM 10 7 09 12 43 PM Page viii ...

Page 13: ...c 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 6 Compressed gas equipment safety 1 6 Gas cylinders can explode if damaged 1 6 Noise can damage hearing 1 7 Pacemaker and hearing aid operation 1 7 A plasma arc can damage frozen pipes 1 7 Additional safety information 1 7 Symbols and markings 1 8 Warning labels ...

Page 14: ... in this manual that may result in minor injury or damage to equipment if not followed correctly Fire Prevention Be sure 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 fla...

Page 15: ... 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 workpiece i...

Page 16: ...he equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations 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 TOXIC FUMES CAN CAUSE INJURY OR DEATH Duration of cutting ...

Page 17: ...ed by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant 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 ...

Page 18: ...r use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete W...

Page 19: ...ndards Institute 1430 Broadway New York NY 10018 3 ANSI Standard Z87 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O ...

Page 20: ...Laboratories Incorporated UL or TÜV CE marking The CE marking signifies the manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC fil...

Page 21: ...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 6 Become trained Only qualified personnel should operate this equipment Use torches specified in the manual Keep non qualified personnel and children away 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protect...

Page 22: ...s 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 in closed spaces Remove fumes...

Page 23: ...initions and explanations of regulatory terms such as deflagration AHJ adopted by reference the Kst value deflagration index and other terms Note 1 Hypertherm s interpretation of these new requirements is that unless a site specific evaluation has been completed to determine that all dust generated is not combustible the 2007 edition of NFPA 68 requires the use of explosion vents designed to the w...

Page 24: ...1 12 Hypertherm 11 08 SAFETY ...

Page 25: ...ent 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 6 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 auditifs 1a 7 Pacemakers et prothèses audit...

Page 26: ... de sécurité ATTENTION précèdent les directives associées dans le manuel qui si elles ne sont pas suivies scrupuleusement peuvent entraîner des blessures secondaires ou endommager l équipement 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 ...

Page 27: ...les instructions 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 cou...

Page 28: ...s 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 d air v...

Page 29: ...t Gants à crispin chaussures et casque de sécurité Vêtements ignifuges couvrant toutes les parties exposées du corps Pantalon sans revers pour éviter 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 trans...

Page 30: ... connectée pour utilisation Éviter à tout prix le contact électrique entre l arc plasma et une bouteille Ne 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 Câble de retour Bien fixer le câble de retour ou de masse à la pièce à couper ou à la tabl...

Page 31: ...ques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un médecin avant de s approcher d un lieu où s effectue le coupage ou le gougeage plasma Pour réduire les risques associés aux champs magnétiques Garder loin de soi et du même côté du corps le câble de retour et le fa...

Page 32: ... Laboratories Incorporated UL ou TÜV Marque CE La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes applicables Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque signalétique ou à proximité ont été mises à l essai de conformité à la directive européenne sur la basse tension et la compatibilité électromagnétique eur...

Page 33: ...ating 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 in closed spaces Remove fumes with ventilation 6 Become trained Only qualified perso...

Page 34: ...gants isolants Remplacer les gants s 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 d entretenir Ne pas toucher les pièces sous tension 4 Les fumées du plasma peuvent être dangereuses 4 1 Ne pas inhaler les fumées 4 2 Utiliser une ventilation forcée ou par aspiration à la source pour éliminer les fumées 4 3 Ne...

Page 35: ...s du bâtiment locaux Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que déflagration autorité compétente adopté par référence valeur du pire cas indice de déflagration et autres termes Note 1 L interprétation d Hypertherm de ces nouvelles exigences est que sauf évaluation particulière du site pour déterminer que toute la poussière produite n...

Page 36: ...11 08 1a 12 Hypertherm SÉCURITÉ ...

Page 37: ...usar 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 6 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 7 Operación de marcapasos y de audífonos 1b 7 Un arco plas...

Page 38: ... muerte Los mensajes de seguridad de CUIDADO o PRECAUCIÓN preceden mensajes relacionados con instrucciones en el manual que puede resultar en lesiones menores o daño a equipo si no se siguen correctamente 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 meno...

Page 39: ...A MUERTE 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 ...

Page 40: ...ar 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 se quita...

Page 41: ...iación ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro Roipa de combustión retardada y que cubra todas las partes expuestas Pantalones sin dobladillos para impedir que recojan chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar Área de cort...

Page 42: ...ros a calor excesivo chispas escorias o llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la válvula del cilindro Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa de traba...

Page 43: ...OS CONGELADOS Los campos magnéticos producidos por las elevadas corrientes pueden afectar la operación de marcapasos y de audífonos Las personas que lleven marcapasos y audífonos deberán consultar a un médico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magnéticos Mantenga el cable de trabajo y la manguera de la an...

Page 44: ...rwriters Laboratories Incorporated UL ó TÜV Marcas CE Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares aplicables Europeos Sólo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo la Compatibilidad Electromagnético Europea EMC...

Page 45: ...ersons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 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 étincelles de coupage...

Page 46: ...Los electrochoques 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...

Page 47: ...igos de construcción locales Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como deflagración AHJ adoptada por referencia el valor Kst índice de deflagración y otros términos Nota 1 La interpretación de Hypertherm de estos nuevos requisitos es que a no ser que se haya completado una evaluación específica del sitio para determinar que todo polvo generado no es c...

Page 48: ...11 08 SEGURIDAD 1b 12 Hypertherm ...

Page 49: ...iption 2 2 Power supply dimensions and weight 2 2 Power supply ratings 2 3 Torch dimensions 2 4 T30v torch ratings 2 4 Symbols and markings 2 5 mark 2 5 CE mark 2 5 IEC symbols 2 5 Section 2 SPECIFICATIONS PMX30_OM_02 qxp PMX30_OM_02 qxd 10 7 09 12 44 PM Page 2 1 ...

Page 50: ... addition to the consumables holder air fitting reducer Operator Manual and Quick Setup Card The power cords on the CSA units have a quick disconnect adapter and are shipped with a 120V 15A NEMA 5 15P plug and a 240V 20A NEMA 6 50P plug in addition to the twist lock 240V 20A NEMA L6 20P plug wired to the system The CE units are shipped without a plug on the power cord See Section 3 Power cord cons...

Page 51: ...0 VAC 50 I2 30 A U2 83 V 75 I2 24 A 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 rated output U2 MAX I2 MAX 120 V 26 A 200 240 V 15 5 13 A Gas type Air Nitrogen Gas quality Clean dry oil free 99 995 pure Minimum required gas inlet pressure and flow 3 5 scfm...

Page 52: ...1 58 40 mm 1 00 25 mm T30v torch ratings 2 00 50 mm Recommended capacity 1 4 inch 6 mm at 30 A 35 duty cycle Maximum capacity 3 8 inch 10 mm at 30 A 35 duty cycle Severance capacity 1 2 inch 12 mm at 30 A 35 duty cycle Weight 2 1 lbs 1 0 kg PMX30_OM_02 qxp PMX30_OM_02 qxd 10 7 09 12 44 PM Page 2 4 ...

Page 53: ...s needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE mark IEC symbols The following symbols may appear on the power supply data plate control labels switches and LEDs SPECIFICATIONS powermax30 Operator Manual 2 5 O l Direct current DC The terminal for the external protective earth conductor AC input power connection Plasma torch cutting ...

Page 54: ...SPECIFICATIONS 2 6 powermax30 Operator Manual PMX30_OM_02 qxp PMX30_OM_02 qxd 10 7 09 12 44 PM Page 2 6 ...

Page 55: ...ltage configurations 3 3 Requirements for grounding 3 3 Power cord considerations 3 4 Power cord and plugs for CSA power supplies 3 4 Power cord for CE power supplies 3 5 Extension cord recommendations 3 6 Generator recommendations 3 6 Gas supply 3 7 Connection 3 7 Additional gas filtration 3 8 PMX30_OM_03 qxp PMX30_OM_03 10 7 09 12 44 PM Page 3 1 ...

Page 56: ... upon request If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Contents Verify the items in the box against the illustra...

Page 57: ...ion and to reduce electromagnetic interference EMI the Powermax30 must be properly grounded The power supply must be grounded through the power cord according to national and local electrical codes Single phase service must be of the 3 wire type with a green or green yellow wire for the protective earth ground Do not use a 2 wire service Refer to Section 1 Grounding Safety for more information Inp...

Page 58: ...ory parts for part number information The power cord on the Powermax30 power supply is equipped with a twist lock plug NEMA L6 20P appropriate for use on a 240V 20A circuit with a twist lock outlet To operate the Powermax30 on a lower amperage circuit attach the female end of the 120V 15A NEMA 5 15P plug adapter to the power supply s twist lock plug Note Do not set the amperage adjustment knob abo...

Page 59: ...n the cord grip s screws Screws should be snug but not overly tight 230 V plug To line 1 terminal brass To line 2 terminal brass To ground terminal green Outer shell Cord grip 1 2 3 4 5 6 1 2 3 4 5 6 Power cord for CE power supplies The CE power supplies are shipped without a plug on the power cord To operate at 230 V obtain the correct plug and have it installed by a licensed electrician as shown...

Page 60: ...umbers below 30 003132 may shut down and show an error condition all LEDs flash when used with a generator that has a higher than normal voltage greater than 250 VAC To avoid shutdown check your generator s voltage regulator for proper operation Engine drive rating Output current Performance 5 5 KW 30 A Full arc stretch 4 KW 25 A Limited arc stretch Input voltage Phase Recommended cord gauge size ...

Page 61: ...and must be capable of delivering gas to the filter on the power supply at 3 5 scfm 65 psi 99 1 l min 4 5 bar To ensure adequate pressure to the power supply set the regulator to 80 to 100 psi 5 5 to 6 9 bar If gas supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and the life for consumables shortens Optional reducer WARNING Do not allow th...

Page 62: ...to the gas line use a three stage coalescing filtration system such as the Eliminizer filter kit part number 128647 available from Hypertherm distributors A three stage filtering system works as shown below to clean contaminants from the gas supply The filtering system should be installed between the 1 4 NPT quick disconnect coupler and the power supply PMX30_OM_03 qxp PMX30_OM_03 10 7 09 12 44 PM...

Page 63: ... consumables 4 3 Attach the work clamp 4 4 Power ON the system 4 4 Hand torch operation 4 6 Safety trigger operation 4 6 Hand torch cutting hints 4 7 To start a cut from the edge of the workpiece 4 8 To pierce a workpiece 4 9 Cut chart 4 10 Duty cycle and overheating 4 11 Common cutting faults 4 11 PMX30_OM_04 qxp PMX30_OM_04 10 7 09 12 45 PM Page 4 1 ...

Page 64: ...ndicates that the consumables are loose improperly installed or missing Power ON LED green When illuminated this LED indicates that the power switch has been set at I ON and that the safety interlocks are satisfied AC AC Front controls and LEDs Temperature LED yellow When illuminated this LED indicates that the power supply temperature is outside the acceptable operating range Amps adjustment knob...

Page 65: ...ch in the OFF O position verify that the torch consumables are installed as shown Retaining cap Nozzle Electrode Swirl ring Deflector optional only included with the deluxe carrying case Tighten only by hand WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated Make sure the power is OFF before changing consumables ...

Page 66: ...ece make good metal to metal contact Attach the work clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields EMF Do not attach the work clamp to the portion of the workpiece to be cut away Power ON the system 1 Set the ON OFF rocker switch to the ON I position I O I O Work clamp PMX30_OM_04 qxp PMX30_OM_04 10 7 09 12 45 PM Page 4 4 ...

Page 67: ...0V 20A 240V 20A 3 Verify that the green power ON LED on the front of the power supply is illuminated and that none of the other LEDs are illuminated If the gas pressure temperature or cap sensor LEDs are illuminated or blinking correct the fault condition before continuing See Basic troubleshooting in Section 5 for more information AC AC When the power ON LED is illuminated none of the other LEDs ...

Page 68: ...and press the torch trigger as show below Hand torch operation WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch trigger is activated The plasma arc will cut quickly through gloves and skin Keep 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...

Page 69: ...her If you fire the torch unnecessarily you shorten the life of the nozzle and electrode Pulling the torch along the cut is easier than pushing it 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 Hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90 angle to the cutting surface and ...

Page 70: ...o the workpiece hold the torch nozzle perpendicular to the edge of the workpiece 2 Press the torch trigger to start the arc Pause at the edge until the arc has cut completely through the workpiece 3 Drag the nozzle lightly across the workpiece to proceed with the cut PMX30_OM_04 qxp PMX30_OM_04 10 7 09 12 45 PM Page 4 8 ...

Page 71: ...tate the torch to a perpendicular 90 position 3 Hold the torch in place When sparks exit from the bottom of the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut WARNING KSPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle P...

Page 72: ...g speed gauge or inches millimeters inches per minute millimeters per minute 18 ga 1 3 Mild steel 30 394 10007 10 ga 3 4 Mild steel 30 87 2210 3 16 4 8 Mild steel 30 52 1321 1 4 6 0 Mild steel 30 33 838 3 8 9 0 Mild steel 30 15 381 18 ga 1 3 Stainless steel 30 221 5613 10 ga 3 4 Stainless steel 30 55 1397 1 4 6 0 Stainless steel 30 24 610 3 8 9 0 Stainless steel 30 11 279 18 ga 1 3 Aluminum 30 399...

Page 73: ...0 50 duty cycle At 24 A the arc can remain on for 7 5 minutes out of 10 75 At 21 A the arc can remain on for 10 minutes 100 If the power supply overheats because the duty cycle is exceeded the temperature LED will illuminate the arc will shut off and the cooling fan will continue to run To resume cutting wait for the temperature LED to extinguish Common cutting faults The torch does not cut comple...

Page 74: ...OPERATION 4 12 powermax30 Operator Manual PMX30_OM_04 qxp PMX30_OM_04 10 7 09 12 45 PM Page 4 12 ...

Page 75: ...move an endcap 5 9 Disconnect the torch lead 5 11 Replace the work lead 5 13 Replace the power cord CSA 5 15 Replace the power cord CE 5 17 Replace the air filter element 5 19 Replacement and accessory parts 5 20 Power cords and adapters 5 20 Accessory parts 5 20 T30v hand torch assembly 5 21 Consumables 5 21 Filter regulator 5 22 Work clamp 5 22 Powermax30 labels 5 23 PMX30_OM_05 qxp PMX30_OM_05 ...

Page 76: ...d air or a vacuum Replace any damaged labels Inspect the consumables for proper installation and wear Inspect the trigger for damage Inspect the torch body for cracks and exposed wires Replace any damaged parts Every 6 months Every 3 months or DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance All work that requires removal of the power supply cover m...

Page 77: ...surface for wear and verify the pit depth Replace if the surface is worn or the pit depth is greater than 1 16 inch 1 6 mm deep Swirl ring The internal surface for damage or wear and the gas holes for blockages Replace if the surface is damaged or worn or any of the gas holes are blocked Torch o ring The surface for damage wear or a lack of lubrication If the o ring is dry lubricate it with a thin...

Page 78: ...tion 2 Specifications for more information The power ON LED is illuminated and the temperature LED is illuminated Leave the power supply on to allow the fan to cool the power supply If the internal temperature of the power supply approaches 22 F 30 C the temperature LED may light Move the power supply to a warmer location MAINTENANCE AND PARTS 0 5 4 powermax30 Operator Manual Basic troubleshooting...

Page 79: ...al times in succession All LEDs blinking indicates a major fault A qualified service technician must service the system Contact your distributor or use the information in the front of this book to contact Hypertherm Technical Service Note Using a generator with a Powermax30 system that has a serial number below 30 003132 can cause the LEDs to blink if the generator delivers a higher than normal vo...

Page 80: ...ent in this section The arc sputters and hisses The gas filter element inside the power supply is contaminated Replace the element See Replace the air filter element in this section Inspect the gas line for water If necessary install or repair the gas filtration to the power supply See Section 3 Gas supply The cut quality is poor Verify that the torch is being used correctly See Section 4 Hand tor...

Page 81: ...the gas supply 2 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the endcaps back slightly so that you can get the edges of the handle out from underneath the endcaps Set the handle screws aside and then lift the cover off the power supply 3 Remove the Nomex barrier from the power board side of the power supply DANGER ELECTRIC SHOCK CAN KILL D...

Page 82: ...e with the long cutout is toward the front torch end of the power supply Slide the barrier into place with the bottom edge in the same track the cover rests in The notches on each edge of the barrier should align with the ribs on the inside of the endcaps 4 Being careful not to pinch any of the wires slide the cover back onto the power supply Make sure that the bottom edges are in the tracks and t...

Page 83: ...the cover and the Nomex barrier 3 Lay the power supply on its side on a workbench or hold it upside down The raised feet on the bottom of the unit have holes to provide access to the snaps that hold the endcaps in place Next to each foot is a raised rib 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 e...

Page 84: ...lat head screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the endcap away from the base 7 Place another screwdriver or similar object into the opening between the endcap and the base to keep the first corner of the endcap from returning to its original position when you release the other corner 8 Repeat steps 5 and 6 on the other corner of the endcap PMX3...

Page 85: ...ws to secure the cover 12 Reconnect the electrical power and the gas supply Disconnect the torch lead 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the cover and remove the Nomex barrier from in front of the power board 3 Compress the hose fitting collar and pull the hose from the fitting to remove the gas hose from the solenoid valve Front endcap Solenoid v...

Page 86: ...l for the white wire group over the left stud labeled wht on the center panel Slide the ring terminal for the red wire onto the stud on the right labeled red on the center panel Tighten the nuts onto the studs 10 Thread the orange blue and purple wire group over the center panel with the wires resting in the notch in the panel Tip the endcap away from the power supply and press the connector into ...

Page 87: ...ct the gas supply 2 Remove the cover from the power supply and remove the Nomex barrier from in front of the power board 3 Remove the screw and washer from J22 on the powerboard also labeled work lead that attaches the lead to the board Set the screw and washer aside Work lead Work lead connection to power board J22 Front end cap Strain relief 4 Either remove the front endcap or gently tilt it awa...

Page 88: ... on either side of it 7 Slide the nut over the work lead connector Gently tilt the end cap away from the power supply and screw the nut onto the strain relief 8 Attach the work lead to the power board at J22 using the screw and washer that you removed earlier The torque setting for this connection is 20 inch pounds 1 4 kg cm 9 Replace or realign the end cap 10 Replace the Nomex barrier and slide t...

Page 89: ...ower board 3 Remove the rear endcap 4 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 Carefully pull the connector for the white wire away from the power switch to disconnect it You can use needlenose pliers or a straight screwdriver to ease it out if necessary 5 Remove the black wire the same way Single phase ...

Page 90: ...wer cord through the hole in the endcap If the old strain relief is still in place thread the wires through the strain relief 10 Slide the strain relief s nut over the wires and screw it to the strain relief from the inside of the endcap 11 Press the connector for the black wire onto the pin on the upper left side of the power switch 12 Press the connector for the white wire onto the pin on the up...

Page 91: ...he power cord and disconnect the gas supply 2 Remove the cover from the power supply and remove the Nomex barrier from in front of the power board 3 Remove the rear endcap 4 The power cord has a brown wire and a blue wire that connect to the power switch and a green and yellow ground wire that connects to the heatsink Carefully pull the connector for the blue wire away from the power switch to dis...

Page 92: ...side of the power supply pull the wires through the strain relief and the hole in the endcap to remove the old power cord 10 Route the plug wires of the new power cord through the strain relief and then through the hole in the endcap Do not remove the tubular ferrite bead from the power switch end of brown and blue wires 11 If you are replacing the strain relief slide the new one onto the new powe...

Page 93: ...d slide the cover back onto the power supply Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 19 Reconnect the electrical power and the gas supply Replace the air filter element 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the cover from the power supply 3 Remove the drain hose from the hole in the bottom ...

Page 94: ...y Replacement and accessory parts The following sections list part numbers and quantities needed for common replacement parts for the Powermax30 Power cords and adapters Part number Description Quantity 228142 Kit Powermax30 CSA power cord and adapters 1 229135 Powermax30 CSA power cord 1 229132 Extension power cord subassembly 120V 15A adapter 1 229133 Extension power cord subassembly 240V 20A ad...

Page 95: ...ription Quantity 088001 T30v Hand Torch Assembly with 15 ft 4 5 m Lead 1 228111 Kit Handle 1 2 075714 Screws 4 x 1 2 SLTD Torx PAN S B 5 3 002244 Safety trigger and spring replacement 1 4 228110 Kit torch head repair 1 5 058503 O ring Viton 626 x 070 1 6 228109 Kit cap sensor replacement 1 7 228113 Kit torch lead replacement 15 ft 4 5 m 1 The torch assembly also includes one set of the consumables...

Page 96: ...erator Manual Part Item number Description Qty 1 011106 Air filter element 1 Filter regulator Work clamp Item Part number Description Qty 1 123868 Work cable with clamp 15 ft 4 6 m 1 1 1 PMX30_OM_05 qxp PMX30_OM_05 10 7 09 12 46 PM Page 5 22 ...

Page 97: ...jurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 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 ...

Page 98: ...MAINTENANCE AND PARTS 5 24 powermax30 Operator Manual PMX30_OM_05 qxp PMX30_OM_05 10 7 09 12 46 PM Page 5 24 ...

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